Calaveras Coal Yard - Exhibit J

Table of Contents 01100 – Scope of Work ............................................................................................................................... 1 01100.1 Technical Scope of Work ........................................................................................................... 1 01100.2 Drawings and Technical Attachments ........................................................................................ 6 01100.2.1 Engineer’s Attachments ....................................................................................................... 6 01621 - Purchaser-Furnished Mechanical Equipment and Materials .................................................... 8 01621.1 General ....................................................................................................................................... 8 01621.1.1 Scope of Supply ................................................................................................................... 8 01621.1.2 Items Furnished by Others and Interfaces .......................................................................... 8 01621.1.3 Equipment and Material Data .............................................................................................. 8 01621.1.4 Codes and Standards .......................................................................................................... 8 01621.1.5 Materials .............................................................................................................................. 8 01621.1.6 Not Used .............................................................................................................................. 8 01621.1.7 Test Requirements .............................................................................................................. 8 01621.1.8 Technical Attachments ........................................................................................................ 9 01621.1.9 Supplemental Specifications ............................................................................................... 9 01621.2 Products ..................................................................................................................................... 9 01621.3 Execution .................................................................................................................................... 9 01621.3.1 General Requirements......................................................................................................... 9 01621.3.2 Manufacturer's Shop Drawings ............................................................................................ 9 01621.3.3 Spare Parts and Maintenance Tools ................................................................................... 9 01621.3.4 Manufacturer's Field Technical Service Representative ................................................... 10 02220 - Earthwork ..................................................................................................................................... 14 02220.1 General ..................................................................................................................................... 14 02220.1.1 Scope of Work ................................................................................................................... 14 02220.1.2 Items Furnished by Others and Interfaces ........................................................................ 14 02220.1.3 Performance and Design Requirements ........................................................................... 14 02220.1.4 Codes and Standards ........................................................................................................ 14 02220.1.5 Materials ............................................................................................................................ 14 02220.1.6 Acceptable Manufacturers of Components ....................................................................... 14 02220.1.7 Test Requirements ............................................................................................................ 15 02220.1.8 Technical Attachments ...................................................................................................... 15 02220.1.9 Supplemental Specifications ............................................................................................. 15 02220.2 Not Used................................................................................................................................... 16 02220.3 Execution .................................................................................................................................. 16 02220.3.1 General .............................................................................................................................. 16 02220.3.2 Sheeting and Shoring ........................................................................................................ 16 02220.3.3 Removal of Water .............................................................................................................. 16 02220.3.4 Blasting .............................................................................................................................. 17 02220.3.5(1) Classification of Excavated Materials ............................................................................ 17 02220.3.6 Freezing Weather Restrictions .......................................................................................... 17 02220.3.7 Preservation of Trees ........................................................................................................ 17 02220.3.8 Maintenance of Traffic ....................................................................................................... 18 02220.3.9 Unauthorized Excavation ................................................................................................... 18 02220.3.10 Testing ............................................................................................................................. 18 02220.3.11 Site Preparation ............................................................................................................... 18 02220.3.12 Roadway and Railroad Roadbeds ................................................................................... 18 02220.3.13 Fills and Embankments ................................................................................................... 19 02220.3.14 Structure Excavation ........................................................................................................ 19 02220.3.15 Structure Subgrades ........................................................................................................ 19 02220.3.16 Structural Fill .................................................................................................................... 19 02220.3.17 Structure Backfill .............................................................................................................. 20 02220.3.18 Compacted Rock Fill ........................................................................................................ 20 02220.3.19 Compacted Sand Fill ....................................................................................................... 20 02220.3.20 Drainage Fills ................................................................................................................... 20 02220.3.21 Controlled Low Strength Material .................................................................................... 20 02220.3.22 Maintenance and Restoration of Fills, Embankments, and Backfills ............................... 20 02220.3.23 Final Grading .................................................................................................................... 21 02220.3.24 Disposal of Materials ....................................................................................................... 21 02221 - Razing and Alterations ................................................................................................................ 27 02221.1 General ..................................................................................................................................... 27 02221.1.1 Scope of Work ................................................................................................................... 27 02221.1.2 Technical Attachments ...................................................................................................... 27 02221.1.3 Supplemental Specifications ............................................................................................. 27 02221.2 Not Used................................................................................................................................... 27 02221.3 Execution .................................................................................................................................. 27 02221.3.1 General .............................................................................................................................. 27 02221.3.2 Razing ................................................................................................................................ 28 02221.3.3 Alterations .......................................................................................................................... 29 02221.3.4 Salvage and Rubbish ......................................................................................................... 31 02221.3.5 Cleanup ............................................................................................................................. 31 03311 - Cast-in-Place Concrete ............................................................................................................... 33 03311.1 General ..................................................................................................................................... 33 03311.1.1 Scope of Work ................................................................................................................... 33 03311.1.2 Items Furnished by Others and Interfaces ........................................................................ 33 03311.1.3 Performance and Design Requirements ........................................................................... 33 03311.1.4 Codes and Standards ........................................................................................................ 33 03311.1.5 Materials ............................................................................................................................ 34 03311.1.6 Acceptable Manufacturers of Components ....................................................................... 36 03311.1.7 Test Requirements ............................................................................................................ 37 03311.1.8 Technical Attachments ...................................................................................................... 37 03311.1.9 Supplemental Specifications ............................................................................................. 37 03311.2 Products ................................................................................................................................... 37 03311.3 Execution .................................................................................................................................. 37 03311.3.1 General .............................................................................................................................. 37 03311.3.2 Placement of Steel Reinforcement .................................................................................... 38 03311.3.3 Formwork ........................................................................................................................... 39 03311.3.4 Embedments ...................................................................................................................... 40 03311.3.5 Placement .......................................................................................................................... 40 03311.3.6 Joints.................................................................................................................................. 42 03311.3.7 Openings in Concrete ........................................................................................................ 43 03311.3.8 Finishing Formed Surfaces ................................................................................................ 43 03311.3.9 Finishing Unformed Surfaces ............................................................................................ 43 03311.3.10 Separate Finishes ............................................................................................................ 44 03311.3.11 Curing .............................................................................................................................. 