402499A.GN1
SECTION 26 20 00
LOW-VOLTAGE AC INDUCTION MOTORS
PART 1
1.01
GENERAL
RELATED SECTIONS
A.
1.02
This section applies only when referenced by a motor-driven equipment
specification. Application, horsepower, enclosure type, mounting, shaft type,
synchronous speed, and any deviations from this section will be listed in the
equipment specification. Where such deviations occur, they shall take
precedence over this section.
REFERENCES
A.
The following is a list of standards which may be referenced in this section:
1.
2.
3.
4.
American Bearing Manufacturers Association (ABMA):
a.
9, Load Ratings and Fatigue Life for Ball Bearings.
b.
11, Load Ratings and Fatigue Life for Roller Bearings.
Institute of Electrical and Electronics Engineers, Inc. (IEEE):
a.
85, Test Procedure for Airborne Sound Measurements on Rotating
Electric Machinery.
b.
112, Standard Test Procedures for Polyphase Induction Motors
and Generators.
c.
114, Standard Test Procedures for Single-Phase Induction Motors.
d.
620, Guide for the Presentation of Thermal Limit Curves for
Squirrel Cage Induction Motors.
e.
841, Standard for Petroleum and Chemical Industry – Severe Duty
Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction
Motors – up to and Including 500 hp.
National Electrical Manufacturers Association (NEMA):
a.
250, Enclosures for Electrical Equipment (1,000 Volts
Maximum).
b.
C50.41, Polyphase Induction Motors for Power Generating
Stations.
c.
MG 1, Motors and Generators.
d.
MG 13, Frame Assignments for Alternating Current Integral
Horsepower Induction Motors.
National Fire Protection Association (NFPA): 70, National Electrical
Code. (NEC)
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5.
1.03
1.04
Underwriters Laboratories (UL):
a.
1, Flexible Metal Conduit.
b.
674, Standard for Safety Electric Motors and Generators for use in
Division 1 Hazardous (Classified) Locations.
c.
2111, Overheating Protection for Motors.
DEFINITIONS
A.
CISD-TEFC: Chemical industry, severe-duty enclosure.
B.
DIP: Dust-ignition-proof enclosure.
C.
EXP: Explosion-proof enclosure.
D.
ODP: Open drip-proof enclosure.
E.
TEFC: Totally enclosed, fan cooled enclosure.
F.
TENV: Totally enclosed, nonventilated enclosure.
G.
WPI: Open weather protected enclosure, Type I.
H.
WPII: Open weather protected enclosure, Type II.
I.
Motor Nameplate Horsepower: That rating after any derating required to
allow for extra heating caused by the harmonic content in the voltage applied
to the motor by its controller.
J.
Inverter Duty Motor: Motor meeting all applicable requirements of
NEMA MG 1, Section IV, Parts 30 and 31.
SUBMITTALS
A.
Action Submittals:
1.
2.
3.
4.
Descriptive information.
Nameplate data in accordance with NEMA MG 1.
Additional Rating Information:
a.
Service factor.
b.
Locked rotor current.
c.
No load current.
d.
Multispeed load classification (e.g., variable torque).
e.
Adjustable frequency drive motor load classification (e.g.,
variable torque) and minimum allowable motor speed for that load
classification.
f.
Guaranteed minimum full load efficiency and power factor.
Enclosure type and mounting (e.g., horizontal, vertical).
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5.
6.
7.
8.
9.
10.
11.
12.
13.
B.
Informational Submittals:
1.
2.
3.
PART 2
2.01
2.02
Dimensions and total weight.
Conduit box dimensions and usable volume as defined in NEMA MG 1
and NFPA 70.
Bearing type.
Bearing lubrication.
Bearing life.
Space heater voltage and watts.
Description, ratings, and wiring diagram of motor thermal protection.
Motor sound power level in accordance with NEMA MG 1.
Maximum brake horsepower required by the equipment driven by the
motor.
Factory test reports.
Manufacturer’s Certificate of Proper Installation.
Operation and Maintenance Data: As specified in Section 01 78 23,
Operation and Maintenance Data.
PRODUCTS
MANUFACTURERS
A.
Baldor.
B.
Reliance Electric.
C.
U.S. Electrical Motors.
GENERAL
A.
For multiple units of the same type of equipment, furnish identical motors and
accessories of a single manufacturer.
B.
In order to obtain single source responsibility, utilize a single supplier to
provide a drive motor, its driven equipment, and specified motor accessories.
C.
Meet requirements of NEMA MG 1.
D.
Frame assignments in accordance with NEMA MG 13.
E.
Provide motors for hazardous (classified) locations that conform to UL 674
and have an applied UL listing mark.
F.
Motors shall be specifically designed for the use and conditions intended, with
a NEMA design letter classification to fit the application.
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G.
Lifting lugs on all motors weighing 100 pounds or more.
H.
Operating Conditions:
1.
2.
3.
2.03
2.04
2.05
Maximum ambient temperature not greater than 40 degrees C.
Motors shall be suitable for operating conditions without any reduction
being required in the nameplate rated horsepower or exceeding the rated
temperature rise.
Overspeed in either direction in accordance with NEMA MG 1.
HORSEPOWER RATING
A.
As designated in motor-driven equipment specifications.
B.
Constant Speed Applications: Brake horsepower of the driven equipment at
any head capacity point on the pump curve not to exceed motor nameplate
horsepower rating, excluding any service factor.
C.
Adjustable Frequency and Adjustable Speed Applications (Inverter Duty
Motor): Driven equipment brake horsepower at any head capacity point on the
pump curve not to exceed motor nameplate horsepower rating, excluding any
service factor.
SERVICE FACTOR
A.
Inverter-duty Motors: 1.0 at rated ambient temperature, unless otherwise
noted.
B.
Other Motors: 1.15 minimum at rated ambient temperature, unless otherwise
noted.
VOLTAGE AND FREQUENCY RATING
A.
System Frequency: 60 Hz.
B.
Voltage Rating: Unless otherwise indicated in motor-driven equipment
specifications:
Voltage
Phases
1/2 hp and smaller
115
1
3/4 hp through 400 hp
460
3
4,000
3
Size
450 hp and larger
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2.06
C.
Suitable for full voltage starting.
D.
100 hp and larger also suitable for reduced voltage starting with 65 or
80 percent voltage tap settings on reduced inrush motor starters.
E.
Suitable for accelerating the connected load with supply voltage at motor
starter supply terminals dipping to 90 percent of motor rated voltage.
EFFICIENCY AND POWER FACTOR
A.
For all motors except single-phase, under 1 hp, multispeed, short-time rated
and submersible motors, or motors driving gates, valves, elevators, cranes,
trolleys, and hoists:
1.
2.
2.07
2.08
2.09
Efficiency: Premium Efficiency tested in accordance with
NEMA MG 1.
Power Factor: High Power Factor, guaranteed 0.90 lagging minimum at
full load.
LOCKED ROTOR RATINGS
A.
Locked rotor kVA Code F or lower, if motor horsepower not covered by
NEMA MG 1 tables.
B.
Safe stall time 12 seconds or greater.
INSULATION SYSTEMS
A.
Single-Phase, Fractional Horsepower Motors: Manufacturer’s standard
winding insulation system.
B.
Motors Rated over 600 Volts: Sealed windings in accordance with
NEMA MG 1.
C.
Three-Phase and Integral Horsepower Motors: Unless otherwise indicated in
motor-driven equipment specifications, Class F with Class B rise at nameplate
horsepower and designated operating conditions, except EXP and DIP motors
which must be Class B with Class B rise.
D.
Motors with Form-Wound Coils: Locked coil bracing system in accordance
with NEMA C50.41.
ENCLOSURES
A.
Enclosures to conform to NEMA MG 1.
B.
TEFC and TENV: Furnish with a drain hole with porous drain/weather plug.
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C.
Explosion-Proof (EXP):
1.
2.
3.
4.
D.
Dust-Ignition-Proof (DIP):
1.
2.
3.
2.10
TEFC listed to meet UL 674 and NFPA 70 requirements for Class I,
Division 1, Group C and D hazardous locations.
Drain holes with drain and breather fittings.
Integral thermostat opening on excessive motor temperature in
accordance with UL 2111 and NFPA 70.
Terminate thermostat leads in terminal box separate from main terminal
box.
TEFC listed to met UL 674 and NFPA 70 requirements for Class II,
Division 1, Group E, F, and G.
Integral thermostat opening on excessive motor temperature in
accordance with UL 2111 and NFPA 70.
Thermostat leads to terminate in a terminal box separate from main
terminal box.
E.
Submersible: In accordance with Article Special Motors.
F.
Chemical Industry, Severe-Duty (CISD-TEFC): In accordance with Article
Special Motors.
TERMINAL (CONDUIT) BOXES
A.
Oversize main terminal boxes for all motors.
B.
Diagonally split, rotatable to each of four 90-degree positions. Threaded hubs
for conduit attachment.
C.
Except ODP, furnish gaskets between box halves and between box and motor
frame.
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D.
Minimum usable volume in percentage of that specified in NEMA MG 1,
Section 1, Paragraph 4.19 and NFPA 70, Article 430:
Voltage
Below 600
Below 600
Below 600
Above 600
E.
2.11
Terminal Box Usable Values
Horsepower
15 through 125
150 through 300
350 through 600
All sizes
Percentage
500
275
225
200
Terminal for connection of equipment grounding wire in each terminal box.
BEARINGS AND LUBRICATION
A.
Horizontal Motors:
1.
2.
3.
4.
B.
Vertical Motors:
1.
2.
C.
3/4 hp and Smaller: Permanently lubricated and sealed ball bearings, or
regreasable ball bearings in labyrinth sealed end bells with removable
grease relief plugs.
1 through 400 hp: Regreasable ball bearings in labyrinth sealed end
bells with removable grease relief plugs.
Above 400 hp: Regreasable antifriction bearings in labyrinth sealed end
bells with removable grease relief plugs.
Minimum 100,000 hours L-10 bearing life for ball and roller bearings as
defined in ABMA 9 and ABMA 11.
Thrust Bearings:
a.
Plate type (Kingsbury) bearing.
b.
Manufacturer’s standard lubrication 100 hp and smaller.
c.
Oil lubricated 125 hp and larger.
d.
Minimum 50,000 hours L-10 bearing life.
Guide Bearings:
a.
Manufacturer’s standard bearing type.
b.
Manufacturer’s standard lubrication 200 hp and smaller.
c.
Oil lubricated 250 hp and larger.
d.
Minimum 100,000 hours L-10 bearing life.
Regreasable Antifriction Bearings:
1.
2.
Readily accessible, grease injection fittings.
Readily accessible, removable grease relief plugs.
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D.
Oil Lubrication Systems:
1.
2.
3.
E.
2.12
2.13
Bearing Isolation: Motors rated for inverter duty shall have electrically
isolated bearings to prevent stray current damage.
NOISE
A.
Measured in accordance with IEEE 85 and NEMA MG 1.
B.
Motors controlled by adjustable frequency drive systems shall not exceed
sound levels of 3 dBA higher than NEMA MG 1.
BALANCE AND VIBRATION CONTROL
A.
2.14
In accordance with NEMA MG 1, Part 7.
EQUIPMENT FINISH
A.
Protect Motor for Service Conditions:
1.
2.
2.15
Oil reservoirs with sight level gauge.
Oil fill and drain openings with opening plugs.
Provisions for necessary oil circulation and cooling.
ODP Enclosures: Indoor industrial atmospheres.
Other Enclosures: Outdoor industrial atmospheres, including moisture
and direct sunlight exposure.
B.
External Finish: Prime and finish coat manufacturer’s standard.
C.
Internal Finish: Bore and end turns coated with clear polyester or epoxy
varnish.
SPECIAL FEATURES AND ACCESSORIES
A.
Screen Over Air Openings: Stainless steel on motors with ODP, WPI, and
WPII enclosures meeting requirements for Guarded Machine in
NEMA MG 1, and attached with stainless steel screws.
B.
Winding Thermal Protection:
1.
Thermostats (for Motors Less than 50 Horsepower):
a.
Motors whose motor data sheets and/or control diagrams require
thermostats and all motors greater than 10HP shall be provided
with thermostats.
b.
Bi-metal disk or rod type thermostats embedded in stator
windings.
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c.
2.
C.
Space Heaters:
1.
2.
3.
4.
5.
D.
Provide winding space heaters with leads wired out to separate condulet
or terminal box.
Provide extra hole or hub on motor terminal box as required.
Clearly identify heater wire leads at conduit box.
Unless shown otherwise, heater shall be suitable for 120V ac supply,
with wattage suitable for motor frame size.
Coordinate power requirements of the space heater with the
manufacturer of motor starters or adjustable frequency drive for sizing
of the control power transformer.
Nameplates:
1.
2.
3.
E.
Automatic reset contacts rated 120 volts ac, 5 amps minimum,
opening on excessive temperature. (Manual reset shall be
provided at motor controller.)
d.
Leads extending to separate terminal box for motors 100 hp and
larger.
Thermistors (for Motors 50 Horsepower and Greater but Less than 300
Horsepower):
a.
Thermistor embedded in each stator phase winding before
winding dip and bake process.
b.
In intimate contact with winding conductors.
c.
Epoxy-potted, solid state thermistor control module mounted in
NEMA 250, Type 4X box on motor by motor manufacturer.
d.
Individual thermistor circuits factory-wired to control module.
e.
Control module rated for 120V ac power supply.
f.
Control module automatically reset contact for external use rated
120 volts ac, 5 amps minimum, opening on abnormally high
winding temperature. Manual reset shall be provided at motor
controller.
Raised or stamped letters on stainless steel or aluminum.
Display motor data required by NEMA MG 1, Paragraph 10.39 and
Paragraph 10.40 in addition to bearing numbers for both bearings.
Premium efficiency motor nameplates to also display NEMA nominal
efficiency, guaranteed minimum efficiency, full load power factor, and
maximum allowable kVAR for power factor correction capacitors.
Anchor Bolts: Provide anchor bolts meeting manufacturer’s recommendations
and of sufficient size and number for the specified seismic conditions.
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2.16
SPECIAL MOTORS
A.
Requirements in this article take precedence over conflicting features
specified elsewhere in this section.
B.
Chemical Industry, Severe-Duty (CISD-TEFC):
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
In accordance with IEEE 841.
TEFC in accordance with NEMA MG 1.
Suitable for indoor or outdoor installation in severe-duty applications
including high humidity, chemical (corrosive), dirty, or salty
atmospheres.
Motor Frame, End Shields, Terminal Box, and Fan Cover: Cast iron.
Ventilating Fan: Corrosion-resistant, nonsparking, external.
Drain and Breather Fittings: Stainless steel.
Nameplate: Stainless steel.
Gaskets between terminal box halves and terminal box and motor frame.
Extra slinger on rotor shaft to prevent moisture seepage along shaft into
motor.
Double shielded bearings.
125,000 hours minimum L-10 bearing life for direct-connected loads.
External Finish: Double-coated epoxy enamel.
Coated rotor and stator air gap surfaces.
Insulation System, Windings, and Connections:
a.
Class F insulation, Class B rise or better at 1.0 service factor.
b.
Multiple dips and bakes of nonhygroscopic polyester varnish.
Service Factor:
a.
At 40 Degrees C Ambient: 1.15.
b.
At 65 Degrees C Ambient: 1.00.
Safe Stall Time Without Injurious Heating: 20 seconds minimum.
C.
Severe-Duty Explosion-Proof: Meet requirements for EXP enclosures and
CISD-TEFC motors.
D.
Severe-Duty, Dust-Ignition-Proof: Meet requirements for DIP enclosures and
CISD-TEFC motors.
E.
Multispeed: Meet requirements for speeds, number of windings, and load
torque classification indicated in the motor-driven equipment specifications.
F.
Inverter Duty Motor:
1.
2.
Motor supplied power by adjustable voltage and adjustable frequency
drives shall be inverter duty rated.
Motor shall be suitable for operation over entire speed range indicated.
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3.
4.
G.
Provide forced ventilation where speed ratio is greater than published
range for motor being installed.
Motor installed in Division 1 hazardous (classified) locations shall be
identified as acceptable for variable speed when used in a Division 1
location.
Submersible Pump Motor:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Manufacturers:
a.
Reliance Electric.
b.
ITT Flygt Corp.
At 100 Percent Load:
Submersible Pump Motors
Guaranteed
Guaranteed
Minimum
Minimum
Horsepower
Efficiency
Power Factor
5 through 10
80
82
10.1 through 50
85
82
50.1 through 100
87
82
Over 100
89
82
Insulation System: Manufacturer’s standard Class B or Class F.
Motor capable of running dry continuously.
Enclosure:
a.
Hermetically sealed, watertight, for continuous submergence up to
65-foot depth.
b.
Listed to meet UL 674 and NFPA 70 requirements for Class I,
Division 1, Group D hazardous atmosphere.
c.
Seals: Tandem mechanical.
Bearing and Lubrication:
a.
Permanently sealed and lubricated, replaceable antifriction guide
and thrust bearings.
b.
Minimum 15,000 hours L-10 bearing life.
Inrush kVA/horsepower no greater than NEMA MG 1 and NFPA 70,
Code F.
Winding Thermal Protection:
a.
Thermal sensor and switch assembly, one each phase, embedded
in stator windings and wired in series.
b.
Switches normally closed, open upon excessive winding
temperature, and automatically reclose when temperature has
cooled to safe operating level.
c.
Switch contacts rated at 5 amps, 120V ac.
Motor Seal Failure Moisture Detection:
a.
Probes or sensors to detect moisture beyond seals.
b.
Probe or sensor monitoring module for mounting in motor
controller, suitable for operation from 120V ac supply.
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c.
10.
11.
12.
H.
Inclined Motors:
1.
2.
3.
2.17
Monitoring module with control power transformer, probe test
switch and test light, and two independent 120V ac contacts, one
opening and one closing when the flux of moisture is detected.
Bearing Overtemperature Protection for Motors Larger than 100 hp:
a.
Sensor on lower bearing housing monitoring bearing temperature.
b.
Any monitoring relay necessary to provide 120V ac contact
opening on bearing overtemperature.
Winding thermal protection, moisture detection, and bearing
overtemperature specified above may be monitored by a single device
providing two independent 120V ac contacts, one closing and one
opening on malfunction.
Connecting Cables:
a.
Two separate cables, one containing power and grounding
conductors, and the other containing control and grounding
conductors.
b.
Each cable suitable for hard service, submersible duty with
watertight seal where cable enters motor.
c.
Length: 30 feet minimum.
d.
UL 1 listed and sized in accordance with NFPA 70.
Motors suitable for operation only in horizontal position not acceptable.
Bearings designed for thrust imposed by driven equipment and by motor
rotor when motor is in inclined position.
Lubrication system designed to provide adequate bearing lubrication
when motor is in inclined position.
FACTORY TESTING
A.
Tests:
1.
2.
3.
4.
In accordance with IEEE 112 for polyphase motors and IEEE 114 for
single-phase motors.
Routine (production) tests on all motors in accordance with
NEMA MG 1. Test multispeed motors at all speeds.
For energy efficient motors, test efficiency and power factor at 50, 75,
and 100 percent of rated horsepower:
a.
In accordance with IEEE 112, Test Method B, and NEMA MG 1,
Paragraph 12.59. and Paragraph 12.60.
b.
For motors 500 hp and larger where facilities are not available to
test by dynamometer (Test Method B), determine efficiency by
IEEE 112, Test Method F.
c.
On motors of 100 hp and smaller, furnish a certified copy of a
motor efficiency test report on an identical motor.
Provide test reports for polyphase motors100 hp and larger.
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B.
Test Report Forms:
1.
2.
3.
4.
PART 3
3.01
3.02
Routine Tests: IEEE 112, Form A-1.
Efficiency and power factor by Test Method B, IEEE 112, Form A-2,
and NEMA MG 1,Table 12-11.
Efficiency and power factor by Test Method F, IEEE 112, Forms F-1,
F-2, and F-3.
Temperature Test: IEEE 112, Form A-2.