44 03311.3.12 Floor Sealer ..................................................................................................................... 45 03311.3.13 Repairing Defective Concrete .......................................................................................... 45 03311.3.14 Duct Banks ...................................................................................................................... 45 03311.3.15 Tolerances ....................................................................................................................... 45 03311.3.16 Special Structures ............................................................................................................ 46 03311.3.17 Field Control Testing ........................................................................................................ 46 03311.3.18 Proportioning ................................................................................................................... 47 03311.3.19 Batching ........................................................................................................................... 48 03311.3.20 Mixing............................................................................................................................... 48 03311.3.21 Delivery ............................................................................................................................ 48 03311.3.22 Evaluation and Acceptance of Concrete ......................................................................... 49 03611 - Grouting ........................................................................................................................................ 53 03611.1 General ..................................................................................................................................... 53 03611.1.1 Scope of Work ................................................................................................................... 53 03611.1.2 Items Furnished by Others and Interfaces ........................................................................ 53 03611.1.3 Performance and Design Requirements ........................................................................... 53 03611.1.4 Codes and Standards ........................................................................................................ 53 03611.1.5 Materials ............................................................................................................................ 53 03611.1.6 Approved Manufacturers of Components .......................................................................... 54 03611.1.7 Test Requirements ............................................................................................................ 54 03611.1.8 Technical Attachments ...................................................................................................... 55 03611.1.9 Supplemental Specifications ............................................................................................. 55 03611.2 Products ................................................................................................................................... 55 03611.3 Execution .................................................................................................................................. 55 03611.3.1 Baseplate Grouting ............................................................................................................ 55 03611.3.2 Surface Preparation ........................................................................................................... 55 03611.3.3 Alignment and Leveling ..................................................................................................... 55 03611.3.4 Mixing................................................................................................................................. 56 03611.3.5 Placement .......................................................................................................................... 56 03611.3.6 Cementitious Grout ............................................................................................................ 56 03611.3.7 Epoxy and Acid Resistant Grouts ...................................................................................... 56 05310 - Steel Roof Deck ............................................................................................................................ 57 05310.1 General ..................................................................................................................................... 57 05310.1.1 Scope of Work ................................................................................................................... 57 05310.1.2 Items Furnished by Others and Interfaces ........................................................................ 57 05310.1.3 Performance and Design Requirements ........................................................................... 57 05310.1.4 Codes and Standards ........................................................................................................ 57 05310.1.5 Materials ............................................................................................................................ 57 05310.1.6 Acceptable Manufacturers of Components ....................................................................... 59 05310.1.7 Test Requirements ............................................................................................................ 59 05310.1.8 Technical Attachments ...................................................................................................... 59 05310.1.9 Supplemental Specifications ............................................................................................. 60 05310.1.10 Submittals of Vendor Drawings ....................................................................................... 60 05310.2 Products ................................................................................................................................... 60 05310.2.1 General .............................................................................................................................. 60 05310.2.2 Materials ............................................................................................................................ 60 05310.2.3 Fabrication ......................................................................................................................... 60 05310.2.4 Finishes.............................................................................................................................. 60 05310.3 Execution .................................................................................................................................. 60 05310.3.1 Handling and Storage ........................................................................................................ 60 05310.3.2 Installation .......................................................................................................................... 61 05310.3.3 Cleaning ............................................................................................................................. 61 05500 – Miscellaneous Metals ................................................................................................................. 62 05500.1 General ..................................................................................................................................... 62 05500.1.1 Scope of Work ................................................................................................................... 62 05500.1.2 Items Furnished by Others and Interfaces ........................................................................ 62 05500.1.3 Codes and Standards ........................................................................................................ 62 05500.1.4 Materials ............................................................................................................................ 63 05500.1.5 Additional Requirements.................................................................................................... 65 05500.1.6 Approved Manufacturers of Components .......................................................................... 66 05500.1.7 Test Requirements ............................................................................................................ 67 05500.1.8 Technical Attachments ...................................................................................................... 67 05500.1.9 Supplemental Specifications ............................................................................................. 67 05500.2 Products ................................................................................................................................... 67 05500.2.1 Drawing Requirements ...................................................................................................... 67 05500.2.2 Materials ............................................................................................................................ 68 05500.2.3 Structural Steel Fabrication ............................................................................................... 68 05500.2.4 Bar Grating Fabrication...................................................................................................... 69 05500.2.5 Bolted Connections ............................................................................................................ 69 05500.2.6 Welding .............................................................................................................................. 69 05500.2.7 Coatings ............................................................................................................................. 69 05500.3 Execution .................................................................................................................................. 69 05500.3.1 General ............................................................................................................................... 69 05500.3.2 Steel Erection .................................................................................................................... 70 05500.3.3 Welding .............................................................................................................................. 72 05500.3.4 Bar Grating Installation ...................................................................................................... 72 05500.3.5 Touchup Painting ............................................................................................................... 72 09900 - Field Applied Protective Coatings ............................................................................................. 73 09900.1 General ..................................................................................................................................... 73 09900.1.1 Scope ................................................................................................................................. 73 09900.1.2 Schedule ............................................................................................................................ 73 09900.1.3 Items Furnished by Others and Interfaces ........................................................................ 73 09900.1.4 Coating Applications and Material Requirements ............................................................. 73 09900.1.5 Codes and Standards ........................................................................................................ 74 09900.1.6 Approved Manufacturers of Components .......................................................................... 75 09900.1.7 Test Requirements ............................................................................................................ 75 09900.1.8 Technical Attachments ...................................................................................................... 76 09900.1.9 Supplemental Specifications ............................................................................................. 76 09900.1.10 Submittals ........................................................................................................................ 76 09900.1.11 Quality Assurance ............................................................................................................ 76 09900.1.12 Receiving, Handling, Storage and Cleaning .................................................................... 77 09900.2 Products ................................................................................................................................... 77 09900.2.1 Materials ............................................................................................................................ 77 09900.2.2 Approved Manufacturers ................................................................................................... 78 09900.3 Execution .................................................................................................................................. 78 09900.3.1 Surface Preparation ........................................................................................................... 78 09900.3.2 Mixing and Thinning ........................................................................................................... 79 09900.3.3 Application ......................................................................................................................... 80 09900.3.4 Protection of Surfaces ....................................................................................................... 80 09900.3.5 Environmental Conditions .................................................................................................. 80 09900.3.6 Field Quality Control .......................................................................................................... 81 13110 - Galvanic Anode Cathodic Protection ........................................................................................ 83 13110.1 General ..................................................................................................................................... 83 13110.1.1 Scope of Supply ................................................................................................................. 83 13110.1.2 Items Furnished by Others and Interfaces ........................................................................ 83 13110.1.3 Performance and Design Requirements ........................................................................... 83 13110.1.4 Codes and Standards ........................................................................................................ 83 13110.1.5 Materials ............................................................................................................................ 83 13110.1.6 Approved Manufacturers of Components .......................................................................... 83 13110.1.7 Test Requirements ............................................................................................................ 83 13110.1.8 Technical Attachments ...................................................................................................... 84 13110.1.9 Supplemental Specifications ............................................................................................. 84 13110.2 Products ................................................................................................................................... 84 13110.2.1 Galvanic Anodes ................................................................................................................ 84 13110.2.2 Aboveground Test Stations ............................................................................................... 84 13110.2.3 Test Station Identification Tags ......................................................................................... 84 13110.2.4 Copper Sulfate Reference Electrodes ............................................................................... 85 13110.2.5 Exothermal Welding Materials ........................................................................................... 85 13110.2.6 Exothermal Weld Coating Repair Materials....................................................................... 85 13110.2.7 Compression Ring-Tongue Terminals ............................................................................... 85 13110.2.8 Cathodic Protection Cable ................................................................................................. 85 13110.2.9 Nondetectable Underground Marking Tape ...................................................................... 85 13110.2.10 Wire and Cable Markers .................................................................................................. 85 13110.2.11 Marking Pens ................................................................................................................... 85 13110.2.12 Solder............................................................................................................................... 85 13110.2.13 Insulated Flange Kits ....................................................................................................... 85 13110.2.14 Insulated Flange Identification Tags ................................................................................ 86 13110.2.15 Polyethylene Mesh .......................................................................................................... 86 13110.2.16 Silver Brazing Materials ................................................................................................... 86 13110.3 Execution .................................................................................................................................. 86 13110.3.1 Installation .......................................................................................................................... 86 13110.3.2 Testing ............................................................................................................................... 88 15225 - General Service Pipe ................................................................................................................... 91 15225.1 General ..................................................................................................................................... 91 15225.1.1 Scope of Supply ................................................................................................................. 91 15225.1.2 Items Furnished by Others and Interfaces ........................................................................ 91 15225.1.3 Performance and Design Requirements ........................................................................... 91 15225.1.4 Codes and Standards ........................................................................................................ 92 15225.1.5 Materials ............................................................................................................................ 94 15225.1.6 Approved Manufacturers of Components .......................................................................... 97 15225.1.7 Test Requirements ............................................................................................................ 98 15225.1.8 Technical Attachments ...................................................................................................... 99 15225.1.9 Supplemental Specifications ............................................................................................. 99 15225.2 Products ................................................................................................................................... 99 15225.2.1 Piping Material Requirements ........................................................................................... 99 15225.2.2 Tubing .............................................................................................................................. 100 15225.2.3 Fittings ............................................................................................................................. 101 15225.2.4 Flanges ............................................................................................................................ 102 15225.2.5 Gaskets ............................................................................................................................ 103 15225.2.6 Bolting .............................................................................................................................. 103 15225.2.7 Unions .............................................................................................................................. 104 15225.2.8 Coating and Wrapping of Pipe To Be Installed Underground ......................................... 104 15225.2.9 Cleaning ........................................................................................................................... 104 15225.2.10 Coatings ......................................................................................................................... 105 15225.2.11 Jointing Materials and Tools .......................................................................................... 106 15225.2.12 Preparation for Shipment ............................................................................................... 106 15225.3 Execution ................................................................................................................................ 106 15226 - Underground Pressure Piping .................................................................................................. 107 15226.1 Schedule of Submittals after Purchase Order Award............................................................. 107 15226.2 Codes and Standards ............................................................................................................. 107 15226.3 Material Specifications ........................................................................................................... 109 15226.4 General Material Descriptions ................................................................................................ 109 15226.4.1 Ductile Iron Pipe and Fittings ........................................................................................... 109 15226.4.2 High Density Polyethylene Fittings .................................................................................. 110 15226.4.3 Carbon and Stainless Steel Pipe and Fittings ................................................................. 110 15226.4.4 Steel Flanges ................................................................................................................... 111 15226.5 Coating of Pipe to be Installed Underground ......................................................................... 111 15226.6 Cleaning ................................................................................................................................. 111 15226.7 Weld End Coatings ................................................................................................................. 111 15226.8 Preparation for Shipment ....................................................................................................... 111 15262 - Steel Valves 2 Inches and Smaller ........................................................................................... 112 15262.1 General ................................................................................................................................... 112 15262.1.1 Scope of Supply ............................................................................................................... 112 15262.1.2 Items Furnished by Others and Interfaces ...................................................................... 112 15262.1.3 Performance and Design Requirements ......................................................................... 113 15262.1.4 Codes and Standards ...................................................................................................... 113 15262.1.5 Materials .......................................................................................................................... 113 15262.1.6 Approved Manufacturers of Components ........................................................................ 114 15262.1.7 Test Requirements .......................................................................................................... 114 15262.1.8 Technical Attachments .................................................................................................... 114 15262.1.9 Supplemental Specifications ........................................................................................... 114 15262.2 Products ................................................................................................................................. 114 15262.2.1 Service Condition ............................................................................................................. 115 15262.2.3 Valve Design .................................................................................................................... 115 15262.2.4 Materials .......................................................................................................................... 116 15262.2.5 Special Features .............................................................................................................. 116 15262.2.6 Installation Instructions .................................................................................................... 117 15262.2.7 Identification ..................................................................................................................... 117 15262.2.8 Drawing Requirements .................................................................................................... 117 15262.3 Execution ................................................................................................................................ 