EXECUTION
INSTALLATION
A.
In accordance with manufacturer’s instructions and recommendations.
B.
Align motor carefully and properly with driven equipment.
C.
Secure equipment to mounting surface with anchor bolts.
MANUFACTURER’S SERVICES
A.
Furnish manufacturer’s representative at Site for installation assistance,
inspection, equipment testing, and startup assistance for motors larger than
100 horsepower.
B.
Manufacturer’s Certificate of Proper Installation.
END OF SECTION
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SECTION 40 99 90
PACKAGE CONTROL SYSTEMS
PART 1
1.01
GENERAL
REFERENCES
A.
The following is a list of standards which may be referenced in this section:
1.
2.
3.
4.
5.
1.02
1.03
The Institute of Electrical and Electronics Engineers, Inc. (IEEE):
C62.41, IEEE Recommended Practice on Surge Voltages in LowVoltage AC Power Circuits.
Instrumentation, Systems, Automation Society (ISA): S50.1,
Compatibility of Analog Signals for Electronic Process Instruments.
National Electrical Manufacturers Association (NEMA):
a.
250, Enclosures for Electrical Equipment (1,000 Volts
Maximum).
b.
AB 1, Molded Case Circuit Breakers and Molded Case Switches.
c.
ICS 2, Industrial Control Devices, Controllers and Assemblies.
National Fire Protection Association (NFPA): 70, National Electrical
Code (NEC).
Underwriters Laboratories Inc. (UL): 508A, Standards for Safety,
Industrial Control Panels.
SYSTEM DESCRIPTION
A.
Assemble panels and install instruments, plumbing, and wiring in equipment
manufacturer’s factories.
B.
Test panels and panel assemblies for proper operation prior to shipment from
equipment manufacturer’s factory.
C.
Test panels and panel assemblies for proper operation in the field and
participate in Performance Acceptance Testing as noted.
SUBMITTALS
A.
Action Submittals:
1.
2.
3.
Bill of material, catalog information, descriptive literature, wiring
diagrams, and Shop Drawings for components of control system.
Catalog information on electrical devices furnished with system.
Shop Drawings, catalog material, and dimensional layout drawings for
control panels and enclosures.
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4.
5.
B.
Informational Submittals:
1.
2.
3.
1.04
Programmable Controller Submittals:
a.
Complete set of user manuals.
b.
Fully documented PLC program.
c.
Cross-reference listing.
Manufacturer’s list of proposed spares, expendables, and test
equipment.
Manufacturer’s Certificate of Proper Installation.
O&M MANUAL SUBMITTALS
A.
Hardware:
1.
B.
Provide the following:
a.
Updated versions of all material described under paragraph
Hardware Documentation.
b.
Component Manufacturers' O&M Manuals: Include manuals to
cover installation, operation, maintenance, troubleshooting, and
calibration.
c.
List of spare parts and expendables provided and list of spare parts
recommended.
Software:
1.
1.05
Panel elementary diagrams of prewired panels. Include in diagrams
control devices and auxiliary devices, for example, relays, alarms, fuses,
lights, fans, and heaters.
Plumbing diagrams of preplumbed panels and interconnecting plumbing
diagrams.
Provide the following:
a.
Programming Manuals: Component manufacturers' standard
programming manuals.
b.
Software Documentation: Provide a final version of the material
called for under Paragraph Software Design Submittal.
HARDWARE DOCUMENTATION FOR ETHERNET NETWORK
CONNECTED PLC’S
A.
Provide the following for all elements of the PLC:
1.
2.
Block Diagram: A diagram showing all major system components.
Identify components by manufacturer and model number. Show
interconnecting cables diagrammatically.
Bill-of-Materials: A list of all PLC components. Group components by
type and include:
a.
Component manufacturer, model number, and part number.
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3.
4.
5.
6.
1.06
b.
Component description.
c.
Quantity supplied.
d.
Reference to component catalog information.
Descriptive Information: Catalog information, descriptive literature,
performance specifications, internal wiring diagrams, power and
grounding requirements, power consumption, and heat dissipation of all
elements of the PLC system. Clearly mark all options and features
proposed for this Project.
Outline Drawings: Equipment envelope Drawings showing external
dimensions, enclosure materials, conduit connections, and installation
requirements.
Installation Details: Any modifications or further details as may be
required to supplement the Purchase Order Documents and adequately
define the installation of the PLC elements.
Input/Output List: For each I/O point, list point type, tag number of the
source or final control element, equipment description, PLC number,
PLC terminal identification, rack number, module slot number, and PLC
address. Refer to I/O list provided in Article Supplements. Provide I/O
list in the format shown in Supplement.
APPLICATION SOFTWARE FOR ETHERNET NETWORK CONNECTED
PLC’S
A.
PLC Application Software Development Methodology: The programmable
controller system (PLC) is required to communicate over a fiber optic data
link with HMI servers to be provided by others and copper Ethernet links to
other PLCs provided as part of the package system. It is extremely important
that each PLC is programmed in a way that allows elegant data exchange
between the HMI, other PLCs, and this PLC. Coordinate data communication
with the HMI applications programmer.
1.
2.
3.
All control and monitoring features of the package system HMI shall be
available over the Plant SCADA control system.
PLC shall be programmed using ladder logic.
Provide annotated data exchange look up tables and other information to
allow the HMI applications programmer to implement efficient data
exchange between HMI and PLC.
B.
Coordinate graphic color standards for indications and alarms with the Owner.
C.
The data exchange table must be submitted for approval with the Emulation
and Data Integration plan.
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1.07
D.
Software Design Submittal: This submittal shall be a detailed description on
the application program. Submit this material during the program
development stage. Provide ladder logic programs to implement all functional
requirements specified in applicable process specifications. This submittal
shall be reviewed by the Contractor, Owner, and Engineer prior to the
submittal of the Preliminary Software Documentation.
E.
Preliminary Software Documentation: Provide this submittal at least 4 weeks
prior to the Factory Test. Here the term "preliminary" refers only to the timing
of this submittal, not the level of detail to be provided. This submittal shall be
a fully detailed version of all the material described hereinafter under
Paragraph O&M Manual, Paragraph Software Documentation, except that the
floppy disc copies are not required at this time.
F.
Provide format of reports to be generated by HMI using data received from
the PLC. Provide any required calculation procedures.
DELIVERY, STORAGE, AND HANDLING
A.
1.08
Prior to shipment, include corrosive-inhibitive vapor capsules in shipping
containers and related equipment as recommended by capsule manufacturer.
EXTRA MATERIALS
A.
Spares, Expendables, and Test Equipment:
1.
2.
3.
4.
PART 2
2.01
Selector Switch, Pushbutton, and Indicating Light: 20 percent, one
minimum, of each type used.
Light Bulb: 100 percent, 2 minimum, of each type used.
Fuse: 100 percent, 5 minimum, of each type used.
Surge Suppressors: 20 percent, one minimum, of each type used.
PRODUCTS
SIGNAL CHARACTERISTICS
A.
Analog Signals:
1.
2.
3.
4.
4 to 20 mA dc, in accordance with compatibility requirements of
ISA S50.1.
Unless otherwise specified or shown, use Type 2, two-wire circuits.
Transmitters: Load resistance capability conforming to Class L.
Fully isolate input and output signals of transmitters and receivers.
PACKAGE CONTROL SYSTEMS
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402449A.GN1
B.
Pulse Frequency Signals: dc pulses whose repetition rate is linearly
proportional to process variable over 10:1 range. Generate pulses by contact
closures or solid-state switches.
1.
C.
Discrete Signals:
1.
2.
3.
2.02
Two-state logic signals.
Utilize 120V ac sources for control and alarm signals extending more
than 500 feet. 120V ac or 24V dc may be used for all other control and
alarm signal circuits.
Alarm signals shall be normally open, close to alarm isolated contacts
rated for 5-ampere at 120V ac and 2-ampere at 30V dc.
CORROSION PROTECTION
A.
Corrosion-Inhibiting Vapor Capsule Manufacturers:
1.
2.
2.03
Power source: Less than 30V dc.
Zerust; Model VC.
Hoffmann Engineering; Model A-HCI.
CONTROL PANEL
A.
Panel Construction and Interior Wiring: In accordance with the National
Electrical Code (NEC), UL 508A, state and local codes, and applicable
sections of NEMA, ANSI, and ICECA.
B.
Conform to NEMA ratings as specified in individual equipment sections.
C.
Minimum Metal Thickness: 14-gauge.
D.
NEMA 250, Type 4X Panels: Type 304 stainless steel construction unless
otherwise specified.
E.
Doors:
1.
2.
Three-point latching mechanisms in accordance with NEMA 250
Type 1 and 12 panels with doors higher than 18 inches.
For other doors, stainless steel quick release clamps.
F.
Cutouts shall be cut, punched, or drilled and finished smoothly with rounded
edges.
G.
Access: Front, suitable for installation with back and sides adjacent to or in
contact with other surfaces, unless otherwise specified.
402449.MF
JULY 16, 2010
©COPYRIGHT 2010 CH2M HILL
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H.
Temperature Control:
1.
2.
3.
I.
Push-to-Test Circuitry: For each push-to-test indicating light, provide a fused
push-to-test circuit.
J.
Lighting: Minimum of one door switch controlled internal fluorescent lighting
package for all panels sized to cover a minimum of 60 percent of panel width.
K.
Minimum of one 120-volt GFCI duplex receptacle for panels 12 cubic feet
and larger.
L.
Finish:
1.
2.
M.
N.
Metallic External Surfaces (Excluding Aluminum and Stainless Steel):
Manufacturer’s standard gray unless otherwise specified.
Internal Surfaces: White enamel.
Panel Manufacturers:
1.
2.
Hoffman.
Rittal.
Breather and Drains: Furnish with NEMA 250, Type 4 and 4X panels.
1.
2.04
Size panels to adequately dissipate heat generated by equipment
mounted on or in the panel.
Furnish cooling fans with air filters if required to dissipate heat.
For panels outdoors or in unheated areas, furnish thermostatically
controlled heaters to maintain temperature above 40 degrees F.
Manufacturer and Product: Cooper Crouse-Hinds; ECD Type 4X Drain
and Breather; Drain Model ECD1-N4D, Breather Model ECD1-N4B.
CONTROL PANEL ELECTRICAL
A.
UL Listing Mark for Enclosures: Mark stating “Listed Enclosed Industrial
Control Panel” per UL 508A.
B.
I&C and electrical components, terminals, wires, and enclosures UL
recognized or UL listed.
C.
Control Panels without Motor Starters:
1.
2.
Furnish main circuit breaker and a circuit breaker on each individual
branch circuit distributed from power panel.
Locate to provide clear view of and access to breakers when door is
open. Group on single subpanel. Provide typed directory.
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402449A.GN1
3.
D.
Circuit Breakers:
a.
Coordinate for fault in branch circuit trips, branch breaker, and
not main breaker.
b.
Branch Circuit Breakers: 15 amps at 250V ac.
c.
Provide UL 489 listed breakers.
d.
Breaker Manufacturers and Products:
1)
Square D; Multi 9 series.
2)
Eaton; WMT series.
3)
Allen-Bradley; 1489-A series.
Control Panels with Three-Phase Power Supplies and Motor Starters:
1.
2.
3.
4.
5.
Interlock main circuit breaker with panel door.
a.
Mount logic controls, branch circuit breakers, overload reset
switches, and other control circuit devices.
b.
Mount operator controls and indications on front access door.
Circuit Breakers:
a.
In accordance with NEMA AB 1.
b.
18,000-ampere RMS symmetrical rating, minimum at 480 volts,
unless otherwise specified.
c.
Breakers, except Motor Branch Breakers: Molded case thermal
magnetic.
d.
Tripping: Indicate with operator handle position.
Magnetic Motor Starters:
a.
Full voltage, NEMA ICS 2, Class A, Size O minimum.
b.
Include three-pole bimetallic or eutectic alloy thermal overload
relays sized for each motor.
c.
Manual reset type with reset button mounted on panel door.
Motor Control: 120V ac (except intrinsically safe circuits where
applicable).
a.
Power Control Transformer:
1)
Sufficient capacity to serve connected load, including
200VA for duplex outlet plus 100VA (minimum).
2)
Limit voltage variation to 15 percent during contact pickup.
3)
Fuse one side of secondary winding and ground the other.
4)
Furnish primary winding fuses in ungrounded conductors.
Power Monitoring Motor Protection Relay:
a.
Protect three-phase equipment from single phasing, phase
imbalance, or phase reversal.
b.
Separate, isolated contact outputs to stop motors and activate
alarm light during abnormal conditions.
c.
Transient Voltage Protection: 10,000 volts.
d.
Manufacturer and Product: Motor Saver.
402449.MF
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6.
7.
E.
Wiring:
1.
2.
3.
4.
5.
6.
F.
ac Circuits:
a.
Type: 600-volt, Type MTW stranded copper.
b.
Size: For current to be carried, but not less than 14 AWG.
Analog Signal Circuits:
a.
Type: 600-volt, Type 2 stranded copper, twisted shielded pairs.
b.
Size: 18 AWG, minimum.
Other dc Circuits.
a.
Type: 600-volt, Type MTW stranded copper.
b.
Size: 18 AWG, minimum.
Separate analog and other dc circuits by at least 6 inches from ac power
and control wiring, except at unavoidable crossover points and at
device terminations.
Enclose wiring in sheet metal raceways or plastic wiring ducts.
Wire Identification: Numbered and tagged at each termination.
a.
Wire Tags: Machine printed, heat shrink.
b.
Manufacturers:
1)
Brady PermaSleeve.
2)
Tyco Electronics.
Wiring Interface:
1.
2.
3.
G.
Power Distribution Blocks: Furnish to parallel feed tap on branch circuit
protective devices. Do not “leap frog” power conductors.
Terminations for Power Conductors: Suitable for use with 75 degrees C
wire at full NFPA 70, 75 degrees C ampacity.
For analog and discrete signal, terminate at numbered terminal blocks.
For special signals, terminate power (240 volts or greater) at
manufacturer’s standard connectors.
For panel, terminate at equipment on/with which it is mounted.
Terminal Blocks:
1.
2.
Quantity:
a.
For external connections.
Wire spare or unused panel mounted elements to their panels’
b.
terminal blocks.
c.
Spare Terminals: 20 percent of connected terminals, but not less
than 10.
General: Group to keep 120V ac circuits separate from 24V dc circuits.
a.
Connection Type: Screw connection clamp.
b.
Compression Clamp:
1)
Hardened steel clamp with transversal grooves penetrating
wire strands providing a vibration-proof connection.
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3.
4.
5.
2)
Guides strands of wire into terminal.
c.
Screws: Hardened steel, captive, and self-locking.
d.
Current Bar: Copper or treated brass.
e.
Insulation:
1)
Thermoplastic rated for minus 55 to plus 110 degrees C.
2)
Two funnel shaped inputs to facilitate wire entry.
f.
Mounting:
1)
Rail.
2)
Terminal block can be extracted from an assembly without
displacing adjacent blocks.
3)
End Stops: One at each end of rail, minimum.
g.
Wire Preparation: Crimp type ferrule or stripping only.
h.
Jumpers: Allow jumper installation without loss of space on
terminal or rail.
i.
Marking System:
1)
Terminal number shown on both sides of terminal block.
2)
Allow use of preprinted and field marked tags.
3)
Terminal strip numbers shown on end stops.
4)
Mark terminal block and terminal strip numbers as shown.
Spare Fuse Holder:
a.
Provide spare fuse holder(s) for all enclosures containing fuses.
b.
Quantity: As required to hold all spare fuses for each enclosure.
c.
DIN Rail Mountable.
d.
Manufacturer and Product: Weidmuller, 7914760001 or equal.
Terminal Block, 120-Volt Power:
a.
Rated Voltage: 600V ac.
b.
Rated Current: 30 amp.
c.
Wire Size: 22 through 10 AWG.
d.
Rated Wire Size: 10 AWG.
e.
Color: Gray body.
f.
Spacing: 0.25 inch, maximum.
g.
Manufacturers and Products:
Weidmuller.
1)
2)
Entrelec; Type M4/6.
3)
Phoenix Contact.
4)
Allen-Bradley.
Terminal Block, Ground:
a.
Wire Size: 22 through 12 AWG.
b.
Rated Wire Size: 12 AWG.
c.
Color: Green and yellow body.
d.
Spacing: 0.25 inch, maximum.
e.
Grounding: Ground terminal blocks electrically grounded to the
mounting rail.
f.
Manufacturers and Products:
1)
Weidmuller; 1010100000.
2)
Entrelec; Type M4/6.P.
402449.MF
JULY 16, 2010
©COPYRIGHT 2010 CH2M HILL
PACKAGE CONTROL SYSTEMS
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6.
7.
8.
3)
Phoenix Contact.
4)
Allen-Bradley.
Terminal Block, Blade Disconnect Switch:
a.
Rated Voltage: 600V ac.
b.
Rated Current: 10 amp.
c.
Wire Size: 22 through 12 AWG.
d.
Rated Wire Size: 12 AWG.
e.
Color: Gray body, orange switch.
f.
Spacing: 0.25 inch, maximum.
g.
Manufacturers and Products:
1)
Weidmuller; 7910210000.
2)
Entrelec; Type M4/6.SN.T.
3)
Phoenix Contact.
4)
Allen-Bradley.
Terminal Block, Fused, 24V dc:
a.
Rated Voltage: 600V dc.
b.
Rated Current: 6.3 amp.
c.
Wire Size: 22 through 12 AWG.
d.
Rated Wire Size: 12 AWG.
e.
Color: Gray body.
f.
Fuse: 5 by 20 GMA fuses.
g.
Fuse Marking: Fuse amperage rating shown on top of terminal
block.
h.
Indication: LED diode 24V dc.
i.
Leakage Current: 5.2 mA, maximum.
j.
Spacing: 0.32 inch, maximum.
k.
Manufacturers and Products:
1)
Weidmuller 1880410000.
2)
Entrelec; Type M10/13T.SFL.
3)
Phoenix Contact.
4)
Allen-Bradley.
Terminal Block, Fused, 120V ac:
Rated Voltage: 600V ac.
a.
b.
Rated Current: 6.3 amp.
c.
Wire Size: 22 through 12 AWG
d.
Rated Wire Size: 12 AWG.
e.
Color: Gray body.
f.
Fuse: 5 by 20 GMA fuses.
g.
Fuse Marking: Fuse amperage rating shown on top of terminal
block.
h.
Indication: Neon lamp 110V ac.
i.
Leakage Current: 1.8 mA, maximum.
j.
Spacing: 0.32 inch, maximum
PACKAGE CONTROL SYSTEMS
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JULY 16, 2010
©COPYRIGHT 2010 CH2M HILL
402449A.GN1
k.
H.
Grounding:
1.
2.
3.
4.
5.
6.
7.
8.
I.
Manufacturers and Products:
1)
Weidmuller 1880420000.
2)
Entrelec; Type M10/13T.SFL.
3)
Phoenix Contact.
4)
Allen-Bradley.
Internal copper grounding bus for ground connections on panels,
consoles, racks, and cabinets.
Furnish and install door grounding kit for enclosures.
Ground all DIN rail.
Ground all components in accordance with manufacturer’s instructions.
Ground surge suppressors with shortest possible ground conductor
length.
Ground bus grounded at a common signal ground point in accordance
with National Electrical Code requirements.
Coordinate ground connection for control panels with Electrical
Contractor.
Single Point Ground for Each Analog Loop:
a.
Locate signal ground at dc power supply for loop.
b.
Use to ground wire shields for loop.
c.
Ground terminal block rails to ground bus.
Relays:
1.
2.
General:
a.
Relay Mounting: Plug-in type socket.
b.
Relay Enclosure: Provide dust cover.
c.
Socket Type: Screw terminal interface with wiring.
d.
Socket Mounting: Rail.
e.
Furnish holddown clips.
Control Circuit Switching Relay, Nonlatching:
a.
Type: Compact general purpose plug-in.
b.
Contact Arrangement: 2 Form C contacts.
c.