117 15901 - Mechanical Equipment Erection .............................................................................................. 119 15901.1 General ................................................................................................................................... 119 15901.1.1 Scope of Work ................................................................................................................. 119 15901.1.2 Scope Responsibilities ..................................................................................................... 119 15901.1.3 Detailed Erection Requirements ...................................................................................... 119 15901.1.4 Codes and Standards ...................................................................................................... 120 15901.1.5 Materials .......................................................................................................................... 120 15901.1.6 Approved Manufacturers of Components ........................................................................ 120 15901.1.7 Test Requirements .......................................................................................................... 120 15901.1.8 Technical Attachments .................................................................................................... 120 15901.1.9 Supplemental Specifications ........................................................................................... 120 15901.2 Products ................................................................................................................................. 120 15901.3 Execution ................................................................................................................................ 120 15901.3.1 General ............................................................................................................................ 120 15901.3.2 Code Requirements ......................................................................................................... 121 15901.3.3 Location Tolerances ........................................................................................................ 121 15901.3.4 Piping Connections .......................................................................................................... 121 15901.3.5 Leveling and Grouting ...................................................................................................... 121 15901.3.6 Equipment Piping ............................................................................................................. 121 15901.3.7 Pump Suction Strainers ................................................................................................... 121 15901.3.8 Welding ............................................................................................................................ 121 15901.3.9 Shaft Alignment ............................................................................................................... 121 15901.3.10 Motors ............................................................................................................................ 122 15901.3.11 Equipment Checkout ..................................................................................................... 122 15901.3.12 Miscellaneous Equipment .............................................................................................. 122 15901.3.13 Defects ........................................................................................................................... 122 15901.3.14 Maintenance Tools ........................................................................................................ 122 15921 - Piping Erection ........................................................................................................................... 123 15921.1 General ................................................................................................................................... 123 15921.1.1 Scope of Work ................................................................................................................. 123 15921.1.2 Items Furnished by Others and Interfaces ...................................................................... 124 15921.1.3 Performance and Design Requirements ......................................................................... 124 15921.1.4 Codes and Standards ...................................................................................................... 124 15921.1.5 Materials .......................................................................................................................... 124 15921.1.6 Acceptable Subsuppliers ................................................................................................. 126 15921.1.7 Test Requirements .......................................................................................................... 126 15921.1.8 Technical Attachments .................................................................................................... 127 15921.1.9 Supplemental Specifications ........................................................................................... 127 15921.2 Products ................................................................................................................................. 127 15921.2.1 Pipeline List ..................................................................................................................... 127 15921.3 Execution ................................................................................................................................ 127 15921.3.1 Welding ............................................................................................................................ 127 15921.3.2 Miscellaneous Piping ....................................................................................................... 128 15921.3.3 Temporary Piping ............................................................................................................ 128 15921.3.4 Piping in Existing Areas ................................................................................................... 129 15921.3.5 Alterations and Cut-ins .................................................................................................... 129 15921.3.6 Thermal Expansion .......................................................................................................... 129 15921.3.7 Pipe Supports .................................................................................................................. 130 15921.3.8 Cutting and Drilling Structures ......................................................................................... 130 15921.3.9 Equipment Connections................................................................................................... 131 15921.3.10 Valve Installation ............................................................................................................ 133 15921.3.11 Not Used ........................................................................................................................ 133 15921.3.12 Relief Valve Piping ......................................................................................................... 133 15921.3.13 Making Flanged Connections ........................................................................................ 133 15921.3.14 Hot Tap Branch Connections ........................................................................................ 135 15921.3.15 Traps .............................................................................................................................. 135 15921.3.16 Miscellaneous Small Connections ................................................................................. 135 15921.3.17 Damage to Machined Surfaces ..................................................................................... 135 15921.3.18 Piping Isolation .............................................................................................................. 135 15921.3.19 Rainhoods ...................................................................................................................... 136 15921.3.20 Flexible Weatherproofing ............................................................................................... 136 15921.3.21 Penetration Seals .......................................................................................................... 136 15921.3.22 Drainlines ....................................................................................................................... 136 15921.3.23 Protective Coatings ........................................................................................................ 136 15921.3.24 Underground Piping ....................................................................................................... 138 15921.3.25 Concrete Pipe Installation .............................................................................................. 139 15921.3.26 Mechanical Joint Pipe Installation ................................................................................. 140 15921.3.27 Push-on Joint Pipe Installation ...................................................................................... 140 15921.3.28 Installation of Restrained Push-on Joint Pipe ................................................................ 140 15921.3.29 Nonmetallic Pipe Installation ......................................................................................... 140 15921.3.30 Underwater Installation of Piping ................................................................................... 140 15921.3.31 Testing ........................................................................................................................... 140 15921.3.32 Cleaning of Pipe ............................................................................................................ 142 15921.3.33 Flushing of Oil Piping ..................................................................................................... 142 15921.3.34 Sterilization of Equipment and Piping ............................................................................ 143 15921.3.35 Final Adjustment ............................................................................................................ 143 15921.3.36 Freeze Protection .......................................................................................................... 143 15921.3.37 Identification ................................................................................................................... 143 16410 - Junction Boxes .......................................................................................................................... 145 16410.1 General ................................................................................................................................... 145 16410.2 Description.............................................................................................................................. 145 16410.2.1 Nameplates ...................................................................................................................... 145 16410.3 Construction ........................................................................................................................... 145 16430 - Disconnect Switches ................................................................................................................. 146 16430.1 General ................................................................................................................................... 146 16430.2 Codes and Standards ............................................................................................................. 146 16430.3 Description.............................................................................................................................. 146 16430.4 Installation .............................................................................................................................. 146 16430.5 Manufacturers......................................................................................................................... 146 16501 - Lighting ....................................................................................................................................... 147 16501.1 General ................................................................................................................................... 147 16501.1.1 Scope of Supply ............................................................................................................... 147 16501.1.2 Items Furnished by Others and Interfaces ...................................................................... 147 16501.1.3 Performance and Design Requirements ......................................................................... 147 16501.1.4 Codes and Standards ...................................................................................................... 