Contact Rating: 10A at 28V dc or 240V ac.
d.
Contact Material: Silver cadmium oxide alloy.
e.
Coil Voltage: As noted or shown.
f.
Coil Power: 1.8 watts (dc), 2.7VA (ac).
g.
Expected Mechanical Life: 10,000,000 operations.
h.
Expected Electrical Life at Rated Load: 100,000 operations.
i.
Indication Type: Neon or LED indicator lamp.
j.
Push-to-test button.
402449.MF
JULY 16, 2010
©COPYRIGHT 2010 CH2M HILL
PACKAGE CONTROL SYSTEMS
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k.
3.
4.
J.
Manufacturers and Products:
1)
Weidmuller; Riderseries II.
2)
Potter and Brumfield; Series KUP.
3)
IDEC.
Control Circuit Switching Relay, Latching:
a.
Type: Dual coil magnetic latching relay.
b.
Contact Arrangement: 2 Form C contacts.
c.
Contact Rating: 10A at 28V dc or 120V ac.
d.
Contact Material: Silver cadmium oxide alloy.
e.
Coil Voltage: As noted or shown.
f.
Coil Power: 2.7 watts (dc), 5.3VA (ac).
g.
Expected Mechanical Life: 500,000 operations.
h.
Expected Electrical Life at Rated Load: 50,000 operations.
i.
Manufacturers and Products:
1)
Potter and Brumfield; Series KUL .
2)
IDEC; Series RR2KP.
Control Circuit Switching Relay, Time Delay:
a.
Type: Adjustable time delay relay.
b.
Contact Arrangement: 2 Form C contacts.
c.
Contact Rating: 10A at 240V ac.
d.
Contact Material: Silver cadmium oxide alloy.
e.
Coil Voltage: As specified or shown.
f.
Operating Temperature: Minus 10 to 55 degrees C.
g.
Repeatability: Plus or minus 2 percent.
h.
Delay Time Range: Select range such that time delay setpoint fall
between 20 to 80 percent or range.
i.
Time Delay Setpoint: As specified or shown.
j.
Mode of Operation: As specified or shown.
k.
Adjustment Type: Integral potentiometer with knob external to
dust cover.
l.
Manufacturers and Products:
Weidmuller; 8647700000.
1)
2)
Potter and Brumfield:
a)
Series CB for 0.1 second to 100 minute delay time
ranges.
b)
Series CK for 0.1 to 120 second delay time ranges.
3)
IDEC.
Programmable Controllers:
1.
General:
a.
Provide PLCs meeting the following minimum requirements
unless otherwise noted in specific package Specification sections.
PACKAGE CONTROL SYSTEMS
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402449A.GN1
b.
2.
3.
Function: Used for process monitoring and control by emulating
functions of conventional panel mounted equipment such as
relays, timers, counters, current switches, calculation modules,
PID controllers, stepping switches, and drum programmers.
c.
Type: Microprocessor based device programmable using ladder
logic.
d.
Parts: Central processing unit (CPU), power supply, local and
remote input/output modules, local and remote base (chassis/rack)
controllers, I/O bases (chassis/rack), data highway, and factory
assembled interconnecting cables. Provide components required to
make a complete and totally operational system.
Environmental:
a.
Temperature: Operating range 32 to 120 degrees F (0 to
50 degrees C).
b.
Humidity: Operating range 5 to 95 percent noncondensing.
c.
Vibration:
1)
Sinusoidal: IEC 68-2-6, Test Fc; 0.15 mm peak-to-peak,
10-to 57-Hz; 1 g, 57- to 150-Hz.
2)
Random: IEC 68-2-34, Test Fdc; 0.4 g2/Hz, 80- to 350-Hz,
and 3dB/octave rolloff, 80- to 20-Hz and 350- to 2-KHz at
10 min/axis.
d.
Noise: IEC 801, Part 3, Level 3 and Part 4, Level 3;
MIL STD-461B.
e.
Isolation: User-side to PLC side 1,500V rms.
Central Processing Unit (CPU):
a.
Type: Microprocessor, 16-bit minimum.
b.
Scan Time: Less than 1 ms/K words of relay ladder logic.
c.
PLC Communications:
1)
Minimum 1 serial or Ethernet communication port for
communication with a PC or programmer.
d.
Instruction Set:
1)
Timers and Counters: minimum 256, minimum timer
resolution 0.1 seconds; minimum counter count range 0 to
32,000.
2)
Math: Signed integer and floating-point math including add,
subtract, multiply, divide, square root, and compare.
3)
Register Operations: Shift registers, bit shift, bit set, bit
clear, data move and data format conversion.
4)
Process Loop Control: User configurable direct or reverse
acting PID loop control computation with the capability of
both AUTO and MANUAL modes of operation, remote
access to controller tuning constants; minimum of 16 PID
loops.
5)
Real Time Clock: Date and time set and compare.
402449.MF
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©COPYRIGHT 2010 CH2M HILL
PACKAGE CONTROL SYSTEMS
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e.
4.
5.
6.
Diagnostics:
1)
Indicators: Battery status, PLC status, PLC operation mode,
remote I/O communication status.
2)
Status Word: With failure status for PLC battery, scan
overrun, communications, I/O, special functions.
3)
Power Up: PLC checks status of PROMs upon power up;
runs self-diagnostics on power-up; periodically runs selfdiagnostics while in RUN mode, halts logic processor and
sets outputs to configured state if fatal error is detected.
4)
Diagnostic Tables: Tables, displayable by programming
computer, that describe nature and location (address)
existing faults and errors.
f.
Agency Approvals and Standards:
1)
UL listed.
2)
CSA certified.
3)
DIN Standard 41494.
4)
IEC-65A/WG6 draft proposal.
5)
Factory Mutual approved.
Random Access Memory (RAM):
a.
Type: CMOS type.
b.
Word Size: 16 bits, minimum.
c.
Battery Backup: 1 month, minimum.
d.
Memory Size: Sufficient to implement all applications software.
e.
Memory Size: 8 K words of ladder logic memory, 2 K words of
variable memory, plus required overhead for standard functions.
f.
Read only memory (ROM) for controller’s operating system and
diagnostics.
Power Supply: One unit for each input/output base assembly:
a.
Voltage: 120/220 volts (user selectable) or 24Vdc, 60-Hz input.
Input/Output: Complete input/output system.
a.
Discrete Input Modules:
1)
Voltage:
a)
120 volts, 60-Hz.
24 volts dc.
b)
2)
Operating Power: 2 watts.
3)
Points per Module: 16 maximum.
4)
LED status indicator for each point.
5)
Isolation: Between input point and PLC, 1,500 volts rms.
b.
Discrete Output Modules:
1)
Voltage: 24 volts dc.
2)
Operating Power: 2 watts.
3)
Load Rating: 2 amps continuous.
4)
Isolation: Between PLC and output point, 1,500 volts rms.
5)
Points per Module: 16 maximum.
6)
LED status indicator for each point.
7)
Wire each output to interposing relay.
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402449A.GN1
c.
7.
8.
K.
Analog Input/Output Modules:
1)
Voltage: 24 volts dc.
2)
Power: 3 watts.
3)
Differential Analog Points Per Module: 8 maximum.
4)
Isolated Analog Output Points Per Module: 8 maximum.
5)
Isolation: Between PLC and I/O point and between I/O
points, 1,500 volts rms.
d.
Pulse Input Modules:
1)
Input Voltage: 5V or 12-24V (user selectable).
2)
Input Current: 7 mA at 5V; 7.0 to 1.5 mA at 12-24V.
3)
Points per Module: 4, maximum.
4)
Maximum Input Frequency: 100 KHz in counter mode.
5)
Maximum Count Value: 0-999,999 (programmable).
Identification: Nameplates installed above/below each PLC component
(CPU, I/O rack, power supply).
Manufacturers:
a.
Koyo; DirectLogic.
b.
Or Owner and Engineer approved equal.
Front-of-Panel Devices Used in Conjunction with NEMA 250, Type 4X
Panels:
1.
2.
3.
Potentiometer, Watertight:
a.
Three-terminal, heavy-duty NEMA 250, Type 4X watertight
construction, resolution of 1 percent and linearity of plus or minus
5 percent.
b.
Single-hole, panel mounting accommodating panel thicknesses
between 1/8 and 1/4 inch.
c.
Include engraved legend plates with service markings.
d.
Manufacturer and Product: Allen-Bradley; Bulletin 800H.
Indicating Lights, Watertight:
a.
Heavy-duty, push-to-test type, NEMA 250, Type 4X watertight,
industrial type with integral transformer for 120V ac applications
and corrosion-resistant service.
b.
Screwed on prismatic lenses and factory engraved legend plates
for service legend.
c.
Manufacturers and Products:
1)
Square D; Type SK.
2)
Allen-Bradley; Type 800H.
Pushbutton, Momentary, Watertight:
a.
Heavy-duty, NEMA 250, Type 4X watertight, industrial type with
momentary contacts rated for 120V ac service at 10 amperes
continuous and corrosion-resistant service.
b.
Standard size, black field, legend plates with white markings for
service legend.
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©COPYRIGHT 2010 CH2M HILL
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c.
4.
2.05
INSTRUMENT TAG NUMBERS
A.
2.06
Manufacturers and Products:
1)
Square D; Type SK.
2)
Allen-Bradley; Type 800H.
Selector Switch, Watertight:
a.
Heavy-duty, NEMA 250, Type 4X watertight, industrial type with
contacts rated for 120V ac service at 10 amperes continuous and
corrosion-resistant service.
b.
Standard size, black field, legend plates with white markings, for
service legend.
c.
Operators: Black knob type.
d.
Single-hole mounting, accommodating panel thicknesses from
1/16 to 1/4 inch.
e.
Manufacturer and Products:
1)
Square D; Class 9001, Type SK.
2)
Allen-Bradley; Type 800H.
Provide manufacturer’s standard tagging unless otherwise shown on the
Drawings.
NAMEPLATES, NAMETAGS, AND SERVICE LEGENDS
A.
Nametags: Permanently mounted bearing entire ISA tag number.
1.
2.
B.
Service Legends (Integrally Mounted with Instrument) and Nameplates:
1.
2.
3.
4.
C.
Panel Mounted: Plastic, mounted to instrument behind panel face.
Field Mounted: Engraved Type 316 stainless steel, 22-gauge minimum
thickness, attached with stainless steel.
Engraved, rigid, laminated plastic type with adhesive back. Furnish
service legends and nameplates to adequately describe functions of
panel face mounted instruments.
Color: White with black letters.
Letter Height: 3/16 inch.
For each panel, face mounted laminated nameplate inscribed with the
panel name and tag number. Color shall be white with black letters
1/2-inch high.
Standard Light Colors and Inscriptions: Unless otherwise specified in
individual equipment specifications, use the following color code and
inscriptions:
Tag
Inscription(s)
Color
ON
ON
Red
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1.
2.
Tag
Inscription(s)
Color
OFF
OFF
Green
OPEN
OPEN
Red
CLOSED
CLOSED
Green
LOW
LOW
Amber
FAIL
FAIL
Amber
HIGH
HIGH
Amber
AUTO
AUTO
White
MANUAL
MANUAL
Yellow
LOCAL
LOCAL
White
REMOTE
REMOTE
Yellow
FORWARD
FORWARD
Red
REVERSE
REVERSE
Blue
Lettering: Black on white and amber lenses; white on red and green
lenses.
Standard Pushbutton Colors and Inscriptions:
a.
Use following unless otherwise noted:
Tag Function
Inscription(s)
Color
OO
ON
OFF
Black
Black
OC
OPEN
CLOSE
Black
Black
OCA
OPEN
CLOSE
AUTO
Black
Black
Black
OOA
ON
OFF
AUTO
Black
Black
Black
MA
MANUAL
AUTO
Black
Black
SS
START
STOP
Black
Black
RESET
RESET
Black
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b.
2.07
Tag Function
Inscription(s)
Color
EMERGENCY
STOP
EMERGENCY
STOP
Red
Lettering Color:
1)
Black on white and yellow buttons.
2)
White on black, red, and green buttons.
ELECTRICAL SURGE AND TRANSIENT PROTECTION
A.
Equip control panels with surge-arresting devices to protect equipment from
damage as a result of electrical transients induced in interconnecting lines
from lightning discharges and nearby electrical devices.
B.
Suppressor Locations:
1.
2.
3.
4.
C.
Suppressor Design:
1.
2.
3.
4.
5.
D.
Provide at all Control Panel 480Vac and 120Vac power feeds.
At point of connection between an equipment item, including ac
powered transmitters, and power supply conductor (direct-wired
equipment).
On analog pairs at each end when the pair travels outside of building.
In other locations where equipment sensitivity to surges and transients
requires additional protection beyond that inherent to design of
equipment.
Construction: First-stage, high-energy metal oxide varistor and secondstage, bipolar silicon avalanche device separated by series impedance;
includes grounding wire, stud, or terminal.
Response: 5 nanoseconds maximum.
Recovery: Automatic.
Temperature Range: Minus 20 degrees C to plus 85 degrees C.
Enclosure Mounted: Encapsulated inflame retardant epoxy.
Suppressors on 120V ac Power Supply Connections:
1.
2.
3.
4.
Occurrences: Tested and rated for a minimum of 50 occurrences of
IEEE C62.41 Category B test waveform.
First-Stage Clamping Voltage: 350 volts or less.
Second-Stage Clamping Voltage: 210 volts or less.
Power Supplies for Continuous Operation:
a.
Four-Wire Transmitter or Receiver: Minimum 5 amps at 130V ac.
b.
All Other Applications: Minimum 30 amps at 130V ac.
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E.
Suppressors on Analog Signal Lines:
1.
2.
F.
Manufacturers and Products:
1.
2.
3.
4.
5.
G.
2.
3.
4.
3.01
Panel Mounted on Analog Signals Lines: Emerson/Edco PC-642 series
or Phoenix Contact PLUGTRAB series.
Panel Mounted on 120V ac Lines: Emerson/Edco HSP-121.
Panel Mounted on 480-Volt, Three-Phase Power Supplies:
Emerson/Liebert PowerSure Panel LPM/IM.
Field Mounted at Two-Wire Instruments:
a.
Encapsulated in stainless steel pipe nipples.
b.
Emerson/Edco SS64 series.
Field Mounted at Four-Wire Instruments: all in NEMA 4X enclosure.
a.
Enclosure:
1)
NEMA 4X Polycarbonate with door.
2)
Maximum Size: 12 inches by 12 inches by 8 inches deep.
b.
Emerson/Edco; SLAC series.
Grounding:
1.
PART 3
Test Waveform: Linear 8-microsecond rise in current from 0 amp to a
peak current value followed by an exponential decay of current reaching
one-half the peak value in 20 microseconds.
Surge Rating: Tested and rated for 50 occurrences of 2,000-amp peak
test waveform.
a.
dc Clamping Voltage: 20 percent to 40 percent above operating
voltage for circuit.
b.
dc Clamping Voltage Tolerance: Plus or minus 10 percent.
c.
Maximum Loop Resistance: 18 ohms per conductor.
Coordinate enclosure grounding and surge suppressor grounding in field
panels and field instrumentation with Division 26, Electrical, and
suppressor manufacturer’s requirements.
Provide control panels with an integral copper grounding bus for
connection of suppressors and other required instrumentation and
equipment.
Provide control panels with door grounding kit.
Ground all equipment in accordance with manufacturer’s instructions.
EXECUTION
ELECTRICAL POWER AND SIGNAL WIRING
A.
Restrain control and signal wiring in control panels by plastic ties or ducts.
Secure hinge wiring at each end so bending or twisting will occur around the
longitudinal axis of wire. Protect bend area with a sleeve.
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3.02
3.03
B.
Arrange wiring neatly, cut to proper length, and remove surplus wire. Install
abrasion protection for wire bundles passing through holes or across edges of
sheet metal.
C.
Use manufacturer’s recommended tool with sized anvil for crimp
terminations. No more than one wire may be terminated in a single crimp lug.
No more than two lugs may be installed on a single screw terminal.
D.
Do not splice or tap wiring except at device terminals or terminal blocks.
PROTECTION
A.
Protect enclosures and other equipment containing electrical, instrumentation
and control devices, including spare parts, from corrosion through the use of
corrosion-inhibiting vapor capsules.
B.
During Work, periodically replace capsules in accordance with capsule
manufacturer’s recommendations. Replace capsules at Substantial
Completion.
SOURCE QUALITY CONTROL
A.
General:
1.
2.
3.
4.
5.
6.
Contractor, Engineer, and Owner may actively participate in many of
the tests.
Engineer and Owner reserve right to test or retest specified functions.
Engineer’s or Owner’s decision will be final regarding acceptability and
completeness of testing.
Procedures, Forms, and Checklists:
a.
Except for Unwitnessed Factory Test, conduct tests in accordance
with, and documented on, Engineer accepted procedures, forms,
and checklists.
b.
Describe each test item to be performed.
c.
Have space after each test item description for sign off by
appropriate party after satisfactory completion.
Required Test Documentation: Test procedures, forms, and checklists
signed by the Engineer.
Conducting Tests:
a.
Provide special testing materials and equipment.
b.
Wherever possible, perform tests using actual process variables,
equipment, and data.
c.
If not practical to test with real process variables, equipment, and
data provide suitable means of simulation.
d.
Define simulation techniques in test procedures.
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e.
7.
B.
General Factory Test Requirements:
1.
2.
3.
4.
5.
6.
C.
Test Format: Cause and effect.
1)
Person conducting test initiates an input (cause).
2)
Specific test requirement is satisfied if correct result (effect),
occurs.
Test Plan:
a.
Provide a test plan outlining test procedures, descriptions, and
checklists. An Engineer approved test plan is a pre-requisite to
scheduling a factory test.
Provide factory test of all Package Control system components before
shipment to the Site.
Contractor, Engineer, and Owner reserve the right to actively participate
in and witness Factory Testing.
Notify Contractor, Engineer, and Owner of Factory Testing 3 weeks in
advance.
Provide testing in accordance with general testing procedures listed
above and as noted.
Test the following control system features as a minimum:
a.
Wiring from field and panel devices to the PLC.
b.
Signal inputs and outputs from the PLC.
c.
PLC control strategies.
d.
Interface with Operator interface and front of panel controls.
e.
Simulate inputs and outputs for primary elements, final control
elements, and panels excluded from test.
f.
Interface with PICS control system for Ethernet Connected
Package Control Systems.
Provide test documentation to the Engineer and Owner.
Membrane Filtration System Factory Demonstration Test (FDT):
1.
2.
3.
4.
5.
Notify Contractor, Engineer, and Owner of test schedule 3 weeks prior
to start of test.
Scope: Test entire PLC control system to demonstrate it is operational.
Location: Membrane Filtration System Supplier’s facility.
Correctness of wiring from panel field terminals to PLC system
input/output points and to panel components.
a.
Simulate each discrete signal at terminal strip.
b.
Simulate correctness of each analog signal using current source.
Operation of communications between PLCs and Ethernet connected
instrumentation and between PLCs and computers.
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6.
7.
8.
9.
10.
11.
3.04
Emulation of data exchange over Ethernet of the PLC control system
and the PICS HMI/PLC control system. Show that the Membrane
Filtration System PLC control system is set up prior to shipment for
communication and data exchange with the PICS HMI/PLC control
system including coordination of HMI graphic displays.
Functional Requirements: Demonstrate Membrane Filtration System
Equipment meets the functional requirements outlined in
Section 46 61 34, Membrane Filtration Equipment.
Correct deficiencies found and complete prior to shipment to Site.
Failed Tests: Repeat and witnessed.
Make following documentation available to Contractor, Engineer, and
Owner at test site both before and during FDT:
a.
Drawings, Specifications, Addenda, and Change Orders.
b.
Master copy of FDT procedures.
c.
List of equipment to be tested including make, model, and serial
number.
d.
Approved hardware Shop Drawings for equipment being tested.
Daily Schedule for FDT:
a.
Begin each day with meeting to review day’s test schedule.
b.
End each day with each meeting to review day’s test results and to
review or revise next day’s test schedule.
FIELD QUALITY CONTROL
A.
Coordination of data exchange with PICS supplier prior to Field Testing:
1.
B.
Membrane Filtration System:
a.
Provide PICS subcontractor with a listing of all I/O available over
Ethernet and the corresponding addresses.
b.
Provide details in initiating communications and any required
handshaking.
c.
Provide support to PICS subcontractor during initial Ethernet I/O
shakedown: minimum of one 8 hour day.
d.
Correct any Ethernet I/O communication errors found to be the
problem of improper configuration of package system supplied
components.
e.
Schedule: To be coordinated during construction prior to Factory
Testing.
Field Testing Prior to Facility Startup:
1.
Membrane Filtration System Integration Testing:
Participate in PICS Performance Tests Prior to Facility Startup.
a.
b.
Prepare Membrane Filtration System PLC, instruments, and
equipment for testing.
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c.
d.
C.
Participate in testing, correcting any interface problems due to
Membrane Filtration System Ethernet Connected Equipment,
HMI, or PLC programming.
Schedule: To be completed once PICS Functional Testing is
complete.
Performance Acceptance Testing (PAT) During and After Facility Startup:
1.
Membrane Filtration System Services:
a.
Participate in PICS Performance Tests During and After Facility
Startup.
b.
Prepare Membrane Filtration System PLC, instruments, and
equipment for testing.
c.
Participate in testing, correcting any interface problems due to
Membrane Filtration System Ethernet Connected Equipment,
HMI, or PLC programming.
END OF SECTION
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SECTION 44 42 56
PUMPS—GENERAL
PART 1
1.01
GENERAL
REFERENCES
A.
The following is a list of standards which may be applicable to all pumps and
pumping equipment:
1.
2.
3.
4.
5.
6.
American Iron and Steel Institute (AISI):
a.
Type 416 Stainless Steel.
b.
Type 316 Stainless Steel.
c.
Type 1035 Steel.
d.
Type 4140 Alloy Steel.
e.
Type 1045 Carbon Steel.
American Petroleum Institute (API):
a.
610, Centrifugal Pumps for Petroleum, Heavy Duty Chemical, and
Gas Industry Services.
b.
670, Machinery Protection Systems.
Anti Friction Bearing Manufacturers Association (AFBMA):
a.
ANSI/AFBMA 9, Standard for Load Ratings and Fatigue Life for
Ball Bearings.
b.
ANSI/AFBMA 11, Standard for Load Ratings and Fatigue Life
for Roller Bearings.
ASTM International (ASTM):
a.
A48, Standard Specification for Gray Iron Castings.
b.
A53, Standard Specification for Pipe, Steel, Black and HotDipped, Zinc-Coated, Welded and Seamless.
c.
A276, Standard Specification for Stainless and Heat-Resisting
Steel Bars and Shapes.
d.
A576, Standard Specification for steel Bars, Carbon, HotWrought, Special Quality.
e.
B62, Standard Specification for Composition Bronze or Ounce
Metal Castings.
f.
B148, Standard Specification Aluminum-Bronze Sand Castings.
g.
B584, Standard Specification for Copper Alloy Sand Castings for
General Applications.
Hydraulic Institute Standards (HIS):
a.
1.6, Standard for Centrifugal Pump Tests.
b.
2.6, Standard for Vertical Pump Tests.
c.
9.6.4, Vibration Measurements and Allowable Values for
Centrifugal and Vertical Pumps.
Institute of Electrical and Electronics Engineers (IEEE): 112, Standard
Test Procedure for Polyphase Induction Motors and Generators.
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7.
1.02
DEFINITIONS
A.
1.03
National Electrical Manufacturer’s Association (NEMA): MG 1, Motors
and Generators.
Terminology pertaining to pumping unit performance and construction shall
conform to the ratings and nomenclature of the Hydraulic Institute Standards,
latest edition.
SUBMITTALS
A.
Shop Drawing Submittals:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Pump name, identification number, and specification section number.
Make, model, and weight of each equipment assembly.
Complete catalog information, descriptive literature, Supplier’s
specifications, and identification of materials of construction.
Performance data curves showing head, capacity, horsepower demand,
NPSH required, and pump efficiency over the entire operating range of
the pump. The equipment supplier shall indicate separately the head,
capacity, horsepower demand, overall efficiency, and minimum
submergence required at the design flow conditions and the maximum
and minimum flow conditions. A family of performance curves at
intervals of 100 rpm, unless otherwise specified, from minimum speed
to maximum speed, shall be provided for each adjustable speed
centrifugal pump. Indicate on the performance curves, the limits
recommended for stable operation without surge, without damaging
cavitation, and without vibration in excess of the specified allowable
vibration limits.
Where required by each pump specification section, submit estimated
maximum reverse runaway speed for the pump and motor assembly.
The coincident reverse flow and pump head shall also be submitted with
the speed estimates.
Where required by each pump specification section, submit vibration
monitoring system including technical product bulletins and
descriptions, specification data sheets, wiring diagrams,
communications hardware and software, documentation sufficient for
configuration of functions specified herein and shown on the Drawings.
Detailed structural, mechanical, and electrical drawings showing the
equipment dimensions, size, and location of connections and weights of
associated equipment.
Assembly and installation drawings including shaft size, seal, coupling,
bearings, anchor bolt plan, part nomenclature, material list, outline
dimensions, and shipping weights.
Calculations of seismic response of the pump and motor assembly.
Seismic loading and stress shall be included in the pump and motor
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10.
11.
12.
13.
14.
15.
16.
17.
18.
PART 2
2.01
assembly and anchor bolt design analysis. Seismic design criteria shall
be as specified in Section 01 60 00, Material and Equipment.
Data, in accordance with Section 26 20 00, Motors, for each electric
motor.
Shipping, storage, and protection, and handling instructions.
Supplier’s printed installation instructions.
Suggested spare parts list. Include a list of special tools required for
checking, testing, parts replacement, and maintenance with current price
information.
List special tools, materials, and supplies furnished with equipment for
use prior to and during startup and for future maintenance.
Operational and maintenance data as specified in Section 01 78 23,
Operation and Maintenance Data.
Supplier’s signed, dated, and certified factory test data report for each
pump system which requires factory testing, submitted before shipment
of equipment.
Supplier’s certification of proper installation.
Supplier’s certification of satisfactory field testing.
PRODUCTS
GENERAL
A.
A single pump Supplier shall be made responsible for furnishing the pump,
motor, and for coordination of design, assembly, testing, and for compliance
with the requirements of each pump section. Each pump shall be produced
and assembled by the Supplier at a facility owned or operated by the Supplier
and under the direct supervision and control of the Supplier.
B.
All centrifugal pumps shall have a continuously rising head curve from
maximum to minimum specified flows. In no case shall the required
horsepower at any point on the performance curve exceed the rated
horsepower of the motor or engine, or require operation at a service factor
greater than 1.0.
C.
No damaging cavitation will be allowed for pumps operating within the stable
operating range for the specified operating conditions.
D.
Each unit of pumping equipment shall incorporate all required components,
coupling, electric motor, appurtenances and necessary mountings.
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E.
Dynamically balance rotating parts of each pump and its driving unit before
final assembly.
1.
F.
Limits:
a.
Driving Unit Alone: Less than 80 percent of NEMA MG 1 limits.
b.
Complete Rotating Assembly Including Coupling and Motor: Less
than 90 percent of limits established in the Hydraulic Institute
Standards.
Where specified by the individual pump sections, a complete lateral and
torsional vibration analysis shall be required for each unique pump-couplingmotor rotating assembly and shall be submitted for review prior to pump
fabrication.
1.
2.
Each lateral vibration analysis shall identify the lateral natural
frequencies for both the pump and motor shafts. The pump shaft
analysis shall include both dry and wet impeller cases. A natural
frequency map shall be provided demonstrating that a lateral natural
frequency does not occur within plus or minus 20 percent of the
specified operating speed.
Each torsional vibration analysis shall include calculation of the system
torsional natural frequencies and the steady-state and transient startup
torsional response. An interference diagram shall be provided
demonstrating a separation margin of at least plus or minus 20 percent
between running speed and the expected excitation frequencies. The
expected excitation frequencies for steady-state operation shall include
but not be limited to, electrical line frequency, mechanical running
speed (1 times shaft speed) and blade-pass frequency. The analysis shall
include variable frequency drive wave-form components (where used).
All motor excitation frequencies shall be provided by the motor
supplier. The calculated steady-state and transient dynamic torsional
shaft stresses and coupling torques shall be shown to be below
allowable levels, such that the motor shaft, pump shaft, and associated
drive train components are capable of an unlimited number of startups
and shutdowns. The allowable shaft shear stresses (endurance limits)
shall be determined in accordance with ASME B106.1M (Design of
Transmission Shafting) or an equivalent method. A factor of safety of at
least 2.0 shall be included in the allowable stress levels. The allowable
dynamic torque in the couplings shall be compared to the coupling
supplier’s allowable torques.
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2.02
MATERIALS
A.
All materials shall be suitable for the intended application and shall conform
to the following requirements unless otherwise specified in the pump data
sheet:
1.
2.
3.
4.
2.03
Cast iron pump casings and bowls shall be close-grained gray cast iron,
conforming to ASTM A48, Class 30, or equal.
Bronze pump impellers shall conform to ASTM B62 or ASTM B584.
Stainless steel pump shafts shall be Type 416. Miscellaneous stainless
steel parts shall be of Type 316.
All anchor bolts, nuts, and washers that are not buried or submerged
shall be galvanized. Buried or submerged bolts, nuts, and washers shall
be Type 316 stainless steel.
PUMP COMPONENTS – GENERAL
A.
Suction and discharge nozzle flanges shall conform to ANSI/ASME B16.1
and ANSI/ASME B16.5, dimensions as required.
B.
Shaft Seals: The sealing system for pump shafts shall be packed stuffing box
or mechanical seal as indicated in the pump data sheet supplements.
1.
Mechanical Seal Requirements:
a.
Mechanical seals shall be of a nonfretting type requiring no
wearing sleeves for the shafts. Pump shafts shall be furnished with
no reduction in size through the seal area. Mechanical seals for
vertical turbine pumps shall be split type, requiring no field
assembly other than assembly around the shaft and insertion into
the pump or shall be balanced cartridge design in conjunction with
a spool type spacer coupling as specified in the pump data sheet
supplements. The arrangement shall allow removal of the seal
without disturbing the pump or driver. For clear water services
and solids up to 5 percent by weight, the face combination shall be
hard/soft. Otherwise, hard/hard faces shall be used. The seal
design shall be such that the dynamic O-ring moves towards a
clean surface as the face wears and the springs are not in the
pumped fluid. The stationary seal face shall be spring loaded to
provide self-alignment despite stuffing box misalignment.
Mechanical seals for horizontal pumps shall be split type,
requiring no field assembly other than assembly around the shaft
and insertion into the pump or shall be balanced cartridge design
as specified in the pump data sheet supplements.
b.
Where split type mechanical seals are specified, nonshaft O-rings
shall be of ball and socket type requiring no gluing. Initial seal
installation at the factory shall be with nonsplit seal faces, with all
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c.
d.
e.
PUMPS—GENERAL
44 42 56 - 6
spare seals and spare kits to have split faces. Unless otherwise
specified, split mechanical seals for pumping equipment shall be
capable of 400 psig service, be self-aligning, self-centering,
single, Chesterton 442, or equal.
Where cartridge type mechanical seals are specified, the cartridge
seal shall be single, balanced, flexible stator design capable of
600 psig service with O-ring secondary seals and setscrew drive
with three point centering to ensure 0.003 inch of maximum
perpendicularity of rotary face to the shaft. The gland shall have a
flush port and be affixed to the equipment with adjustable tabs to
fit irregular bolt patterns. Unless otherwise specified, the seal shall
be a Chesterton 155, Crane 1B, or equal.
Seal Materials:
1)
Metals: Type 316 stainless steel minimum for loaded parts
over 0.060-inch cross-section. For thinner parts (springs),
Hastelloy-C, Alloy 20, AMS5876 Elgiloy, or other alloy
that is not vulnerable to chloride stress corrosion shall be
used.
2)
Elastomers: Fluorocarbon Viton, preferred unless seal
supplier recommends ethylene propylene for service
conditions.
3)
Faces: All faces shall be of homogeneous constructionsurface treatments and plated faces are unacceptable.
Acceptable hard faces include nickel bound tungsten
carbide, self sintered silicon carbide, reaction bonded silicon
carbide, or graphitized silicon carbide. Silicon carbide is
preferred because of its higher pressure-velocity capability.
Acceptable soft face is carbon-graphite, either Union
Carbide 658RC or Purecarbon P8412.
Seal Environmental Controls:
1)
The seal flush ports shall be piped to drain to wet well or
hub drain as shown on the Drawings with a 1/8-inch orifice
plate in the line. Provide venting of the seal chamber.
2)
Where specified in the pump data sheet supplements,
mechanical seals shall be fitted with an Enviroseal
SpiralTrac Version F, N or D, installation Type I, as
recommended by A.W. Chesterton Company, Stoneham,
Massachusetts. SpiralTrac shall:
a)
Provide fluid circulation in the seal chamber that
removes frictional heat from the mechanical seal.
b)
Convey particulate matter and contaminants for
removal by conveying them from the bore to the shaft
by means of an integral machined spiral.
c)
Remove particulate matter from the seal chamber,
without seal flush water, through an integral machined
exit groove.
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3)
2.
2.04
Material of construction shall be Type 316 stainless steel.
The mechanical seal shall be connected to the water purge
supply where indicated on the Drawings.
Packing Requirements:
a.
Where shaft packings are specified, stuffing boxes shall be tapped
to permit introduction of seal liquid and shall hold a minimum of
five rows of packing and a lantern ring. Stuffing boxes shall be
face attached. Stuffing box and shaft shall be suitable for field
installation, without machining or other modifications, of the
mechanical seal outlined above for the applicable pump and
operating conditions.
b.
Packing shall be three asbestos-free die-molded packing rings of
braided graphite material free of PTFE, Chesterton 1400R or
equal for nonpotable water services and braided PTFE material,
Chesterton 1725 or equal that is FDA/NSF acceptable for potable
water services. Glands shall be two piece split construction.
Where specified in the pump data sheet supplements, the impeller
end of the packing shall be fitted with an Enviroseal SpiralTrac,
Version P, packing protection.
c.
Where the pumped fluid is clear water, pump discharge run
through a 1/8-inch orifice can be used for packing lubrication.
Otherwise, provide seal water flow control and monitoring as
detailed on the Drawings to control external seal water flow with
5 to 30 gallon per hour flow rate, plus or minus 10 percent
accuracy, Chesterton SingleFlow, or approved equal.
d.
The section of each shaft or impeller hub that extends through or
into the stuffing box shall be fitted with a replaceable stainless
steel sleeve with a Brinell hardness of not less than 500. The
sleeve shall be held to the shaft to prevent rotation and shall be
gasketed to prevent leakage between the shaft and the sleeve.
Minimum shaft sleeve thickness shall be 3/8 inch.
PUMP APPURTENANCES
A.
Each pump shall be quipped with a 16-gauge stainless steel nameplate with
1/4-inch die-stamped equipment tag number securely mounted in a readily
visible location.
B.
Pumps shall be manufactured with lifting lugs for equipment weighing over
100 pounds.
C.
Anchor Bolts: Galvanized sized by equipment supplier and as specified in
Section 05 50 05, Anchorage of Equipment.
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2.05
FACTORY TESTING
A.
The following tests shall be conducted on each indicated pump system, unless
otherwise specified in the specific pump section:
1.
2.
3.
PART 3
3.01
Motors: See Section 26 20 00, Motors.
Pump Systems: Unless otherwise specified, all centrifugal pump
systems 100 hp and larger shall be tested at the pump factory in
accordance with the Test Code for Centrifugal Pumps of the Hydraulic
Institute Standards, latest edition. Unless otherwise indicated, the
acceptance criteria shall be Level A with total head and pump efficiency
meeting the requirements at design flow and rated rpm as specified.
Testing of prototype models shall not be acceptable. The following
minimum test data shall be submitted:
a.
Hydrostatic test data.
b.
A minimum of three hydraulic test readings between shutoff head
and 25 percent beyond the rated capacity, recorded on data sheets
as defined by the Hydraulic Institute.
c.
Pump curves showing head, flow, brake horsepower, efficiency,
and NPSH required.
d.
Certification that the pump horsepower demand did not exceed the
rated motor horsepower beyond the 1.0 service rating at any point
on the curve.
e.
Pumps shall be tested at full rated speed as specified in the
specific pump section.
f.
Test for a continuous 3-hour period without malfunction.
Acceptance: In the event of failure of any pump to meet the specified
requirements, the Supplier shall make all necessary modifications,
repairs, or replacements to conform to the requirements of the Contract
Documents and the pump shall be re-tested until found satisfactory.
EXECUTION
INSTALLATION
A.
Install in accordance with Supplier’s printed instructions.
B.
Level base by means of steel wedges (steelplates and steel shims). Wedge
taper not greater than 1/4 inch per foot. Use double wedges to provide a level
bearing surface for the pump and driver base. Accomplish wedging so that
there is no change of level or springing of the baseplate when the anchor bolts
are tightened.
C.
Adjust pump assemblies such that the driving units are properly aligned,
plumb, and level with the driven units and all interconnecting shafts and
couplings. Do not compensate for misalignment by use of flexible couplings.
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D.
After the pump and driver have been set in position, aligned, and shimmed to
the proper elevation, grout the space between the bottom of the baseplate and
the concrete foundation with a poured, nonshrinking grout of the proper
category. Remove wedges after grout is set and pack void with grout.
E.
Connect suction and discharge piping without imposing strain to pump
flanges.
F.
Anchor Bolts: Accurately place using equipment templates and as specified in
Section 05 50 05, Anchorage of Equipment.
G.
Pipe pump drain(s) to hub drain or scupper.
SERVICES OF SUPPLIER
A.
Inspection, Startup, and Field Adjustment: Where required by the individual
pump sections, an authorized service representative of the Supplier shall visit
the Site to witness the following and to certify in writing that the equipment
and controls have been properly installed, aligned, lubricated, adjusted, and
readied for operation.
1.
2.
3.
4.
5.
B.
3.03
The Supplier shall provide all necessary oil and grease required for initial
operation.
PROTECTIVE COATING
A.
3.04
Installation of the equipment.
Inspection, checking, and adjusting the equipment.
Startup and field testing for proper operation.
Performing field adjustments to ensure that the equipment installation
and operation comply with the specified requirements.
Provide instruction and training in the operation and maintenance of the
equipment, including step-by-step troubleshooting with all necessary
test equipment. Instruction shall be specific to the models of equipment
provided. All training material and a detailed outline of each lesson
shall remain with the equipment at the Project Site.
Materials and equipment shall be coated as required by the individual pump
sections and Section 09 90 00, Painting and Coating.
FIELD TESTING
A.
Each pump system shall be field tested after installation to demonstrate
satisfactory operation without excessive noise, vibration, cavitation, or
overheating of bearings.
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B.
The following field testing shall be conducted:
1.
2.
3.
4.
5.
C.
All pumping equipment shall be tested to verify proper alignment,
operation as specified, and freedom from binding, scraping, vibration,
shaft run-out, or other defects. Pump drive shafts shall be measured just
prior to assembly to ensure correct alignment without forcing.
Startup, check, and operate the pump system over its entire speed range.
Vibration shall not exceed 80 percent of the limits specified in HIS 9.6.4
at a minimum of three pumping conditions specified in the specific
pump section.
Obtain concurrent readings of motor voltage, amperage, pump suction
head, and pump discharge head for at least three pumping conditions at
each specified rotational speed. Check each power lead to the motor for
proper current balance.
Determine bearing temperatures by contact type thermometer. A run
time of at least 30 minutes shall precede this test.
Electrical and instrumentation tests shall conform to the requirements of
the sections under which that equipment is specified.
After each pumping system has satisfied the requirements, the Supplier shall
certify in writing that the equipment has been satisfactorily tested and that all
final adjustments have been made. Certification by the Supplier shall include
the date of the field tests.