147 16501.1.5 Materials .......................................................................................................................... 148 16501.1.6 Approved Manufacturers of Components ........................................................................ 148 16501.1.7 Test Requirements .......................................................................................................... 149 16501.1.8 Technical Attachments .................................................................................................... 149 16501.1.9 Supplemental Specifications ........................................................................................... 149 16501.2 Products ................................................................................................................................. 150 16501.2.1 Luminaires ....................................................................................................................... 150 16501.2.2 Luminaire Supports .......................................................................................................... 150 16501.2.3 Plugs ................................................................................................................................ 150 16501.2.4 Switches .......................................................................................................................... 150 16501.2.5 Device Plates ................................................................................................................... 150 16501.2.6 Lamps .............................................................................................................................. 150 16501.2.7 Lighting Contactors .......................................................................................................... 150 16501.2.9 Lighting and Convenience Receptacle Conductors ........................................................ 150 16501.2.10 Lighting and Convenience Receptacle Raceway .......................................................... 150 16501.3 Execution ................................................................................................................................ 151 16510 - Conductors and Accessories ................................................................................................... 152 16510.1 General ................................................................................................................................... 152 16510.1.1 Scope of Supply ............................................................................................................... 152 16510.1.2 Items Furnished by Others and Interfaces ...................................................................... 152 16510.1.3 Performance and Design Requirements ......................................................................... 152 16510.1.4 Codes and Standards ...................................................................................................... 152 16510.1.5 Materials .......................................................................................................................... 153 16510.1.6 Approved Manufacturers of Components ........................................................................ 153 16510.1.7 Test Requirements .......................................................................................................... 153 16510.1.8 Technical Attachments .................................................................................................... 154 16510.1.9 Supplemental Specifications ........................................................................................... 154 16510.1.10 Certification Requirements ............................................................................................ 154 16510.2 Products ................................................................................................................................. 154 16510.2.1 Conductors and Accessories - General Requirements ................................................... 154 16510.2.2 AEIC/ICEA/UL Cable - Technical Requirements ............................................................. 156 16510.2.3 Accessories ..................................................................................................................... 159 16510.3 Execution ................................................................................................................................ 163 16910 - Electrical Equipment Installation ............................................................................................. 164 16910.1 General ................................................................................................................................... 164 16910.1.1 Scope of Supply ............................................................................................................... 164 16910.1.2 Items Furnished by Others and Interfaces ...................................................................... 164 16910.1.3 Performance and Design Requirements ......................................................................... 164 16910.1.4 Codes and Standards ...................................................................................................... 164 16910.1.5 Materials .......................................................................................................................... 164 16910.1.6 Approved Manufacturers of Components ........................................................................ 164 16910.1.7 Test Requirements .......................................................................................................... 164 16910.1.8 Technical Attachments .................................................................................................... 164 16910.1.9 Supplemental Specifications ........................................................................................... 164 16910.2 Products ................................................................................................................................. 164 16910.3 Execution ................................................................................................................................ 165 16910.3.1 Installation Requirements Applicable to All Equipment ................................................... 165 16910.3.2 Transformer Erection – Not Used .................................................................................... 167 16910.3.4 Batteries and Battery Chargers Installation – Not Used. ................................................. 167 16910.3.5 Panelboard Installation – Not Used. ................................................................................ 167 16910.3.6 Isolated Phase Bus Duct Installation – Not Used. ........................................................... 167 16910.3.7 Nonsegregated or Segregated Phase Bus Duct or Cable Bus Installation – Not Used. . 168 16910.3.8 Electrical Distribution and Control Equipment Installation ............................................... 168 16920 - Raceway Components and Installation ................................................................................... 170 16920.1 General ................................................................................................................................... 170 16920.1.1 Scope of Supply ............................................................................................................... 170 16920.1.2 Items Furnished by Others and Interfaces ...................................................................... 170 16920.1.3 Performance and Design Requirements ......................................................................... 170 16920.1.4 Codes and Standards ...................................................................................................... 170 16920.1.5 Materials .......................................................................................................................... 170 16920.1.6 Approved Manufacturers of Components ........................................................................ 170 16920.1.7 Test Requirements .......................................................................................................... 171 16920.1.8 Technical Attachments .................................................................................................... 172 16920.1.9 Supplemental Specifications ........................................................................................... 172 16920.2 Products ................................................................................................................................. 172 16920.3 Execution ................................................................................................................................ 172 16920.3.1 General Installation Requirements .................................................................................. 172 16920.3.2 Raceway Installation Records ......................................................................................... 175 16920.3.3 Conduit Components ....................................................................................................... 175 16920.3.4 Wireway Components...................................................................................................... 183 16920.3.5 Junction Boxes and Pull Boxes ....................................................................................... 184 16920.3.6 Cable Tray Components .................................................................................................. 186 16920.3.7 Duct Bank and Electrical Manhole Components ............................................................. 192 16920.3.8 Grout ................................................................................................................................ 194 16925 - Conductors Installation ............................................................................................................. 195 16925.1 General ................................................................................................................................... 195 16925.1.1 Scope of Supply ............................................................................................................... 195 16925.1.2 Items furnished by Others and Interfaces........................................................................ 195 16925.1.3 Performance and Design Requirements ......................................................................... 195 16925.1.4 Codes and Standards ...................................................................................................... 195 16925.1.5 Materials .......................................................................................................................... 196 16925.1.6 Approved Manufacturers of Components ........................................................................ 196 16925.1.7 Test Requirements .......................................................................................................... 196 16925.1.8 Technical Attachments .................................................................................................... 197 16925.1.9 Supplemental Specifications ........................................................................................... 197 16925.2 Products ................................................................................................................................. 197 16925.3 Execution ................................................................................................................................ 197 16925.3.1 Handling of Cable ............................................................................................................ 197 16925.3.2 Cable Placement ............................................................................................................. 197 16925.3.3 Splices ............................................................................................................................. 201 16925.3.4 Terminations .................................................................................................................... 202 16925.3.5 Tests After Placement ..................................................................................................... 202 16925.3.6 Fiber-Optic Conductor Installation and Termination. Not Used. ...................................... 203 16925.3.7 Fiber-Optic Test Requirements Not Used. ...................................................................... 203 16925.3.8 Circuit Installation Records Not Used. ............................................................................. 203 16930 - Grounding Components and Installation ................................................................................ 204 16930.1 General ................................................................................................................................... 204 16930.1.1 Scope of Supply ............................................................................................................... 