END OF SECTION
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SECTION 46 61 33.01
MEMBRANE SYSTEM WARRANTY
PART 1
1.01
GENERAL
GENERAL
A.
All membrane system performance documents shall be furnished to the
Owner, in a form acceptable to the Owner, simultaneously with the execution
of the Agreement with Owner. Refer to the General Conditions for specific
requirements.
B.
The membrane system supplier (MSS) shall provide manufacturer’s warranty
certificates for the membrane modules and individual equipment as specified
in individual equipment specification sections, in a form acceptable to the
Owner, simultaneously with the initial shop drawing submittals for the
membrane system and individual equipment.
C.
As stated herein, the MSS shall submit a Certificate of Extended Membrane
Module Warranty to the Owner after completion of the acceptance test.
D.
See also warranty information included in Section 46 61 34, Membrane
Filtration Equipment.
E.
In no event shall Seller be liable for any product altered outside of the Seller's
factory by someone other than Seller or for a product subjected to misuse,
abuse, improper installation, application, operation, maintenance or repair,
alteration, accident, or negligence in use, storage, transportation or handling.
F.
Seller shall not be liable for any damage or defect to equipment caused by
improper use or mishandling of consumable items (i.e. process feed or
cleaning chemicals) used in the operation of the treatment plant or impact.
G.
Seller shall not be liable for any damage or defect to equipment caused by
operation of the equipment not in accordance with seller provided Operation
and Maintenance manual even if seller is not aware of the existence of these
conditions. Neither shall seller be liable for repairs, alterations or
replacements to or uses of the equipment, which go beyond the equipment
specification.
H.
Seller shall not be liable for any damage or defect to equipment caused by
operation of the equipment at pressures during forward flow, air scour and
reverse flow modes higher than those recommended in the Operation and
Maintenance manual
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1.02
I.
Limitation of Liabilities: Notwithstanding anything elsewhere herein
contained, PALL shall not be liable for any loss or damage in excess of the
purchase price of the equipment.
J.
Warranty does not cover fiber damage due to foreign debris that is not native
to the source water or that is larger than the fine screens.
K.
Warranty is void if customer is in default of payment to Pall Corporation as
defined in the terms and conditions of the contract.
L.
These warranties are not the exclusive remedy for the Owner in the event of
any breach of this Agreement.
MEMBRANE SYSTEM EQUIPMENT AND SOFTWARE WARRANTY
A.
For a period of 1 year, commencing from the date of successful completion of
the acceptance test, the MSS guarantees the following:
1.
2.
Membrane System Equipment Warranty: That all work, materials,
equipment and products provided by the MSS, exclusive of the
membrane modules, will be free from defects in materials and
workmanship.
Programmable Logic Controller (PLC) Software Warranty: That MSS
will make necessary changes and implement upgrades to the PLC
software relating to providing solutions to all membrane system
programming defects or deficiencies encountered during testing and
operation of the membrane system.
B.
The MSS shall make, or have made at the expense of the MSS, repairs,
adjustments, replacements, or other corrective work necessary to restore or
bring into full compliance with the requirements of the specifications any part
of the work, materials, or equipment, which during the 1-year warranty period
is found to be deficient with respect to any provision of the Specification.
C.
If a defect or deficiency is of a kind which in the reasonable opinion of the
Owner does not require immediate correction, and the MSS has failed to
mobilize to the Site or has failed to undertake corrective work within
7 calendar days of notification from the Owner, then the Owner may make or
have made such repairs, adjustments, replacements, or other corrective work
and the MSS agrees to promptly pay the Owner’s invoice. Such payment shall
be made within 30 days of the date shown on the Owner's invoice to the MSS.
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1.03
D.
If, in the performance testing or operation of the equipment after installation,
the Owner finds latent defects or finds that equipment and/or software
programming fails to meet any requirements of the Specifications, the Owner
shall have the right to make reasonable use of such equipment until it can be
shut down for correction of defects without injury to the Owner; provided that
the period of such operation pending the correction of defects shall not exceed
6 months without the written consent of the MSS.
E.
All necessary software documentation will be including the O&M manuals prior
to system startup. Documentations of post-startup changes to the programming
will be provided as part of the final submittal.
SYSTEM PERFORMANCE WARRANTY
A.
For a period of 12 months from the date of successful completion of the Initial
Performance Test as described in Section 46 61 34, Membrane Filtration
Equipment, the MSS shall:
1.
2.
Warrant that the membrane equipment and ancillary systems, when
operated within conditions specified in the Contract Documents, will
meet the performance criteria as specified in Section 46 61 34,
Membrane Filtration System, and
Repair or replace, at no cost to the Owner, any membrane modules if
membrane modules fail. Failure is defined as any of the following:
a.
Inability of membrane to pass integrity test as specified in
Section 46 61 34, Membrane Filtration Equipment, Article Direct
Membrane Integrity Test System (MITS).
b.
Inability to meet production capacity requirements under
feedwater, flux, and recovery conditions specified in
Section 46 61 34, Membrane Filtration Equipment, Article
Performance Requirements.
c.
Inability to meet cleaned membrane permeability requirements as
specified in Section 46 61 34, Membrane Filtration Equipment,
Article Performance Requirements.
d.
Inability to meet membrane filtered water quality requirements
specified in Section 46 61 34, Membrane Filtration Equipment,
Article Performance Requirements.
B.
Owner shall make available to MSS electronic records of historical
performance for MSS review.
C.
Within 7 calendar days of notification by Owner of unsatisfactory
performance of the membrane system, the MSS will take the necessary
actions, to maintain the performance of the membrane system in accordance
with the membrane performance requirements set out in Section 46 61 34,
Membrane Filtration Equipment.
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D.
Where actual membrane performance falls or is anticipated to fall below the
values set out in Section 46 61 34, Membrane Filtration Equipment, the MSS
shall take one or more of the following corrective actions in order to maintain
required membrane performance.
1.
2.
3.
4.
5.
6.
E.
1.04
Review and optimize system operation as appropriate.
Repair modules.
Perform additional cleaning.
Replace modules with new modules.
Add modules into expansion slots.
Replace modules with new modules of different version, acceptable to
the Owner and Design Consultant, which offer technological
advantages.
If the MSS is unable to modify the system through addition of membranes or
other elements, and the system fails to meet the specified performance criteria
in Section 46 61 34, Membrane Filtration Equipment, then the MSS shall be
responsible for complete removal of the nonconforming system and
subsequent installation of membrane products that are capable of meeting the
specified performance conditions where the cost of such replacement does not
exceed the total contract value.
EXTENDED MEMBRANE MODULE WARRANTY
A.
For a period of 10 years, following the Initial Performance Test, the MSS
guarantees that the membrane modules will be free from defects in materials
and workmanship. Defects shall be defined as herein.
B.
MSS shall provide a warranty certificate, in a form acceptable to the Owner,
to secure MSS’s performance of its obligations herein. Certificate shall be
submitted for Owner review and approval within 7 days of the startup of the
membrane system.
C.
During the first two years of the warranty period, repair and replacement shall
be the sole responsibility of the MSS. MSS shall be responsible for services
and all costs required to repair and/or replace defective modules, including
labor, materials, tools, packaging, shipping, shipping coordination.
D.
During the remaining 8-year term of the warranty, MSS shall be compensated
on a pro-rata basis for replacement membrane modules supplied under the
terms of this warranty to replace modules originally installed as part of the
Work. The amount to be paid to MSS shall be the lower of the prices
determined in accordance with the following price calculation formula:
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Replacement Module Price = (Guaranteed Membrane Module Replacement
Price) X (# of months from Startup) / (120 months).
OR
Replacement Module Price = (Guaranteed Membrane Module Replacement
Price) X (# of months from Delivery - 6) / (120 months).
1.
2.
Dates and warranty period determined on monthly basis.
Actual Guaranteed Membrane Module Replacement Price included in
bid submittal.
E.
Owner shall be responsible for pulling, transferring, and returning modules to
and from the preservation solution and the skid.
F.
Membrane modules that serve as replacement modules under the terms of the
extended membrane module warranty shall be free from defects in materials
and workmanship as described herein. During the term of the extended
membrane module warranty, any further replacement of the replacement
modules shall be subject to the remaining membrane warranty terms as listed in
Article 1.04.D.
G.
The Owner shall provide the MSS with notification of any defect at least
7 calendar days in advance of its intent to remove the membrane module(s)
from service to preservation. MSS shall have the option during such advance
notice period to send in a technician to witness the membrane module(s) in
operation prior to removal. The MSS shall repair or replace defective
membrane module(s) within 14 calendar days of notification during the first
year of the term. During the last 8 years of the warranty term, MSS shall ship
and deliver to the site of the Work replacement membrane modules and
supplies for module repairs for installation by the Owner. The 7-day advance
notice shall be waived by the MSS if immediate membrane module removal
and replacement is required to meet capacity requirements.
H.
Defects in materials and workmanship are as defined herein:
1.
Integrity Failure Defects: Membrane integrity testing shall be
established to meet the design and performance criteria for each
membrane module and for each membrane skid. Membrane modules
shall be considered to have integrity failure defects under the following
conditions:
a.
If a module possesses integrity breach, and cannot be repaired by
plant operations staff or manufacturer.
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b.
2.
If for a single membrane module more than 0.50 percent (one-half
of one percent) of the fibers have required repair (i.e., by pinning
or gluing) over the extended membrane module warranty period,
then that module shall be considered to be defective and the sole
remedy shall be module replacement. An individual fiber shall be
defined as requiring repair if it has been determined that it is
causing the system to fail the membrane integrity test as specified
in the performance criteria (Section 46 61 34, Membrane
Filtration Equipment).
Irreversible Production Loss Failure Defects: During the Initial
Performance Test, the lowest observed 10-minute average cleanmembrane transmembrane pressure (TMP) will be recorded. This
observed value will be the benchmark to determine whether future
operational TMPs (corrected for temperature to 20 degrees C) are within
the specified allowance for determination of membrane module
operational life. TMP will be adjusted based on the following formula:
TMP20°C = TMP Observed*e(-0.0239*(TObserved-20))
The membrane module’s operational life will be deemed to have ended
and require replacement when:
a.
b.
After a CIP, the module exhibits a loss of membrane specific flux
(temperature-corrected flux per unit TMP) equivalent to
50 percent or greater from the benchmark clean-membrane TMP
that was recorded during the commissioning test.
The module TMP becomes greater than the maximum allowable
TMP as stated by the MSS in its proposal over the entire
membrane performance warranty period.
END OF SECTION
MEMBRANE SYSTEM WARRANTY
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SECTION 46 61 34
MEMBRANE FILTRATION EQUIPMENT
PART 1
1.01
GENERAL
SUMMARY
A.
Section specifies Membrane System Supplier (MSS) requirements for hollow
fiber membrane filtration system (MFS). MSS is responsible to provide a
functional MFS. Requirements and materials not specified herein shall be
selected by MSS for specified performance requirements and environmental
conditions based on standard practice.
B.
Generally, requirements include equipment supply, delivery, installation,
startup testing, commissioning, training, and functional and performance
testing of membrane system, support equipment, pumps, valves,
instrumentation and control, and other accessories. System components shall
be complete and operable, sized to treat required volume of specified water,
and perform in accordance with requirements of the Contract Documents.
C.
The MFS is for treatment of either raw or lime softened water at the Marco
Island North Water Treatment Plant (NWTP). The MFS shall be sized to
produce a maximum 6.7 mgd of net filtrate flow with the capability for future
expansion to 10.0 mgd of net filtrate flow by adding two additional trains and
one feed pump. The system will treat a constant feed flow rate from upstream
processes and shall produce a constant filtrate flow rate to downstream as
specified in this Section.
D.
Work to be provided by MSS includes, as a minimum:
1.
2.
3.
4.
5.
6.
E.
Design and fabricate MFS components and assemblies.
Conduct factory testing.
Deliver MFS equipment.
Provide installation assistance, quality control, quality assurance, field
inspection, and installation certification.
Provide onsite testing, equipment startup, and training of Owner’s
personnel.
Provide As-Built Drawings.
Work to be provided by Contractor:
1.
2.
3.
Construct building to house MFS.
Install MFS with assistance of MSS.
Assist MSS with onsite testing and equipment startup.
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1.02
REFERENCES
A.
The following is a list of standards which may be referenced in this section:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1.03
American National Standards Institute (ANSI).
American Bearing Manufacturers’ Association (ABMA).
American Society of Mechanical Engineers (ASME): PTC 10,
Performance Test Code on Compressors and Exhausters.
American Water Works Association (AWWA):
a.
ANSI/AWWA B110-09, Membrane Systems
ASTM International (ASTM):
a.
ASTM Task Group D6908-06, Standard Practice for Integrity
Testing of Water Filtration Membrane Systems.
b.
D1784, Standard Specification for Rigid Poly (Vinyl Chloride)
(PVC) Compounds and Chlorinated Poly (Vinyl Chloride)
(CPVC) Compounds.
c.
D1785, Standard Specification for Poly (Vinyl Chloride) (PVC)
Plastic Pipe, Schedules 40, 80, and 120.
d.
D4189, Standard Test Method for Silt Density Index (SDI) of
Water.
Hydraulic Institute Standards (HIS).
National Electrical Manufacturers’ Association (NEMA): MG 1, Motors
and Generators.
NSF International (NSF): 61, Drinking Water System Components Health Effects.
Occupational Safety and Health Act (OSHA).
United States Environmental Protection Agency (EPA):
a.
Long Term 2 Enhanced Surface Water Treatment Rule, as
published in U.S. Federal Register (January 5, 2006).
b.
Membrane Filtration Guidance Manual (November 2005).
DEFINITIONS
A.
Refer to ANSI/AWWA B110-9 Membrane Systems Standard for general
definitions. Definitions here expand on the Membrane Systems Standard and
take precedence, where applicable:
B.
Basis of Design: Synonymous with “Design Conditions” as defined herein.
C.
Chemical Wash (CW) Train Interval:
1.
2.
Period of operation between CW events for a train of MFS.
Where CWs are conducted sequentially using two different chemical
solutions e.g., citric acid followed by hypochlorite, the sequential CWs
shall be considered as one CW event.
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D.
Clean In Place (CIP) Train Interval:
1.
2.
Period of operation between CIP events for a train of MFS.
Where CIPs are conducted sequentially using two different chemical
solutions e.g., citric acid followed by hypochlorite, sequential CIPs shall
be considered as one CIP event.
E.
Cleaned Membrane Permeability: Permeability, temperature-corrected to
20 degrees Celsius, of a membrane train following return to service after a
CIP and calculated as first-hour average permeability.
F.
Feedwater: raw water or softened water.
G.
Filtrate Production Capacity: Net filtrate flow available for further treatment
over a 24-hour period of normal operation as defined herein.
H.
Functional Test: Operation of MFS valves, controls, and other devices to
ensure they are functional and ready for performance testing.
I.
Initial Performance Test: Test, with MSS’s assistance, to demonstrate
installed system meets performance requirements specified herein. 30-day
operational period of MFS starting after successful completion of Functional
Test.
J.
Instantaneous Flux:
1.
2.
Filtrate flow rate of a membrane train measured at a given time train is
in production, divided by active membrane surface area (feed side) of
membrane train. May be calculated as Net Flux divided by percent
on-line service factor (%SF), expressed in gallons per day per square
foot (GFD)
For example, system with net flux rate of 40 GFD and a %SF of
96.7 percent has a calculated instantaneous flux of 41.4 GFD
(40 GFD÷96.7%=41.4 GFD).
K.
Membrane Module Warranty Period: Length of Guaranteed Membrane Life
(GML) as provided in Purchase Order. Membrane Module Warranty Period
shall begin after successful completion of Initial Performance Test.
L.
MFS Recovery:
1.
Net volume of membrane-filtered water available for further treatment
divided by total volume of feed water entering membrane train(s) from
prefilter system over a 24-hour period, expressed as a percentage. MFS
Recovery is equal to 1 minus combined MFS waste liquid volume
(considering backwash, tank drainage, etc.) divided by membrane feed
water volume, then multiplied by 100 to convert to a percentage.
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2.
3.
M.
Membrane Train:
1.
2.
N.
2.
The 24-hour average filtrate production available for further treatment
in gallons per day divided by active membrane surface area (feed water
side) in square feet. Units of net flux are gallons per square feet per day
(GFD). Net Flux is equal to Instantaneous Flux multiplied by percent
on-line service factor (%SF).
For example, system with Instantaneous Flux of 41.4 GFD and a %SF
of 96.7 percent has a calculated net flux of 40 GFD
(41.4 GFD x 96.7% = 40 GFD).
Normal Operating Mode:
1.
2.
P.
Membrane unit that has single feed water connection point, operates in
parallel with other membrane units, and is independently controlled,
backwashed, and cleaned. A train shall be fully isolatable from other
trains.
Synonymous with Train.
Net Flux:
1.
O.
For example, system with 0.5 MLD waste liquid volume and 10 MLD
feed water has a feed water recovery of 95 percent
[[1 - (0.5/10)] x 100 = 95%].
Synonymous with Membrane System Recovery, Membrane Recovery
and Feedwater Recovery.
Encompasses operating modes routinely used by MFS, including
forward flow, normal backwash, chemical wash, and other operations
proposed by MSS on a daily basis to meet performance requirements
herein. Normal operation also encompasses membrane integrity testing
(MIT) as required to meet performance requirements herein.
Also defined as follows:
a.
N Condition: All trains in operation.
b.
N-“x” Condition: All but “x” trains in operation, with nonoperating train(s) not to be used for meeting filtrate production
requirements when other train(s) are out of service for backwash,
chemical wash or MIT; “x” is defined as a whole integer ranging
from 1 to 4.
c.
Where MFS is required to meet Filtrate Production Capacity in a
“N-1” condition (all but one train in service), “N-1” does not
account for additional trains being out of service
On-Line Service Factor (%SF): Average percent of time per day membrane
train is producing treated water (forward flow) other than for use in cleaning
operations as part of Normal Operating Mode.
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Q.
Permeability: Instantaneous Flux rate (in GFD) divided by transmembrane
pressure (in psi). Units of permeability are GFD per psi.
R.
Post-CIP Fouling Rate: Percent decrease in temperature-corrected
permeability over 5 days of run time following a clean-in-place; expressed in
units of GFD per psi per day at 20 degrees C.
S.
Pre-filter (Strainer or Screen) System Recovery: Total volume of pre-filtered
water delivered to MFS divided by total volume of feed water entering
prefilter system over a 24-hour period; expressed as a percentage.
T.
Proposed Guaranteed Performance Criteria: MSS’s guaranteed values for the
following parameters at the measured feed water quality, with feed water
quality and guaranteed values taken as a 24-hour average (midnight to
midnight):
1.
2.
3.
4.
5.
6.
7.
Filtrate production capacity.
Maximum instantaneous flux.
Minimum system recovery.
Minimum train CW interval.
Minimum train CIP interval.
Minimum filtrate quality.
Minimum train integrity.
U.
Service Cycle: Period of time between startup of membrane process following
a CIP event and initiation of subsequent CIP event.
V.
Temperature-Corrected Flux or Flux at 20 degrees C: Measured Net Flux or
Instantaneous Flux multiplied by a temperature correction factor (TCF)
warranted by MSS, expressed in the following form:
J 20 = J T x TCF
( 20 − T )
Where:
J20 = Flux at 20 degrees C
JT = Flux at measured water temperature
T
= Measured water temperature in degrees C
W.
Temperature-Corrected Permeability or Permeability at 20 degrees C:
Temperature-corrected Instantaneous Flux rate (in GFD) divided by measured
transmembrane pressure (in psi). Units of temperature-corrected permeability
are GFD/psi.
X.
Terminal TMP:
1.
2.
Highest transmembrane pressure under which membrane train would
typically be operated, expressed in units of pounds per square inch (psi).
Used as criteria for indicating when membrane train requires CIP.
Synonymous with maximum TMP.
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1.04
SYSTEM REQUIREMENTS
A.