204 16930.1.2 Items Furnished by Others and Interfaces ...................................................................... 204 16930.1.3 Performance and Design Requirements ......................................................................... 204 16930.1.4 Codes and Standards ...................................................................................................... 204 16930.1.5 Materials .......................................................................................................................... 204 16930.1.6 Approved Manufacturers of Components ........................................................................ 204 16930.1.7 Test Requirements .......................................................................................................... 205 16930.1.8 Technical Attachments .................................................................................................... 205 16930.1.9 Supplemental Specifications ........................................................................................... 205 16930.2 Products ................................................................................................................................. 205 16930.3 Execution ................................................................................................................................ 205 16930.3.1 Grounding Components................................................................................................... 205 16930.3.2 Grounding Installation ...................................................................................................... 206 16930.3.3 Ground System Resistance ............................................................................................. 209 18031 – Electrical Startup, Testing, and Checkout .............................................................................. 211 18031.1 General ................................................................................................................................... 211 18031.1.1 Scope of Work ................................................................................................................. 211 18031.1.2 Items Furnished by Others and Interfaces ...................................................................... 212 18031.1.3 Electrical Startup, Testing, and Checkout Requirements ................................................ 212 18031.1.4 Codes and Standards ...................................................................................................... 212 18031.1.5 Materials .......................................................................................................................... 212 18031.1.6 Approved Manufacturers of Components ........................................................................ 212 18031.1.7 Test Requirements .......................................................................................................... 212 18031.1.8 Technical Attachments .................................................................................................... 212 18031.1.9 Supplemental Specifications ........................................................................................... 212 18031.2 Products ................................................................................................................................. 212 18031.3 Execution ................................................................................................................................ 212 18031.3.1 Calibration, Testing, and Checkout Procedures .............................................................. 212 18031.3.2 Personnel ......................................................................................................................... 214 18031.3.3 Tools and Test Equipment ............................................................................................... 214 18031.3.4 Test Instrument Certification ............................................................................................ 215 18031.3.5 Calibration or Testing Certification Sticker ...................................................................... 215 18031.3.6 Checkout and Test Report Forms ................................................................................... 215 18031.3.7 Startup ............................................................................................................................. 215 18031.3.8 Electrical and Instrumentation Checkout ......................................................................... 216 19000 - Quality System Requirements .................................................................................................. 221 19000.1 General Quality System Requirements .................................................................................. 221 19000.1.1 Quality System ................................................................................................................. 221 19000.1.2 Quality System Manual .................................................................................................... 221 19000.1.3 Subtier Suppliers ............................................................................................................. 222 19000.1.4 Inspection and Test Plan ................................................................................................. 222 19000.1.5 Inspections by Purchaser ................................................................................................ 223 21000 - Technical Supplemental Specifications .................................................................................. 224 Section 60.0050 – Contractor-Furnished Submittals ............................................................................ 225 Section 60.0100 - Supplier Furnished Equipment and Material Requirements .................................... 238 1.0 General ....................................................................................................................................... 238 2.0 Referenced Standards ................................................................................................................ 238 3.0 Materials and Equipment ............................................................................................................ 238 4.0 Arrangement ............................................................................................................................... 238 5.0 Experience of Equipment Suppliers............................................................................................ 238 6.0 Product Substitution .................................................................................................................... 239 7.0 Factory Tests and Reports ......................................................................................................... 239 8.0 Shipment of Equipment and Materials ........................................................................................ 240 9.0 Special Tools .............................................................................................................................. 241 10.0 Manufacture and Assembly ...................................................................................................... 241 11.0 Correction of Errors .................................................................................................................. 241 12.0 Numbering System ................................................................................................................... 241 13.0 Nameplates ............................................................................................................................... 242 14.0 Welding ..................................................................................................................................... 242 15.0 Shop Coating ............................................................................................................................ 242 16.0 Alignment and Balance ............................................................................................................. 243 17.0 Noise Level ............................................................................................................................... 244 18.0 Lubrication ................................................................................................................................ 244 19.0 Enclosed Gear Drive Units ....................................................................................................... 244 20.0 Shaft Couplings ........................................................................................................................ 244 21.0 Safety Guards ........................................................................................................................... 244 22.0 Equipment Bases ...................................................................................................................... 244 23.0 Piping ........................................................................................................................................ 244 24.0 Equipment Lockout Devices ..................................................................................................... 244 25.0 Miscellaneous Mechanical Equipment and Materials ............................................................... 244 26.0 Not Used ................................................................................................................................... 246 27.0 Instrumentation ......................................................................................................................... 246 28.0 Not Used ................................................................................................................................... 255 29.0 Electrical Enclosures ................................................................................................................ 255 30.0 Not Used ................................................................................................................................... 256 31.0 Not Used ................................................................................................................................... 256 32.0 Not used.................................................................................................................................... 256 33.0 Termination of Power Cable ..................................................................................................... 256 34.0 Terminal Blocks ........................................................................................................................ 256 35.0 Fuse Blocks .............................................................................................................................. 256 36.0 Fuses ........................................................................................................................................ 256 37.0 Electrical Accessory Devices .................................................................................................... 256 38.0 Molded Case Circuit Breakers .................................................................................................. 257 39.0 Not Used ................................................................................................................................... 258 40.0 Not Used ................................................................................................................................... 258 41.0 Not Used ................................................................................................................................... 258 42.0 Control Power ........................................................................................................................... 258 Section 60.0110 - Site Design Conditions ............................................................................................. 259 Section 60.0200 - Electric Motor General Requirements ...................................................................... 261 1.0 General ....................................................................................................................................... 261 2.0 Codes and Standards ................................................................................................................. 261 3.0 Rating .......................................................................................................................................... 261 4.0 Torque Characteristics ................................................................................................................ 261 5.0 Guarantees ................................................................................................................................. 262 Section 60.0220 - 460 Volt Integral Horsepower Motor Requirements ................................................. 263 1.0 Design and Construction ............................................................................................................. 263 2.0 Quality Control Tests and Inspections ........................................................................................ 266 3.0 Manufacturers ............................................................................................................................. 267 4.0 Design and Construction ............................................................................................................ 267 Section 60.0230 - Motor Control ........................................................................................................... 269 1.0 General Requirements ................................................................................................................. 269 2.0 Combination AC Motor Starters .................................................................................................. 269 Section 60.0400 - Quality System Requirements ................................................................................. 271 1.0 General Quality System Requirements ...................................................................................... 271 2.0 ASME Boiler and Pressure Vessel Code Compliance ............................................................... 273 Section 60.0500 – Shop and Field Welding Requirements................................................................... 274 1.0 General ....................................................................................................................................... 274 2.0 Application .................................................................................................................................. 274 3.0 Procedures for Welding .............................................................................................................. 274 4.0 Testing and Inspection ................................................................................................................ 274 Section 60.0500A - Carbon and Low Alloy Steel Welding .................................................................... 276 1.0 General ....................................................................................................................................... 276 2.0 Joints ........................................................................................................................................... 276 3.0 Filler Metal .................................................................................................................................. 276 4.0 Welding Procedure Specifications .............................................................................................. 276 5.0 Welding Methods ........................................................................................................................ 277 6.0 Testing and Inspection ................................................................................................................ 277 Section 60.0500B – Pressure Vessel Welding ...................................................................................... 278 1.0 General ....................................................................................................................................... 278 2.0 Qualification and Procedures ...................................................................................................... 278 3.0 Welding Methods ........................................................................................................................ 278 4.0 End Preparation .......................................................................................................................... 278 5.0 Filler Metal .................................................................................................................................. 278 6.0 Preheat and Interpass Temperature ........................................................................................... 279 7.0 Postweld Heat Treatment ........................................................................................................... 279 8.0 Testing and Inspection ................................................................................................................ 279 Section 60.0600 - Compressed Air ....................................................................................................... 280 Attachments Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 01100 – Scope of Work 01100.1 Technical Scope of Work The CPS Energy Calaveras coal yard utilizes several mechanical devices that require a clean and moisture-free supply of compressed air. The coal yard air consumers are supplied by several air compressors through a compressed air piping distribution system. The existing compressor facilities for the coal yard compressed air system is not as reliable and needs consolidation and updating, as it has damages and is aged. All the existing compressors, except the two compressors that are located at the railcar dumper building, are single compressor installations tied together through the use of small bore compressed air piping distribution system to supply the air consumers that are mostly dust collectors, air cannons, fire protection systems instrumentation and general maintenance equipment. The railcar dumper building air compressor supplies compressed air to the railcar dust collector. The railcar dumper building maintenance air compressor supplies compressed air to the railcar dumper building and Transfer Tower, T-1. This compressor project involves the installation of a single enclosed air-cooled compressor with a twin tower regenerative desiccant dryer system that will be connected to the existing compressed air system at the CPS Energy Calaveras coal yard. The new air compressor and dryer shall be skid mounted and located outdoors under a roof for rain-fall protection. Installation shall be done by the Contractor. This compressor project shall consist of the design, engineering, fabrication, testing, warranty and placing into operation the complete air compressor and dryer system. In addition to the installation of the new Client purchased air compressor, this project includes the installation of piping to tie the rail car dump compressed air system to the rest of the coal yard compressed air system by way of an underground small bore piping and the demolition of older ‘standalone’ air compressor systems. The Calaveras Plant Site is located southeast of San Antonio, Texas, on Calaveras Lake. The Site is served by Highway 181 to Southeast to Foster Road, to Burshard Road. Contractor access and deliveries shall use the Knowlton Road entrance. New coal yard air compressor system re-configuration shall include the installation, connection and supply (where applicable) of the following:       One skid-mounted, air-cooled, rotary screw air compressor of the Ingersoll Rand brand with a capacity of 560 cfm. This capacity shall provide the coal yard with 2 x 100 percent capacity to provide compressed air redundancy for coal yard reliability and performance, supplied by others. The new compressor will be tagged as CCAD-CMP-4 and is similar in brand and capacity as CCAD-CMP-1. CCAD-CMP-4 will utilize a new skid-mounted heatless regenerative twin tower air dryer of the Ingersoll Rand brand tagged CCAD-DRY-4, equipped a single inlet and a single outlet particulate filter and an independent control panel, supplied by others. The new dryer (CCAD-DRY-4) shall be located outdoors adjacent to CPS Energy coal yard air compressor (CCAD-CMP-1) and air dryer (CCAD-DRY-1) equipment. The new air dryer will be cross-tied to the existing air dryers at the air dryer inlets and at the outlet to a common compressed air receiver tank (CCAD-TNK-1) through manual operated valves supplied and installed by the Contractor. The compressed air from CCAD-DRY-4 will be output and plumbed by the Contractor to existing coal yard air receiver CCAD-TNK-1. There are no new air receiver tanks at the CCAD-CMP-1 and CCAD-CMP-4 compressor locations. A new 200 gallon compressed air receiver, CCAD-TNK-5, supplied by others, shall be installed at the railcar dump building. Source: 01100, 2014, v.2.0 Scope of Work Page 1 of 280 Calaveras Coal Yard 186144.77.1000    Bid Issue 2Mar2015 Compressed Air Equipment Construction Existing CCAD-CMP-1 and CCAD-DRY-1 controls shall be modified to output alarms to the CPS Energy DCS New CCAD-CMP-4 and CCAD-DRY-4 controls shall be modified to output alarms to the CPS Energy DCS The compressor controls will be designed so that the compressors can be swapped automatically on a weekly or monthly basis. The Contractor shall provide the cabling and connections. New air compressor arrangement shall comprise of the following:      CCAD-CMP-4 shall have a sound enclosure supplied by others and shall be located and installed by the Contractor outdoors on a new concrete pad (14 x 20 foot) protected by a structure supporting a roof, installed by the Contractor (11-12 feet in height) similar to that for CCAD-CMP1 structure. The structure shall be furnished with task and area lighting per the specifications herein. All below grade grounding shall be furnished by the Contractor to extend the existing ground grid. Stingers shall be furnished from the below grade grounding to ground pads furnished on the new compressor skid. CCAD-CMP-4 will be located north of the CCAD-CMP-1 coal yard compressor on a similar multipedestal foundation supplied and installed by the Contractor near the northwest corner of the coal yard maintenance building (location shown on drawing 186144-DM-0001). The new compressor foundation is located on top of an existing buried 2 inch compressed air line so the pipe line that shall be required to be incorporated in the new foundation and shielded from any contact to foundation reinforcing bar or any steel embedment. The Contractor shall provide a roof gutter and down spout for new compressor structure similar but independent of the existing compressor roof gutter and drain system. The Contractor shall provide grating to connect the new foundation with the existing compressor foundation. The grating will be installed with sloped plates or grouting to prevent any trip hazards that may exist between the new and the existing foundations. Under the grating the Contractor shall provide drainage rock for site drainage. Electrical, instrumentation and control connections for the new compressor system installed and connected by the Contractor shall include the following:      The new CCAD-CMP-4 compressor shall include a skid-mounted motor starter, supplied by others. CCAD-CMP-4 shall be electrically fed from the MCC in Transfer Building 1A 480 V MCC 1C3 (CAPN-MCC-01C3) shown on drawing 13968-CAPN-E1026. The Contractor shall provide control cabling from the Transfer Building 1A 480 V MCC 1C3 to both existing air compressor (CCAD-CMP-1) and new air compressor (CCAD-CMP-4). Control cabling required is estimated to be 12 conductor control cable with #14 conductors for both compressors. Each compressor shall have the minimum of 4 control connections; Alarm 1, Alarm 2, Remote stop, and stop. A circuit breaker shall be installed by the Contractor on the 1,600 ampere bus at location MCC in Transfer Building 1A 480 V MCC 1C3, in existing spare bucket location 1-D for service to the new compressor. The new air compressor, CCAD-CMP-4 is expected to require a full load current of 172 amps. The Contractor shall furnish a breaker capable of serving this expected load. The Contractor shall provide compressor and dryer power cabling and conduit. Distance from the Transfer Building 1A MCC to the compressor location is estimated at over 400 feet. Estimated routing is shown on drawing 186144-DM-0001. As shown most routing electrical and control cabling shall be routed above grade with a section (approximately 25 feet) below grade at the conveyor 5 and compressor location. All power cabling shall be appropriately sized to handle any voltage drop associated with the proposed length. Any lug kits required to accommodate oversized cable shall be furnished by the Contractor. The air compressor supplier shall provide a blank gland plate for an electrical power inlet. Source: 01100, 2014, v.2.0 Scope of Work Page 2 of 280 Calaveras Coal Yard 186144.77.1000       Compressed Air Equipment Construction Bid Issue 2Mar2015 A local field disconnect (Siemens Heavy Duty Safety Switch - 225 amp 600 VAC 600 VDC, or Client approved equivalent) with control and power cabling and conduit shall be supplied by the Contractor and located on the compressor support structure. The Contractor shall re-use demolished air compressor electrical connections at the rail car dump air receiver location for the power source for the new air receiver (CCAD-TNK-5) drain trap. The Contractor shall supply and install any and all drain and pneumatic balancing lines for the condensate drain trap (supplied by others). The Contractor shall provide a pressure transmitter for the existing air receiver tank (CCAD-TNK1) with signal communication and connection to both existing air compressor (CCAD-CMP-1) and new air compressor (CCAD-CMP-4). Contractor