1.05
See ANSI/AWWA Membrane Systems Standard Sec. 4.2.
PERFORMANCE REQUIREMENTS
A.
Guaranteed Performance Criteria:
1.
2.
3.
MSS’s proposed guaranteed performance criteria for the following
parameters shall be met on a daily basis calculated as an arithmetic
mean of values measured over a 24-hour period (midnight to midnight).
a.
Filtrate production capacity.
b.
Steady feed flow.
c.
Steady filtrate flow.
d.
Maximum net flux.
e.
Maximum instantaneous flux.
f.
Minimum net system recovery.
g.
Minimum train CW interval.
h.
Minimum train CIP interval.
i.
Minimum train filtrate quality.
j.
Minimum train integrity.
If MFS feed water turbidity, TSS, or TOC values exceed respective
maximums shown in Table 46 61 34-2, one or more of the guaranteed
performance criteria may be subject to modification with consent of
Engineer and Owner.
Filtrate Production Capacity: Over a 24-hour period shall be as follows:
a.
Met with MFS operating in an “N” condition unless otherwise
specified, where “N” is defined under Normal Operating Mode in
Article Definitions.
b.
Met with at the specified reduced filtrate flow rate with the MFS
operating in an “N-1” condition unless otherwise specified, where
“N-1” is defined under Normal Operating Mode in Article
Definitions.
c.
Met over entire range of MFS feed water quality conditions.
d.
Met while meeting other requirements specified herein including
membrane system recovery, CW/CIP frequency, flux,
permeability, and filtrate quality.
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B.
Performance limits:
1.
Performance criteria limits are presented in Table 46 61 34-1.
Criterion
Filtrate production
capacity
Table 46 61 34-1
MFS Performance Requirements
Units
Value
Notes
mgd
6.7
During Normal operation
mgd
5.0
During N-1 operation
mgd
10.0
Future expansion capacity (N+2)
Steady feed flow
Size system to manage flow within the
equalization capacity of the feed tank
Steady filtrate flow
percent
Membrane system
flux
GFD
65
Maximum 24-hour net average
GFD
90
Maximum instantaneous
Design temperature
Celsius
20
Design for filtrate production capacity
Membrane train CW
interval
Hypochlorite
hours
24
36
Minimum
Average over 30-day period
hours
72
168
Minimum
Average over 30-day period
days
30
Minimum
45
Average over 180-day period
Citric acid
Membrane train CIP
Interval
Membrane train
filtrate quality
Membrane train
integrity
Trans-membrane
pressure
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+/- 5
Maximum change over 5 minutes
NTU
<0.1
>95% of time
NTU
<0.3
100% of the time
Or in accordance with USEPA MFGM
LRV
4.0
95% of the time
3.5
100% of the time
PSI
Less than value stated by MSS
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Chemical cleaning
performance
C.
2.
3.
Of initial permeability during years 1-2
percent
percent
70
50
Of initial permeability during years 3-5
Of initial permeability during years 6-10
MFS shall include an automated direct integrity monitoring system
(DIMS) for each membrane train meeting requirements of U.S. EPA
Long Term 2 Enhanced Surface Water Treatment Rule, as published in
the U.S. Federal Register (January 5, 2006) and in accordance with U.S.
EPA Membrane Filtration Guidance Manual (November 2005).
Integrity of each membrane train shall be maintained at a log removal
value (LRV) of 3.5 or greater at all times based on measurements from
the DIMS and as described in Article Direct Integrity Monitoring
System.
DIMS shall be operated in a manner to detect integrity breach of 3 um
or less.
Chemical Cleaning of Membranes:
1.
2.
3.
1.06
80
Membrane Train Integrity:
1.
D.
percent
Perform through CWs and CIPs.
Restoration of Membrane Permeability: CIP operation shall be
sufficient such that, following return of each membrane train to service,
cleaned membrane permeability shall be greater than or equal to the
following values following completion of Initial Performance Test:
a.
80 percent of initial permeability (corrected to 20 degrees C)
during years one and two of operation.
b.
70 percent of initial permeability (corrected to 20 degrees C)
during years three through five of operation.
c.
50 percent of initial permeability (corrected to 20 degrees C)
during years six through ten.
If cleaned membrane permeability is less than specified minimum, or if
post-CIP fouling rate does not meet specified tolerance, two additional
CIPs will be allowed to attain specified requirements. If, after the two
additional CIPs, membranes fail to conform with cleaned membrane
permeability or post-CIP fouling rate requirements, MFS will replace
one or more membrane modules to achieve required 20 degree C
permeability during membrane guarantee and warranty period at no cost
to Owner.
MSS SUBMITTALS
A.
Bid Submittal:
1.
Provide electronic copy in PDF format of items described herein with
Bid Proposal.
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2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
B.
First Submittal:
1.
2.
3.
4.
5.
C.
Exceptions: Identify exceptions to Specification(s).
See AWWA Standard B110 Section 4.3.1 for additional requirements
MSS standard terms and conditions with supplemental terms per
agreement with the City
Equipment list that indicates items included in the MSS scope of supply
Proposed system description including sizing, functional description and
operating conditions that indicate compliance with the Specifications
Life Cycle cost factors including anticipated first-year annual average
power and chemical consumption, as well as guaranteed membrane
replacement price.
Per Diem rate for additional on-site service days in addition to those
included in this Specification.
Warranty:
a.
Information on membrane warranty, specific to this Project and as
specified.
b.
Confirm number of years of non-pro-rata period of membrane
warranty.
c.
Indicate number of years for pro-rata membrane warranty.
Air system requirements
Chemical feed system requirements
MSS shall provide a CD with electronic versions in PDF format, as well
as six hard copy sets of the following Shop Drawing items.
Updated Bid Submittal items as required.
Process & Instrumentation Drawings.
Electrical one-line diagram.
Mechanical layout and plan drawings of proposed skid equipment.
Shop Drawings:
1.
2.
3.
MSS shall provide a CD with electronic versions in PDF format, as well
as six hard copy sets.
See AWWA Standard B110 Section 4.3.2 for additional requirements.
System Components:
a.
Mechanical:
1)
Cut sheets and data sheets including, but not limited to,
manufacturer, model, weight, horsepower, size, options,
power requirements, manufacturer’s catalog information,
descriptive literature, specifications, identification of
materials of construction, range (if applicable), and pump
curve (if applicable) on the following mechanical
components:
a)
Feed pumps.
b)
Feed strainers.
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4.
c)
Backwash pumps.
d)
CIP recirculation pumps.
e)
Motors.
f)
Valves.
g)
Other equipment.
2)
Provide expected outside utility requirements such as high
pressure air, water, power, and drain for each component.
3)
Define hoisting equipment, if any.
b.
Instrumentation and Control:
1)
Cut sheets and data sheets including, but not limited to,
manufacturer, model, power requirements, manufacturer’s
catalog information, descriptive literature, specifications,
identification of materials of construction, range on
instruments.
2)
List and provide catalog information for major process PLC
control and communication.
3)
Describe instrumentation, software, hardware, control
features, remote system monitoring, data storage, and
alarms.
c.
Electrical:
1)
Provide total connected electrical load in kW, kVA, and
amperes for MFS including ancillary equipment furnished.
2)
List three-phase electrical components and horsepower
rating or load in amperes and voltage.
3)
List components that will run off power supply other than
480 volts, three-phase.
4)
Provide wiring diagrams for equipment and interconnection
wiring diagrams.
5)
Provide calculation of the average power consumption.
d.
Spare Parts:
1)
List of manufacturer’s “standard” spare parts, including
items listed in Article Extra Materials.
2)
Recommendations for spare parts and materials for first
12 months of system operation.
3)
Provide price list for standard, recommended, and specified
spare parts.
Narrative Operation Descriptions:
a.
Describe MFS and operation control procedures for an individual
train and entire system, including operation of backwash water
recycle system.
b.
Describe procedures for access, inspection, and removal, repair,
and replacement of membrane modules.
c.
Describe startup, and normal operation procedures as well as
methods for maintaining and recovering membrane system
permeability (backwashing, CWs, CIPs as applicable).
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d.
5.
6.
7.
8.
D.
Pre-Startup Submittal:
1.
2.
3.
E.
Shutdown/Storage/Startup:
1)
Describe procedures for complete shutdown, storage of
membranes and related equipment, and startup.
2)
Detail process equipment necessary to accomplish long term
shut down of the plant.
3)
Detail chemical(s) required and estimated annual use for
storage.
e.
Detail, if necessary, minimum membrane flow requirements to
preserve membrane integrity during shut down.
For software, provide narrative description of control system, logic
diagrams, summary of control functions, summary of monitoring
functions, description of alarms, and other information to describe the
control system.
a.
Final OIT Graphics and I/O Lists:
1)
Coordinated and conformed.
2)
Include tags to/from PCS and plant-wide SCADA.
3)
Final OIT graphics shall illustrate functionality required to
operate MFS.
MSS shall submit factory test procedures
Refer to Section 40 99 90, Package Control System for additional
submittal requirements.
Refer to Section 26 20 00, Low Voltage AC Induction Motors for
additional submittal requirements.
See ANSI/AWWA Standard Spec Section 4.3.3.
Testing related submittals.
MSS shall provide eight sets and one PDF file formatted CD-ROM disc
of Operation and Maintenance Data (O&M):
a.
In accordance with Section 01 78 23, Operation and Maintenance
Data.
b.
Submit preliminary O&M data 30 days prior to equipment
delivery and subsequent functional and performance testing.
Post-Startup Submittal: MSS shall provide six copies, unless otherwise noted,
of the following items prior to final completion:
1.
2.
3.
4.
Executed warranties.
Manufacturer’s Certificate of Proper Installation, in accordance with
Section 01 43 33, Manufacturers’ Field Services.
Three copies of data summary from testing and startup period in
electronic format on CD ROMs.
List of original equipment by model and part number (detailed bill of
materials). List manufacturer names, addresses, and phone numbers.
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5.
6.
7.
8.
9.
1.07
QUALITY ASSURANCE
A.
1.08
1.09
Three copies of the Final O&M Manual in electronic MS Word and
PDF format on CD ROMs incorporating review comments from draft
manual and lessons learned from completion of start-up and testing.
Three copies of the Final O&M Manual in hard copy format
incorporating review comments from draft manual and lessons learned
from completion of start-up and testing.
Three copies of final HMI screen programs with the MSS standard
comments and documentation in electronic format. Provide on CDROMs.
Three copies of each final PLC program with the MSS standard
annotations, comments and documentation in electronic format. Provide
on CD-ROMs.
One copy of the PLC software identical to software used by MSS to
develop PLC(s) programs.
MSS’s Field Representative Qualifications: Individual who has previously
provided onsite services for installation, testing, and startup of MSS’s
identical system at a minimum of one treatment facility plant of similar size
but no less than 2 mgd design capacity.
SCHEDULING
A.
Bid Submittal: With final proposal before contract execution.
B.
First Submittal: Within 35 days from NTP.
C.
First Resubmittal (if required): Within 14 days of receiving comments.
D.
Shop Drawings: Within 45 days from approved First Submittal.
E.
Shop Drawings Resubmittal (if required): Within 14 days of receiving
comments.
F.
Pre-Startup Submittal: Greater than 30 days before Equipment Delivery.
G.
Equipment Delivery: Within 21 weeks from approved Shop Drawings.
H.
Post-Startup Submittal: Within 30 days of successful completion of initial
performance test.
GUARANTEE AND WARRANTY
A.
MSS shall provide a guarantee and warranty for MFS in accordance with
requirements of Section 46 61 33.01, Microfiltration and Ultrafiltration
Membrane Equipment Warranty.
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PART 2
2.01
PRODUCTS
GENERAL
A.
Products to be furnished under this section are as follows:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
2.02
B.
Items to be furnished shall be MSS’s standard unless otherwise indicated.
Items shall be new and unused and shall be MSS’s most current product line
at time of product submittal. Provide and list separately a deduct for use of
standard equipment in lieu of specified equipment manufacturers.
C.
Equipment shall comply with OSHA standards.
D.
Terminal point connections shall be ANSI standard flanges.
MFS SUPPLIER
A.
Materials, equipment, and accessories specified in this section shall be
products of:
1.
2.
2.03
Strainers.
Membrane filtration trains, including modules.
Membrane feed pumps, including appurtenances.
Backwash system, including filtrate equalization/backwash supply tanks
and pumps, as applicable.
Cleaning system for conducting CW and CIP, including tanks pumps
and valves, as applicable.
Membrane integrity test system.
Intra-system piping, including piping on racks and skids.
Manual and actuated valves outside of skids as shown on P&IDs.
Electrical.
Motors in accordance with Section 26 20 00, Low Voltage AC
Induction Motors.
Instrumentation and controls in accordance with Section 40 99 90,
Package Control Systems.
Spare equipment, special tools, and chemicals.
GE Water & Process Technologies.
PALL Corporation.
SERVICE CONDITIONS
A.
Owner will provide raw or softened water to MFS via gravity pipeline into a
feed tank. Contractor shall provide the Work necessary for delivery of raw or
softened water from the feed tank to MFS’s connection point.
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B.
Upstream water treatment process includes one of the following unit
processes:
1.
2.
3.
C.
No treatment.
In-line alum coagulation.
Lime softening/clarification.
MSS shall provide coordination and integration of processes and process
control for interfaces to immediate upstream and downstream processes.
1.
2.
3.
Provide process control logic for interfaces to upstream and downstream
processes.
This effort shall include, but not be limited to, process control logic,
coordination, testing, and startup of items associated with interface to
upstream and downstream processes.
Process control requirements shall be included in final process control
narrative.
D.
Equipment will be installed in an Owner-provided building, which will be
constructed by Contractor. Temperature within building will range from 50 F
to 104 F at minimum and maximum conditions, respectively.
E.
Backwash wastewater will be discharged to a dedicated line for equalization,
treatment and recycle to treatment plant.
F.
Filtrate required for backwash will be supplied from backwash tank, included
in the MSS scope of supply. Filtrate produced for downstream use shall be
discharged at a minimum pressure of 14 psig.
G.
Filtrate required for CW and CIP will be supplied from a plant water system,
not included in the MFS scope.
H.
Feed Water Quality:
1.
2.
3.
Water quality data for raw or softened water, heretofore referred to as
MFS feed water, is presented in Table 46 61 34-2.
Represents expected quality for MFS feed water.
Performance guarantees and system performance criteria listed herein
shall be achieved by MFS when operating on feed water having a
quality that falls within ranges for each parameter listed in
Table 46 61 34-2.
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Table 46 61 34-2
MFS Feed Water Quality
WQ Parameter
pH
Alkalinity
Total Hardness
Turbidity
TDS
Color
Chloride
TOC
Temperature
Iron
Manganese
2.04
Units
Std. Units
mg/L as
CaCO3
mg/L as
CaCO3
NTU
mg/L
PCU
mg/L
mg/L
ºF
mg/L
mg/L
Maximum
Minimum
Average
8.8
8.4
8.6
40
25
35
120
15.0
522
45
160
18.0
84
<0.3
<0.05
100
1.0
223
5
81
6.0
68
<0.3
<0.05
110
2.5
442
7
122
8.4
77.1
<0.3
<0.05
PROCESS CONTROL
A.
Membrane system will receive and treat feed water and pass filtrate to the
downstream process. MFS shall continuously process feed water as required
by Filtrate Production Capacity requirements. MSS shall provide automated
features with system design, PCS, and equipment to automatically operate the
membrane system 24 hours per day accounting for individual membrane trains
being out of service for backwashing, MIT, or CW.
B.
Steady Feed Flow:
1.
2.
3.
4.
Flow to MFS system will be steady throughout the day with changes
occurring less than 4 times per day. MSS shall provide a process control
strategy that responds automatically to changing feed flows throughout
the day. MSS process control strategy shall also be coordinated with
upstream process and provide a constant flow to downstream processes.
Membrane process control strategy shall accommodate incoming
variable flow. Process control strategy shall adjust operation of MFS to
maintain operating level in the feed water tank. Process control strategy
shall not depend on a constant MFS feed flow or being able to bypass
flow around MFS to be able to maintain a constant flow through
membrane systems.
Membrane system performance requirements shall be met with constant
membrane feed flow and constant membrane filtrate flow (downstream
of the filtrate equalization/backwash tank) process control strategy.
The membrane system must be capable of treating steady feed flow at
the required rate when one train is removed for service to conduct MIT
or CW. Such operation shall not be considered an N-1 or N-2 condition.
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5.
C.
Steady Filtrate Flow:
1.
2.
3.
4.
2.05
The membrane system shall be programmed so that only one train is out
of service at any given time for backwash, CW or MIT thus maintaining
the N condition.
Steady over a 24-hour period as specified herein.
To provide smooth, uninterrupted flow to downstream systems, when a
membrane train enters backwash, filtrate production shall be maintained
by ramping up filtrate production of trains in service.
The system shall be sized to ensure constant filtrate production at the
design flow rate when one train is removed from service to conduct
MIT or CW. Such operation shall not be considered an N-1condition.
The membrane system shall be programmed so that only one train is out
of service at any given time for backwash, CW or MIT thus maintaining
the N condition.
CONNECTION POINTS
A.
Terminal point connections to MFS shall be ANSI standard flanges.
B.
Provide single connection points at MFS for the following:
1.
2.
3.
4.
5.
6.
7.
C.
Provide single connection points for each membrane train for the following:
1.
2.
3.
4.
5.
6.
7.
8.
D.
Feed water.
Filtrate.
CW/CIP waste.
Sodium Hypochlorite.
Citric acid.
Sodium hydroxide.
Other chemical as specified by MSS.
Feed.
Filtrate.
Backwash supply.
Backwash waste.
Cleaning solution feed.
Cleaning solution return.
High pressure compressed air.
Low pressure compressed air.
Provide connection points at each train for:
1.
2.
MFS PLC remote I/O network.
Electrical Power: Single connection point.
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E.
Piping and electrical connection points to strainers, backwash pumps, and feed
pumps shall be as required for each component. Provide a single connection
point at each motor for electrical power and motor protective devices.
F.
Connections for the CIP system as follows:
1.
2.
3.
4.
G.
Connections for the drain pump skid:
1.
2.
3.
4.
H.
2.06
Acid tank makeup water fill, chemical fill, overflow, CIP return, and
drain.
Caustic tank makeup water fill, chemical fill, overflow, CIP return, and
drain.
CIP skid electrical (single point connection), control signal terminal
block, piping inlet, piping outlet and piping drain
As needed for tank heaters and tank instrumentation
Electrical (single point connection).
Control signal terminal block.
Piping inlet.
Piping outlet.
Air compressors, silencer, filters, dryer and other accessories for a fully
functional system shall have one connection point for interconnecting piping
between air compressor system and membrane trains and one connection point
for electrical power.
MEMBRANE SYSTEM EQUIPMENT
A.
Chemical Metering Pumps: The MFS will control the operation of these
pumps. But, chemical feed equipment is excluded from the MFS scope.
B.
Prefilter (Strainer) System: MFS shall be suitable for operation with a prefilter
system fitted with a (300-micron) sized screen. Prefilter system shall be
supplied by MSS.
C.
Membrane Trains and Modules:
1.
2.
Each membrane train shall be designed for installation of additional
modules equal to or greater than 10 percent of installed number of
modules (empty module spaces). Where MFS instantaneous flux rate
must be reduced to meet performance requirements, MSS may install, at
no additional cost to Owner, additional modules in empty module
spaces.
Membranes: Meet the following requirements:
a.
Comprised of hollow fibers.
b.
Operate in an outside-in flow configuration.
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3.
4.
D.
Membrane Feed Pumping:
1.
2.
3.
E.
c.
Have a nominal pore size equal to 0.1 um or less.
d.
Resistant to free chlorine and other oxidants.
Membrane module rack (skid) shall be manufactured of powder-coated
steel. Skid shall include bolt holes for mounting on concrete pad.
Isolation and Removal of Membrane Modules: Provide valves or other
means of isolating each individual module from remainder of system,
enabling train to produce water with one or more modules out of
service.
Approximate pump discharge elevation is 39.75 feet. Approximate pipe
length of membrane permeate piping to downstream process is 300 feet.
MSS shall confirm permeate/feed pump requirements with Engineer.
Floor elevation where pumps are to be installed is approximately 9.3
feet. For conservative pump sizing, assume that only a flooded suction
and minimum Net Positive Suction Head (NPSH) requirements will be
provided.
The Membrane System Feed Pumps shall meet all requirements in
Section 44 42 56, Pumps - General, but modified as follows:
a.
Testing shall be performed on one pump at a minimum.
b.
If test on initial pump do not meet requirements, all remaining
pumps must be tested at supplier’s cost.
c.
On-site vibration testing for feed pumps only.
Manufacturer: Peerless.
Backwash System:
1.
2.
3.
4.
5.
6.
Provide backwash pumps, agitation air blowers, isolation and check
valves, meters and controls, and other components to provide automated
backwash system, as applicable.
Pumps: Provide a minimum of one duty backwash pump and one
standby pump.
Backwash and supply water supplied from combined permeate pipe
header provided by Contractor.
Initiation and functions shall be automatically controlled by MFS PLC.
Backwash shall be automatically initiated based on time, TMP, or
filtrate (permeate) volume. System shall also allow operator to initiate a
backwash and control each piece of equipment and valves manually.
MFS PLC shall record time and duration of each backwash.
Refer to Section 44 42 56, Pumps – General, for additional
requirements.
Manufacturer: Peerless.
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F.
Direct Integrity Monitoring System (DIMS):
1.
2.
3.
4.
5.
6.
G.
Include DIMS for each membrane train meeting requirements of the
U.S. EPA Long Term 2 Enhanced Surface Water Treatment Rule, as
published in the U.S. Federal Register (January 5, 2006) and in
accordance with the U.S. EPA Membrane Filtration Guidance Manual
(November 2005).
Features:
a.
Operate automatically, controlled by MFS PLC.
b.
Operator-adjustable frequency of testing with a range of 12 hours
and 168 hours.
c.
Automatically alarm a failure.
Frequency:
a.
Once every 24 hours.
b.
If a 30-minute running average turbidity for a membrane train is
above 150 mNTU (0.15 NTU), perform direct integrity test on
train.
LRV for each train shall be calculated in accordance with requirements
of the U.S. EPA Long Term 2 Enhanced Surface Water Treatment Rule,
as published in the US Federal Register (January 5, 2006) and in
accordance with the U.S. EPA Membrane Filtration Guidance Manual
(November 2005).
a.
MSS shall submit detailed methodology that clearly shows how
train LRV is calculated based on DIMS results and train/system
configuration.
Conduct direct integrity testing using pressure applied to filtrate side of
membrane in accordance with ASTM Task Group D19.08.02:
REVISION J.
Train integrity failure shall be defined as air pressure decay rate that
equates to a LRV of less than 3.5 for membrane train.
Membrane Cleaning and Other Associated Equipment:
1.
2.
3.
4.
Provide pumps, tanks, mixing devices, actuated valves, chemical
injection assemblies, controls, and other system components to provide
for proper operation and functioning of the CW and CIP systems.
All tanks shall have its discharge invert located flush with the bottom of
the tank.
CIP system shall be designed to remove solids and dissolved
compounds that have accumulated in membrane modules, including on
membrane surface and within membrane pores, such that clean water
permeability of membrane is consistently restored to a minimum value
as specified in Article, Performance Requirements.
Cleaning system shall be designed for automatic operation once a
cleaning cycle has been initiated by operator.
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5.
6.
H.
Spent cleaning solutions shall be discharged to the existing reclaimed
water wet well to be connected by the Contractor.
a.
MSS shall provide equipment and systems discharge waste to wet
well.
CIP and CW Control and Monitoring:
a.
Provide controls for chemical systems through MFS PLC(s).
1)
MFS PLC(s) shall record time between chemical cleanings
and send alarm when next chemical cleaning is needed
based on operator-entered time interval or an increase in
TMP.
2)
Controls shall automatically shut down membrane train if
pH or chlorine residual levels are outside set points.
3)
Control system shall record time between CWs and CIPs.
Piping:
1.
2.
General:
a.
Install true union fittings where future disconnection may be
required.
b.
Piping color shall be selected by Owner.
MSS shall be responsible for:
a.
Piping within each membrane train and within train’s
corresponding pipe rack:
1)
Feed.
2)
Filtrate.
3)
Backwash supply.
4)
Backwash waste (normal and CW).
5)
CIP feed and return.
6)
High and low pressure air.
b.
Actuated valves, and in-line instruments and controls for ancillary
systems, including:
1)
Pre-strainer system.
2)
Chemical feed systems for CIP and CW.
3)
Low-pressure air system.
4)
High-pressure air system.
5)
Backwash system
6)
Membrane integrity test system.
7)
Air distribution to on-rack valves and off-rack valves
specified in this Specification.
c.
Automated isolation system on filtrate and CIP lines to prevent
contamination of filtrate with chemical cleaning solution.
Preference is given for a block-and-bleed system that establishes
an air gap.
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3.
4.
5.
6.
7.
I.
Contractor shall provide interconnecting process piping between trains’
pipe racks for MFS, and between membrane trains/pipe racks and
ancillary equipment including backwash pumps, CIP system, low
pressure air system, and high pressure air system.
Liquid Service Piping:
a.
Piping for liquid service shall be Type 316L or higher-grade
stainless steel, or HDPE. Piping shall meet all applicable ASTM
and AWWA standards.
b.
All Type 316L stainless steel piping shall be pickled and
passivated (including factory and field welds) and be provided
with low point drains to empty all piping when not in use for
extended periods of time.
c.
Designed to limit maximum flow velocities to 8 feet per second
(fps) at maximum flow.
1)
If unable to meet 8 feet per second flow criteria, indicate
and describe locations where velocities are greater than 8
feet per second.
2)
Velocities greater than 8 feet per second shall be considered
as part of the nonprice factor evaluation.
High-Pressure Air Lines:
a.
Type 316 stainless steel pipe.
b.
PVC is not acceptable for air pipelines.
Low-Pressure Air Lines:
a.
Designed to limit maximum flow velocities to 40 feet per second
at maximum flow.
b.
If unable to meet 40 feet per second flow criteria, indicate and
describe locations where velocities are greater than 40 feet per
second.
c.
Velocities greater than 40 feet per second shall be considered as
part of the nonprice factor evaluation.
Chemical Solution Piping: Schedule 80 PVC, conforming to Type I,
Grade I, ASTM D1784 and ASTM D1785.
Manual and Actuated Valves:
1.
MSS shall provide check valves, control valves, and isolation valves
except for feed pump inlet/outlet, strainer inlet/outlet, chemical feed
systems and backwash pump inlet/outlet valves required for a
completely functional system (shipped loose and properly labeled, if not
provided as part of each membrane train or pipe rack):
a.
Gate Valves:
1)
Conform to AWWA C500.
2)
Iron body, bronze mounted, flanged ends, double disc gate,
nonrising bronze stem, rated 150-pound WOG.
3)
AWWA C550 epoxy lining.
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b.
2.
3.
J.
Ball Valves, (PVC) 2-Inch and Smaller: Nibco True-Bloc, ASAHI
America Duo-Bloc, or equal.
c.
Equipment Air Ball Valves: Milwaukee BA100ELD, Apollo
75-100-41, or equal.
d.
Butterfly Valves:
1)
Conform to AWWA C504.
2)
Class 150B, flanged end, short body type, cast iron body,
cast or ductile iron disc with Type 316 stainless steel shaft,
EPDM seat and stainless steel seating surface.
3)
AWWA C550 epoxy lining.
4)
Manufacturers and Products:
a)
Bray; Series 30.
b)
Valves located on a manufacturer’s valve rack may be
“equals”
e.
Solenoid Valves: MSS’s standard, 120 volts, 60 HZ ac.
f.
Check Valves:
1)
Lever-weighted swing check, cast-iron body, bronze body
seat, bronze mounted cast-iron clapper with rubber seat,
stainless steel hinge shaft.
2)
Manufacturers: Kennedy or Mueller Co.; No. A-2600
Series.
Pneumatic Actuators:
a.
Guaranteed for 1,000,000 cycles with less than 5 percent failure.
b.
Include air sets, exhaust mufflers, speed controls, pilot solenoids,
and accessories.
c.
Manufacturer:
1)
Pneumatic Actuator: Keystone 79U.
2)
Pilot Solenoid Valves: Asco Red Hat or C.A. Norgren Co.
Sample Valves: Provide 1/2-inch stainless steel ball valve sample taps,
with female thread on outlet, at the following locations:
a.
Strainer influent.
b.
MFS feed (strainer effluent).
c.
Filtrate (from each train).
d.
Backwash supply (following CW chemical injection)
e.
Backwash waste (normal and CW).
f.
CIP solution (at CIP pump discharge).
Instrumentation and Controls:
1.
General:
a.
Control functions contained and described herein are intended to
provide proposed minimum performance requirements. They do
not necessarily identify each and every control function,
connection, communications, or equipment to achieve the
requirements. Additional specificity and details shall be
coordinated at time of submittals
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b.
2.
Provide control system components and testing in accordance
with Section 40 99 90, Package Control Systems.
c.
Panel Numbers: Manufacturer’s standard.
d.
Control panels shall be freestanding NEMA 4X Type 304
stainless steel. Power supply to each panel will be one 120V ac,
60-Hz, single-phase circuit.
e.
Provide application software for digital, programmable
components of membrane systems. Provide Owner with a copy of
the professional version of Rockwell Automation RSLogix 5000
PLC programming software with Ladder Logic, Structured Text,
and Function Block programming packages and any required
software licenses
f.
Provide standard software and software licenses.
Controls:
a.
Controls for components of membrane system shall be provided
by a dedicated non-redundant programmable logic controller
(PLC) mounted in a main membrane control panel.
1)
Provide dedicated remote input/output (I/O) rack for each
membrane mounted at each membrane train.
b.
PLC shall provide control and monitoring functions as required
for operation, monitoring, and control of membrane systems
including but not limited to timing, interlocks, start-up
sequencing, normal start-up/ shutdown sequences, emergency
shutdown, operator interface, permissives, and process control
interfaces to/from upstream processes and downstream processes.
1)
Programming Standards:
a)
Manufacturer’s Standard.
b)
Programming shall be customized for this Project as
required.
c)
Tags shall be accessible by plant SCADA system for
monitoring.
2)
PLC I/O Signals: Refer to P&ID Drawings.
3)
Field alarm instruments and contacts shall be wired for
failsafe operations where an open circuit will alarm.
c.
PLC communications and faults shall be monitored.
1)
Indicating Lights:
a)
Colors in accordance with Owner I&C Design
Standards.
b)
Equipment tag numbering will Manufacturer’s
standard.
d.
Uninterruptible power supply (UPS) backup power for MSS
control panels (main control panel and remote I/O panels) will be
supplied by the MSS.
1)
Provide UPS in the main control panel and size to provide
120V AC power to all control devices in the control panel
and on membrane trains including but not limited to the
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e.
f.
g.
h.
PLC, Remote I/O, OIU, Ethernet Switches, 24V dc power
supplies, network equipment, and other electronic devices.
The batteries for the UPS shall be sized to power all
connected equipment to provide a safe shutdown of the
membrane filtration system.
2)
PLC I/O, control circuits, instrument components, and all
other devices required to provide safe shutdown of
membrane control system shall be included on UPS power.
Communications Network: Provide Ethernet TCP/IP 10/100 mbps
network communications module to support communications
between PLC and Owner’s plant control system network. Provide
Ethernet TCP/IP Fast Ethernet connections between remote I/O
panels and main MFS control panel as shown on the Drawings.
1)
MSS communication protocol shall be Ethernet/IP and the
MSS shall provide coordination of membrane system to
plant system communications.
2)
Provide all I/O modules as required to support the
membrane system plus 20 percent spare. All I/O shall be
wired to field terminations and include surge arrestor and
isolation.
3)
Provide Ethernet modules for communications from PLC to
I/O, and to SCADA. Provide EN2T Ethernet modules; one
each for PLC I/O communications network and one for
HMI/PLC communications network.
4)
Provide all work and programming to incorporate MFS
system graphics onto the Owner’s existing Wonderware
SCADA system. Provide all necessary drivers and software
updates.
5)
Ethernet Switch Manufacturer and Product:
a)
N-Tron 716TX having (16) 10/100BASE-TX ports.
MSS to coordinate firmware revision with Owner at time of
supply.
PLC Manufacturers and Products: Refer to Section 40 99 90,
Package Control Systems.
HMI: Provide an industrial panel-mounted PC preloaded with
Wonderware In-Touch HMI software for local control and
monitoring from the MFS main control panel.
1)
MSS to provide complete applications software and
graphics for Industrial panel-mounted PC. Graphics shall be
the same as those created for the Owner’s SCADA system
HMI.
2)
Industrial Panel mounted PC minimum requirement:
a)
17-inch color TFT LCD display.
b)
Fanless cooling system design.
c)
Minimum 100GB hard drive, (2) USB ports, and
(1) DVD-RW drive.
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3.
4.
d)
Manufacturer: Arista, or approved equal.
3)
MSS to coordinate version with Owner at time of supply. At
a minimum provide Wonderware In-Touch 10.0HMI
software.
i.
The HMI software of the plant SCADA system will be
Wonderware. This software is existing and programming will be
provided by the Contractor. Provide a copy of all Wonderware
graphic screens developed for the MF Control Panel OIU to the
Contractor for incorporation to the Plant Wonderware SCADA
system. The plant SCADA software will be programmed to
monitor and provide supervisory control of the Membrane
Filtration control system. Complete operation of each membrane
train shall be possible at the OIU at the main MF Control Panel or
at the plant SCADA HMI graphical screen. The Proposer shall
assist the Contractor in programming the SCADA HMI computer.
Provide for Owner and Engineer input into graphics, displays, etc.
The Proposer shall be responsible for the proper sizing, programming
and operation of the associated control equipment to adequately protect
and control the equipment specified in this Section.
Instrumentation and Monitoring Equipment:
a.
Provide turbidimeters, laser turbidimeters, pH/ORP meters, flow
meters, and related appurtenances mounted in accessible
locations.
b.
Electromagnetic Flow Meters:
1)
Provide for each membrane train and each backwash flow as
shown on the P&IDs.
2)
Electromagnetic flow meters shall use pulsed dc type coil
excitation principle with high impedance Type 316 stainless
steel electrodes and shall be designed for use in potable
water. 120Vac 60-Hz power, remote wall mounted
IP67/NEMA 4X transmitter, isolated 4 to 20 mA DC signal
type output, minimum of 60 feet of IP 68 rated transmitter
to element interconnecting cable, Type 316L stainless steel
ANSI 150 pound flanges and grounding rings, straps and
mounting brackets, epoxy coated exterior surfaces.
Minimum accuracy including transmitter of plus or minus
0.5 percent of actual rate between 10 percent and 100
percent of design flow. Transmitter shall have LCD display
with adjustable parameter access using a keypad or other
non-intrusive means.
3)
Provide factory calibration certificate for each meter.
4)
Manufacturers and Products:
a)
ABB Automation; Magmaster.
b)
Emerson Process Management Rosemount Division;
Model 8705 flow element and Model 8732
transmitter.
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c.
c)
Endress & Hauser; Promag 53 series.
Pressure/Differential Pressure Transmitters:
1)
General:
a)
Function:
(1) Measure pressure or differential pressure as
shown on P&IDs.
(2) Transmit signal proportional to either
differential pressure or pressure, as applicable.
b)
Type:
(1) Electronic variable capacitance or silicon strain
gauge.
(2) Two-wire transmitter; “smart electronics”.
c)
Parts: Transmitter and accessories.
2)
Performance:
a)
Range: As required.
b)
Accuracy: Plus or minus 0.10 percent of span, unless
otherwise noted.
c)
Process Operating Temperature: Minus 40 degrees F
to plus 250 degrees F.
d)
Humidity: 0 to 100 percent relative humidity.
3)
Features:
a)
Linear or square-root output, user-configurable.
b)
Adjustable damping.
c)
LCD indicator.
d)
Display in either percent or engineering units, field
configurable.
e)
Wetted Metallic Parts: Type 316 stainless steel, unless
otherwise noted.
f)
Includes drain/vent valves; process flanges and
adapters, and process isolating diaphragm.
g)
Wetted O-Rings: Glass-filled TFE, graphitefilled PTFE, or Viton, unless otherwise noted.
h)
Bolts and Nuts (if required): Type 316 stainless steel.
i)
Fill Fluid: Silicone.
4)
Process Connections:
a)
Line Size: 1/2 inch.
Connection Type: FNPT.
b)
5)
Signal Interface:
a)
4 mA to 20 mA dc output with digital signal based on
HART protocol.
(1) Nominal Maximum Loop Resistance with
External 24V dc Power Supply: 550 ohms.
6)
Enclosure:
a)
Type: NEMA 4X.
b)
Materials: Coated aluminum.
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c)
d.
e.
Bracket and Accessories: Stainless steel; suitable for
mounting transmitter to panel or 2-inch pipe.
7)
Accessories:
a)
Three-valve manifold.
(1) Includes one equalization and two isolation
valves.
(2) Type 316 stainless steel.
8)
Manufacturers and Products:
a)
Rosemount; Model 2088.
b)
Endress and Hauser; Cerebar.
Pressure Switch:
1)
General:
a)
Function: Monitor pressure, activate switch at set
point, and deactivate switch at reset point.
b)
Type:
(1) Piston-actuated.
(2) Both set point and deadband (the differential
between set point and reset point) adjustable.
2)
Performance:
a)
Set Point:
(1) As required.
(2) Repeatability: Plus or minus 1 percent of range.
b)
Deadband: Adjustable within nominally 25 percent
and 85 percent of range.
c)
Overpressure Proof Pressure:
(1) Pressure psi Ranges: At least 400 percent of
rated maximum static pressure.
(2) Pressure Inches of Water Ranges: 20 psig.
(3) Compound Range: 250 psig.
(4) Vacuum Range: 250 psig.
3)
Features:
a)
Actuator Seal: Buna N.
b)
Adjustable deadband.
c)
Mounting: Surface.
4)
Process Connection:
1/4 inch NPT female connections.
a)
b)
Materials: Type 316 stainless steel.
5)
Enclosure: NEMA 4X.
6)
Signal Interface: SPDT, rated for 10 amps minimum at
120V ac.
7)
Manufacturers and Products: Ashcroft; L or P Series
Rotameters:
a)
Measure smaller flows and provide local indication
only.
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b)
f.
g.
h.
ABB series 10A4500 or Brooks GT 1100 Series.
Alternative manufacturer must be approved by the
Engineer prior to installation.
Pressure Gauges:
a)
General:
(1) Function: Local pressure indication.
(2) Type: Bourdon tube element.
b)
Performance:
(1) Scale Range: As noted.
(2) Accuracy: Plus or minus 0.50 percent of full
scale.
c)
Features:
(1) Dial: 4-1/2 inch diameter
(2) Pointer Vibration Reduction: Required.
(3) Case Material: Black thermoplastic.
(4) Materials of Wetted Parts: Stainless steel.
(5) Pointer: Adjustable by removing ring and
window.
(6) Window: Glass or acrylic.
(7) Threaded reinforced polypropylene front ring.
(8) Case Type: Solid front with blow-out back.
d)
Process Connection:
(1) Mounting: Lower stem.
(2) Size: 1/2-inch MNPT.
e)
Accessories:
(1) Throttling Device: Required.
(a) Type suitable for the intended service.
(b) Install in gauge socket bore.
f)
Manufacturers and Products: Ashcroft; Duragauge
Model, 1279/Model, 1279 PLUS.
Temperature Element and Transmitter:
a)
100 Ohm Platinum 3-wire RTD sensor within sealed
Type 316 Stainless steel sheath, mounting within ¼inch tapered bore Type 316 stainless steel thermowell,
DC loop powered, IP67/NEMA4X housed transmitter,
isolated 4 to 20 mA DC output, min. accuracy of plus
or minus 0.25 percent of reading.
Provide factory calibration certificate for each device.
b)
c)
Manufacturer: Rosemount Model 3144, Foxboro, or
equal. Alternative manufacturer must be approved by
Engineer prior to installation.
Turbidity Element and Transmitter:
1)
General:
a)
Type: Light scatter detection measurement using
90-degree scatter photocell detector.
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b)
2)
3)
4)
5)
6)
Function: Continuously measure, indicate, and
transmit signals proportional to turbidity of raw water
and membrane filtrate from each train.
c)
Parts: Element, transmitter, interconnecting cable,
mounting hardware, and expendables.
d)
Each turbidimeter shall be integrated with MFS PLC
for monitoring, data recording, and alarm/shutdown.
e)
Turbidimeters shall obtain sample water by gravity
flow from source and route wastewater to drain by
gravity flow.
f)
Provide one turbidimeter for each membrane filtration
equipment train.
g)
Provide one turbidimeter for membrane system
influent quality monitoring.
Performance:
a)
Range:
(1) Membrane System Influent: 0 to 100 NTU.
(2) Membrane Filtrate: 0 to 1 NTU.
b)
Resolution: 0.0001 NTU.
c)
Repeatability: Plus or minus 1.0 percent or plus or
minus 0.002 NTU, whichever is greater.
d)
Response Time: For full scale step change, 90 percent
response in 5 minutes at 250 milliliters per minute of
flow.
e)
Required Flow: 250 to 750 milliliters per minute.
f)
Sample Fluid Temperature: 32 degrees F to 122
degrees F.
g)
Operating Temperature: 32 degrees F to
104 degrees C.
Element: Internal bubble trap and vent.
Transmitter:
a)
Features:
(1) Four-digit display.
(2) Capability to display results from a minimum of
eight turbidimeters on single output screen.
b)
Signal Interface:
(1) Output: 4 to 20 mA dc for load impedance of
500 ohms minimum.
(2) Alarm Contacts: Two independent alarm set
points, each adjustable over full range.
c)
Enclosure:
(1) Type: NEMA 4X.
(2) Mounting: Wall mounted.
Cable: 20 feet.
Manufacturer and Product: Hach Company; Model 1720E.
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i.
j.
Laser Turbidimeter:
1)
Type: Laser type for membrane integrity test.
2)
Parts: 660-nanometer laser diode, fiber optics, and
photomultiplier tube.
3)
Function: To allow turbidity measurement of membrane
filtrate from each independent membrane train.
4)
Turbidimeter shall obtain sample water by gravity flow
from source and route wastewater to drain by gravity flow.
5)
Manufacturer and Product: Hach Company; FilterTrak 660.
Temperature/pH Transmitter:
1)
General:
a)
Provide pH and ORP elements and transmitters as
shown on the P&IDs
b)
Function: Continuously, measure, indicate, and
transmit water temperature and pH or ORP of process
streams.
c)
Parts: Analyzer/transmitter unit, mounting hardware,
sample tubing and connectors, reagent bottle, and
expendables.
2)
Service:
a)
Measurement Type: pH or ORP and water
temperature.
b)
Sample Flow: 500 milliliters per minute.
c)
Sample Supply: Continuous.
d)
Sample Temperature Range: 32 degrees F to
100 degrees F.
3)
Performance:
a)
pH Range: 0 to 14 pH.
b)
ORP Range: Minus 1400 mV to plus 1400 mV.
c)
Temperature: 32 degrees F to 100 degrees F.
d)
Sensitivity: 0.01 pH units, 0.1 degree.
e)
Response Time: 4 seconds, maximum.
f)
Accuracy: 1 percent of range.
4)
Features:
a)
Temperature Compensation: Automatic for sample
temperatures between 32 degrees F and
100 degrees F.
b)
Display: LCD.
c)
Reagent Storage: 7-day supply bottle.
5)
Instrument Piping Connections: Pre-piped; sample in,
sample drain, and overflow drain.
6)
Signal Interface: Outputs: Isolated 4 to 20 mA dc for load
impedance 0 to 800 ohms minimum for 24V dc supply
without load adjustment.
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7)
k.
l.
Enclosure:
a)
Electronics: NEMA 4X.
b)
Instrument Mounting: Wall panel mounted.
Manufacturer and Product: Hach Company; GLI Series with
SC100 transmitter.
General Instrumentation and Monitoring Equipment
Requirements:
1)
Provide 40 mm diameter stainless steel identification tags
with punched markings for each field-mounted device.
Permanently attach the tags to the devices with stainless
steel lightweight chain.
2)
All four wire instrument AC supply circuits are to be
supplied with local, watertight, corrosion-resistant
disconnect switch, to be installed by the Contractor within
10 feet of the instrument’s final location.
3)
For all Proposer provided instrumentation and monitoring
equipment, provide all necessary components and fittings
including, but not limited to standard and dielectric unions,
grounding rings and straps, gaskets, bolts, reducers, meter
body and transmitter supports.
4)
Furnish all other instrumentation required to have a
complete, operating system as described in this Document.
These items may include gauges, switches, sensors, etc.
These items should be of high quality, suitable for
continuous, low-maintenance operation in a damp, hot,
industrial environment.
K.
Electrical: Refer to Section 26 20 00, Low-Voltage AC Induction Motors.
L.
Accessories:
1.
M.
Lifting Lugs: Provide suitably attached for equipment assemblies and
components weighing over 100 pounds.
Extra Materials:
1.
Furnish, tag, and box for shipment and storage the following at a
minimum:
a.
Jigs, fixtures, clamps lifting beams, hooks, and other apparatus
required to facilitate removal, disassembly, re-assembly and
installation of each item of equipment within system.
b.
Two sets of new tools required for removal, disassembly,
reassembly, installation, operation, and maintenance of each
specialty item of equipment within MFS (e.g., specialty tool for
removal of membrane module).
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c.
d.
e.
2.07
Two repair kits for sealing off damaged membrane fibers within
membrane module.
Reagents/chemicals and calibration sets as specified for individual
equipment items or instruments.
One shelf spare CIP recirculation pump.
FUNCTIONAL REQUIREMENTS
A.
Provisions shall be made for both LOCAL and REMOTE operations for all
controlled equipment.
1.
2.
Local Operation: All controlled equipment will each have a local
ON/OFF/REMOTE hand switch located close to it. For controlled
equipment with adjustable speed drives, a local speed potentiometer
shall be provided as well.
a.
Local control is for maintenance only or local operation by the
operator.
Remote operation shall be provided by PLC controls. Remote operation
shall include the following functions:
a.
For each train, provide AUTO/OFF hand switch, START/STOP
pushbuttons, and “IN AUTO OPERATION” indicating light.
Locate these devices on the panel front.
b.
Auto mode, which includes startup and shutdown sequences and
steady-state automatic operation:
1)
Include interlocks as appropriate for safe operation and for
equipment protection.
2)
Information from other systems in the Water Treatment
Plant (Facility) and from other systems within the
Membrane System will be obtained from an Ethernet
interface between all PLCs and the Plant SCADA system.
Exchange of data between the plant SCADA control system
and the Membrane System PLCs shall include, but not
limited to:
a)
All control set points.
b)
All alarms.
c)
All measured parameters.
d)
Status of all equipment.
e)
In auto status of all items.
f)
Position of control valves.
3)
Various AUTO Mode Parameters shall be adjusted from:
a)
An Operator Interface Unit (OIU) on the front of the
main control panel.
b)
At the graphic screens of the plant SCADA HMI
computers.
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4)
B.
Create a FAIL alarm for each controlled device; i.e., if a
device is commanded to run from the control panel, but is
not confirmed ON within a preset time, create the FAIL
alarm.
The Proposer’s Control System shall be designed to perform the following
functions as a minimum:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Monitor and trend operational data for feed and filtrate water for each
train including the following at a minimum:
a.
Pressure.
b.
Flow Rate.
c.
Temperature.
Monitor and trend operational data for other membrane system
components for each train including the following at a minimum:
a.
Transmembrane pressure.
b.
Backwash flow rate (air and water).
c.
Chemical flows for chemically enhanced backwashes.
d.
CIP solution flow rate.
e.
Totalized flow.
f.
Hours of Operation.
g.
Flux rate.
Control the sequence of backwashing, CEBs, and CIPs.
Store the backwashes (normal and CEB), air and water backwash
duration, and perform calculations to determine the recovery efficiency.
Interrupt operation and/or sound alarm for high transmembrane
pressure, high membrane filtered water turbidity, high membrane
filtered water particle counts, failed membrane integrity test, low
filtered water flow, high prefilter differential pressure, high or low
filtrate pH, and feed or filtrate pump failure, and any other parameters as
per Manufacturer’s standard.
Automatic control of membrane integrity tests.
Adjust flow through membrane train in response to a manual input
through the control system from operator.
Manual START/STOP and Automatic flow-pace feed or filtrate pumps.
Shutdown train, and alarm upon failure of any defined critical parameter
or component.
Record and alarm power failures, and transfers to and from backup
power.
Provide other features as required by the system for unattended
operation, to meet specified performance requirements, and to meet the
monitoring requirements.
During operation of the Membrane Filtration System, the Owner’s
operators shall select and enter the desired flow rate for each train using
the OIU on the main control panel or via the graphic screen on the plant
SCADA HMI computer.
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C.
Panel Mounted Controls and Indications:
1.
2.
D.
Security:
1.
2.08
Provide security features to access the OIU as follows:
a.
View graphics only.
b.
Issue commands.
c.
Adjust set points.
d.
Re-configure software.
FACTORY FINISHING
A.
Prepare, prime, and finish coat as follows:
1.
2.
3.
2.09
For each train, provide AUTO/OFF hand switches, START/STOP
pushbuttons, and “IN AUTO OPERATION” indicating light. See
Paragraph Functional Requirements above.
Provide an OIU mounted on main control panel front.
a.
OIU shall allow operator to adjust all parameters related to
automatic operation, including speed of adjustable speed drives.
b.
OIU shall display all equipment status and alarm conditions
related to automatic operation.
Ferrous Metal (nonstainless steel) Surfaces in Contact with Effluent:
a.
SP5, white metal blast cleaning surface preparation.
b.
Three coats, 3 MDFTPC NSF 61 epoxy.
Ferrous Metal (nonstainless steel) Surfaces Exposed:
a.
SP10, near white blast cleaning surface preparation.
b.
One coat, 2.5 MDFT, epoxy primer.
c.
One coat, 4 MDFT, high build epoxy; and
d.
One coat, 3 MDFT, polyurethane enamel.
Plastic (PVC, CPVC and FRP without integral UV-resistant gel coat)
Surfaces Directly Exposed to Sunlight:
a.
Hand sand plastic surfaces to be coated with medium grit
sandpaper to provide tooth for coating system.
b.
Two coats, 320 SFPGPC, acrylic latex semigloss.
SOURCE QUALITY CONTROL
A.
Factory Inspections: MSS shall inspect each component of MFS, including
control panels for required construction, electrical connection, and intended
function.
B.
Factory Tests:
1.
Test entire control system actually furnished including panels,
hardware, and software configuration.
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2.
3.
4.
5.
6.
7.
8.
9.
PART 3
3.01
EXECUTION
INSTALLATION
A.
3.02
Perform unwitnessed factory test of entire system prior to a witnessed
factory test.
Tests Witnessed by Owner:
a.
Factory test specified herein.
b.
Factory test for plastic header components supplied within
membrane system.
Test for proper alignment, quiet operation, proper connection, pumping
capacity, and satisfactory performance.
Functional Test:
a.
Perform manufacturer’s standard, motor test on equipment (feed
pumps only).
b.
Include vibration test.
c.
Dynamically balance rotating parts of each pump, blower and
drive units before final assembly. Limits:
1)
Driving Unit Alone: Less than 80 percent of NEMA MG 1
limits.
2)
Complete Rotating Assembly Including Blower, Coupling,
Drive Unit, and Motor: Less than 90 percent mils of limits
established in Hydraulic Institute Standards.
Performance Tests: In accordance with the following:
a.
ANSI/AWWA B110-09
b.
ASME PTC 10.
c.
Hydraulic Institute Standards.
See Section 40 99 90, Package Control Systems, for approvals required
prior to shipment and additional requirements.
Motor Test: In accordance with Section 26 20 00, Low-Voltage AC
Induction Motors (factory test for feed and RF pumps, on-site testing for
feed pumps only).
Provide written certification of tests to Contractor prior to shipping
equipment.
MSS shall furnish installation instructions and recommendations to
Contractor. Contractor shall install MFS in accordance with MSS’s
instructions and recommendations.
LIQUIDATED DAMAGES
A.
The MSS shall be assessed liquidated damages for failure to meet the time
limit for each item listed in the schedule described in Part 1 of this
specification.
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3.03
B.
If submittal is deemed incomplete by the Owner, the MSS shall have 7 days
from notification to submit the missing portions of the submittal before being
assessed liquidated damages.
C.
Additional time for each phase of the project may be granted at the Owner’s
discretion.
D.
The liquidated damages cannot exceed 10 percent of the total contract amount.
E.
Liquidated damages shall be waived if the delay is deemed not the fault of the
MSS, or are due to outside circumstances beyond the reasonable control of the
MSS.
F.
Amounts of liquidated damages are:
1.
$500 USD per day late on each of the submittals
2.
$1000 USD per day late on equipment delivery.
FIELD QUALITY CONTROL
A.
General:
1.
2.
3.
4.
5.
6.
B.
MSS shall conduct testing with assistance from Contractor.
MSS and Contractor shall arrange times for testing and startup
activities, however, Contractor shall confirm times are acceptable to
Owner.
Upon issuance of Certification of Proper Installation, MSS shall
coordinate with Contractor to perform functional testing of the MFS.
Calibrate instruments, including pressure differential transmitters,
process analyzers, and flowmeters in MSS’s scope of supply.
Owner will provide feed water for use in Functional Test if requested by
Contractor.
Complete functional testing to satisfaction of Owner prior to
commencing Initial Performance Test.
Functional Test: Demonstrate effectiveness of the following system
components and features:
1.
2.
3.
4.
Operate MFS valves, controls, and other devices to ensure they are
functional.
Conduct control system functional testing as required in
Section 40 99 90, Package Control Systems.
Automatic START/STOP, flow control, and level control of membrane
system feed pumps using SCADA.
Automatic START/STOP and flow control of membrane trains using
SCADA.
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5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
C.
Manual flow control using membrane train HMI(s) and PLC(s).
Automatic backwashing (normal and CW) at various time intervals.
Automatic shutoff and alarm for various failure modes for each
membrane train and for entire MFS.
START and STOP of air system.
Automatic membrane integrity test system.
Determination of clean water permeability of each membrane train and
temperature correction of clean water permeability for each train.
Monitoring and recovery of operating data.
Monitoring and control from remote workstation.
Automatic switchover from normal power to emergency power, and
emergency power to normal power.
Control functions, both at local system and remote workstation.
Operation of chemical cleaning systems.
Operation of monitoring instruments.
Visual or sonic inspection of membrane modules for integrity (bubble
point testing).
I/O to/from PCS and plant-wide SCADA.
Initial Performance Test:
1.
2.
3.
General:
a.
During Initial Performance Test, Owner shall have option of
collecting samples for independent analyses to confirm
measurements and analyses.
b.
Owner shall have option of witnessing testing performed.
c.
MSS shall notify Owner a minimum of two weeks in advance of
testing.
d.
MSS shall provide Initial Performance Test report within 7 days
of completion of test period.
Operate system continuously over a 30-day test period, and collect and
summarize data to demonstrate system meets Initial Performance Test
requirements for parameters listed below.
Compliance with requirements of Specification shall be determined for
each calendar day. To successfully pass test, MFS shall comply with the
following requirements for each of the 30 consecutive days of Initial
Performance Test:
a.
Filtrate Production Capacity:
1)
System meets design filtrate production capacity
requirements as defined in Article, Performance
Requirements when operated at or below specified
maximum instantaneous flux rate.
2)
Capacity shall be adjusted for actual feed water temperature
in event actual feed water temperature is less than specified
range.
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b.
4.
5.
Recovery: System meets requirements for recovery and for
membrane system recovery.
c.
Pressure Limitations: System operates within specified TMP limit
and system provides adequate filtrate discharge pressure to
discharge to plant break tank as specified.
d.
Instantaneous and Average Flux Rate:
1)
Shall not exceed specified maximum.
2)
Backwash (normal and CW) and membrane integrity test
times shall be included in determination of average flux rate
specified.
3)
Flux rate for system shall not exceed average flux rate
corresponding to train instantaneous flux rate.
e.
Membrane Integrity Test System: Operate integrity test at a
frequency of once every 24 hours.
f.
Membrane Filtrate Quality: Meets requirements for turbidity and
particle concentrations as specified in Paragraph, Membrane
Filtrate Quality.
g.
CW: Conduct at an average and maximum frequency as specified.
h.
Clean-in-Place: Perform at least once on each membrane train
during test period.
i.
Cleaned Membrane Permeability and Post-CIP Fouling Rate:
Following each CIP, calculate Cleaned Membrane Permeability
and Post-CIP Fouling Rate.
j.
CW and CIP Spent Solution Discharge:
1)
.
2)
Each discharge shall comply with requirements for
discharge to sanitary sewer.
k.
Energy Usage: Monitor average power consumption and
maximum power demand for MFS for duration of test period.
l.
Provide control system Performance Testing as defined in
Section 40 99 90, Package Control System.
Successful Test:
a.
Successful completion of Initial Performance Test shall be defined
as 30 continuous days of operation without a major failure in
system and demonstration that system meets performance
requirements established herein.
b.
Downtime resulting from Owner’s operation will not be counted
against criteria of “continuous days of operation”.
Test Failure:
a.
A major failure in MFS is one that decreases system capacity
below 75 percent of design capacity for more than 24 hours, or
requires CWs or CIPs more often than as specified in Article,
Performance Requirements.
b.
For control systems, a major failure is an event that requires
operator intervention to restart or to re-establish normal system
operation beyond that described above.
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c.
6.
7.
3.04
If MFS fails to successfully complete Initial Performance Test,
MSS and Contractor shall have option of repeating test over a
second 30-consecutive-day period.
If system fails to successfully complete Initial Performance Test during
second test period or in opinion of Owner, MSS’s initially supplied and
installed MFS cannot meet performance requirements specified herein,
MSS shall submit written plan within 14 days to modify, supplement, or
remove and replace system as required to meet performance
requirements at sole cost of MSS. Following acceptance of plan a third
Initial Performance Test period shall be completed over 30-day
continuous period.
If MFS, as modified or supplemented, fails to meet third Initial
Performance Test, MSS shall remove initial system and Owner will
select and install alternative membrane system. Cost of system removal
and alternative system procurement and installation shall be
responsibility of MSS. This requirement shall be secured by MSS’s
Performance and Payment Bond.
MANUFACTURER’S SERVICES
A.
Manufacturer’s Representative: Present at Site or classroom designated by
Owner for minimum person-days listed below, travel time excluded. These
hours represent a minimum level of effort that shall be included in the MSS
proposal for these activities and are not in addition to normal service and
support.
1.
2.
3.
4.
5.
6.
7.
8.
B.
4
person-days during 1 trip unloading of MFS equipment.
2
person-days over 1 trip for attendance at design meetings.
1
person-day over 1 trip for attendance at construction meetings.
16 person-days over 4 trips for MFS installation assistance.
4
person-days over 1 trip for training Owner’s operators.
4
person-days over 1 trip for assistance during functional testing
8
person-days over 2 trips for assistance during startup activities.
MSS shall also provide standard rates for the services of a qualified
representative to visit during MTP.
Telephone:
1.
2.
Provide telephone support by means of a toll-free phone number for a
minimum period of 10 years following installation and startup.
Provide a list of three or more names of individuals qualified to support
operation, and provide pager numbers for these individuals, if available.
At least one of the listed individuals shall be available at all times
including nights, weekends, and holidays in the event of an emergency.
END OF SECTION
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