shall provide all equipment grounding including attachment of ground stingers to the air compressor skid ground pads. The Contractor shall change out the two (2) existing lights on the existing compressor pad and add four (4) additional LED lights for the coal yard compressor area. The Owner will provide the six (6) LED lights fed from the existing light power source (maintenance building). The Contractor shall provide the local power cable, conduit and connections and install the lights supported from the air compressor shelter structure. Piping, valves and instrumentation reconfiguration shall include the following:           The inlets of the air dryers the CCAD-CMP-1 and CCAD-CMP-4 shall be cross-tied with manual valving. The outlet of CCAD_CMP-4 shall be tied into the existing air receiver tank, CCAD-TNK001. New 2 inch piping will connect to the railcar dumper maintenance and dust collector compressed air system together and then tie the rail car dump compressor system with the rest of the coal yard compressed air system. The railcar dump compressor pipe line is threaded galvanized pipe so the connection shall require a crossover valve at the cross-over. Contractor shall provide a 2 inch piping and valving (ball valve, quick disconnect and cap) connection for a temporary portable air compressor supplied by others at the existing air receiver (CCAD-TNK-1) location. Estimated length is approximately 225 feet above ground and 250 feet underground routed from the T-1 building to the rail car dump building across the north-south coal yard drive. Above ground piping shall be CS, socket weld and underground piping of SS304. All piping (above and below grade) shall be coated. Below grade piping shall be protected with a passive cathodic protection system provided by the Contractor. Since the underground piping is stainless steel, the connection to the above ground carbon steel shall require a flanged connection with electrically isolated gaskets. Also the pipe supports where the underground piping crosses the drainage trench, shall be electrically isolated between the pipe and the pipe hanger supports. The Contractor shall provide all manual valves with lock closed handles. Valve List is provided in Section 15221. The Contractor shall be responsible for providing the piping and installation of all drain lines; new compressor drains, new air receiver drains, new air dryer drains. The Contractor shall insulate and lag the new air receiver drain lines including the main drain, bypass drain and drain trap with 2 inch calcium silicate insulation and aluminum lagging similar to the existing air receiver drain lines. The Contractor shall route these drains off the equipment foundations into backfilled gravel around foundations. The Contractor shall provide a manual drain valve on the buried compressed air line where the line becomes exposed crossing the yard trench location. The Contractor shall provide sanding and painting the vertical section of the 2 inch piping portion located between Valve 156 and Valve 103 on the southwest column line of Transfer Tower 4. Contractor shall install new air receiver (CCAD-TNK-5) safety valve (furnished by others). The work under these specifications shall include furnishing the following: Source: 01100, 2014, v.2.0 Scope of Work Page 3 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Scope of supply shall include all necessary labor, materials, hardware, and consumables as defined in the sections of these contract documents for the erection/assembly of the following Purchaser-furnished mechanical equipment and materials. Installation/assembly and testing shall conform to the requirements of the manufacturer’s installation/erection documentation. Unless specifically indicated otherwise in these specifications, the Contractor shall be responsible for furnishing any additional quantities of material, accessories, supports, mounting hardware, equipment, devices, fittings, and any other materials or accessories necessary for the complete installation of Purchaser-furnished material for the work. Except as indicated otherwise herein, all work, materials, and additional equipment required for complete installation of the equipment, including receiving from carriers, unloading, inspection, inventory, and storage prior to installation, shall be provided by the Contractor. Claims by the Contractor for additional compensation on the basis that the Contractor was not aware of the scope of the erection or installation work required will not be considered. Bidders shall be thoroughly familiar with the extent of field assembly required, manufacturers' installation recommendations, and all miscellaneous equipment and materials that are to be installed with Purchaser-furnished equipment. Purchaser may provide the services of one or more manufacturer's field technical service representatives to provide technical assistance to the Contractor.  Installation, foundations and startup of Purchaser procured skid-mounted equipment with foundations, drains, all control and power cabling, all conduit and raceway to support cabling and above grade and below grade grounding, connections for all controls and instrumentation, per applicable codes and regulations, for the following: o Air compressor (CCAD-CMP-4) with driver and all auxiliary equipment o Dual tower desiccant air dryer (CCAD-DRY-4) package and all auxiliaries, filters, drains, filling of desiccant at the field o Pre-filters for air dryer o After-filters for air dryer o Service air filter o Moisture separators o Vents and drains o Sample connections o Supply of all associated distribution piping and valves o Compressed air receiver (CCAD-TNK-5), skirt -supported o New control system modifications work for existing air compressor CCAD-CMP-1 o Instrument and control wiring, raceway and supports between Supplier-furnished local wiring junctions and existing Purchaser DCS system o Permanent electrical wiring to connect equipment terminal boxes to the plant electrical system o Operating personnel for startup and tests o Anchor bolts, foundation embedments, grouting materials and the placing thereof. o The air compressor requires four (4) M20 ¾ inches chemically bond anchor bolts supplied band installed by the Contractor. o Leveling blocks, thrust blocks, matching blocks, and shims. o The air compressor base frame requires a cork or rubber seal base to the floor to be supplied and installed by the Contractor. o Valves, instrumentation connections external to the supplier skids o Separate (off-skid) mounted field disconnect switch. o Piping and piping supports between supplied equipment termination points Install desiccant in compressed air dryers per equipment manufacture specifications. Fill desiccant dryers, if not already filled by equipment manufacture.  Fill air compressor with all fluids, if not already filled by manufacture. Source: 01100, 2014, v.2.0 Scope of Work Page 4 of 280  Calaveras Coal Yard 186144.77.1000         Compressed Air Equipment Construction Bid Issue 2Mar2015 Touch up painting per manufacturer’s recommendations for items damaged from installation.. All structural steel shall be primer and final coat painted by the Contractor. The Contractor shall sand blast, prime and final coat above grade carbon steel pipe and below grade stainless steel. The below grade stainless steel welds shall be coated per specifications herein. Installation of all interconnecting Air piping with branch connections for users, fittings, valves, drip legs, low point drains, tie-ins, interfaces, run with all necessary hangers and supports and pipe racks required: o Air piping will consist of carbon steel above ground and stainless steel underground piping in the coal yard. o Drain piping from the compressors, dryers and air receiver tank. o Testing and cleaning of all piping. Supply of items required for the above work, including, all electrical, instrumentation, civil and structural works associated with installation, startup and commissioning of the equipment and piping, including inspection and site management Tests and inspections required by the specifications for site installation and construction Mechanical cleaning of the air system shall involve:  Air blown down from each branch line to remove construction debris.  Blow-down will be conducted at the discretion of start-up personnel to meet the acceptance criteria. Coordinate with the Engineer for any additional requirements. The site work will include unloading and storage of all required equipment at site, complete erection, painting, support supplier’s personnel for commissioning and putting into normal operation, performance and reliability testing on completion, for the operation and maintenance of the complete air compressor system in a safe and expeditious manner, and all obligations during the defects liability period as stipulated in the Conditions of Contract. All equipment, spare parts and materials used in the construction of the plant shall be new and unused. Demolition of the following existing equipment and piping shall also be part of the scope of work in reconfiguring the new compressed air system:           Air compressor Crusher-1 building shall be removed from service and isolation work will be done as required. Compressed air pipelines from Crusher-1 to the southwest corner of Crusher-1 will be removed CMP-2 (CCAD-CMP-2) and air dryer (CCAD-DRY-2) with associated piping and accessories in Crusher-2 building shall be removed from service and isolation work will be done as required. CMP-3 air compressors (CCAD-CMP-3) and air dryers (CCAD-DRY-3) with associated piping and accessories in Transfer tower T-4 building shall be removed from service and isolation work will be done as required. Air compressors and dryers that are to be removed from service shall be disassembled in place without the use of a cutting torch, and then removed from the existing MCC building locations and disposed of offsite by the Contractor. Existing air receiver CCAD-TNK-2 and CCAD-TNK-3 shall remain in service, but the inlet valve BV-135 shall be closed and capped and BV-141 shall be removed and the pipeline isolated with a blind flange. Railcar dumper maintenance (CCAD-CMP-ALL) and dust collectors air compressors (CCCBCMP-001) and dryers shall be removed from service, and then removed from the rail dump building location and disposed of offsite by the Contractor. The demolished air compressor concrete pedestals shall remain, but the anchor bolts shall be ground to prevent trip hazards. All electrical connections shall be terminated back to the cable tray location. No cable tray access shall be allowed. The foundation for the railcar dumper air compressor shall be reused to support the new air receiver (CCAD-TNK-5). Source: 01100, 2014, v.2.0 Scope of Work Page 5 of 280 Calaveras Coal Yard 186144.77.1000  Bid Issue 2Mar2015 Compressed Air Equipment Construction Wherever new installation or demolition occurs, the existing equipment, piping, steel structure, building siding, etc. shall be covered, painted or repaired to match the existing equipment or building. No building siding holes, unsupported or unpainted structure, unconnected electrical or instrumentation, or exposed trenches, etc. shall be left after demolition and/or construction occurs. In the event of technical conflicts, errors, or discrepancies, the detailed technical specifications, including this Section 01100 and all higher numbered sections, take precedence over Section 21000, Technical Supplemental Specifications. 01100.2 Drawings and Technical Attachments This article lists the drawings and other technical attachments that have been prepared for the work under these specifications. 01100.2.1 Engineer’s Attachments The following listed attachments shall be part of the Contract. Drawing No. or Other Designation Rev. No. Title 186144-DM-0001 B Compressed Air Site Plan 186144-DM-1000 A General Piping Plan and Sections, Pipe Installation 13936-CCAD-M2004A 7 Piping and Instrument Diagram, Coal Yard Compressed Air 13968-CCAD-M2004B 6 Piping and Instrument Diagram, Coal Yard Compressed Air 186144-DS-0001 A Coal Yard Air Compressor, Foundation and Structural Steel (bid copy, not for construction) 186144-1CPU-E2701 A Galvanic Anode – Cathodic Protection Details 186144-1CPU-E2702 A Insulated Flange – Cathodic Protection Details 31CC2X Pipe Class – Utility Air 31SANX Pipe Class – Instrument Air 13968-CAPN-E1026 5 One-Line Diagram, Transfer 1A 480V MCC 1C3 186144-DM-1001 A Coal Handling Arrangement, Coal Crusher Building 2 – Plans Demolition (mark-up) 186144-DM-1002 A Coal Handling Arrangement, Coal Transfer Building 4 – Plans Demolition (mark-up) 49083520 (4 Sheets) A General Arrangement, Air Cooled (R90) (bid copy – for information only) Rotary 125 HP 60 HZ Oct 2007 Air Compressor Engineering Data Sheet, R90IU-125 (bid only – for information only) 49083504 ( 2 Sheets) A Decal, Electrical Wiring Schematic (FS-SD) (bid copy – for information only) 47531357 A General Arrangement, HL 6001HGSCHZ01, SO# 81961255 (bid copy – for information only) 47531358 A Wiring Diagram, HL 6001HGSCHZ01, SO# 81961255 Source: 01100, 2014, v.2.0 Scope of Work Page 6 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 HL600 Feb 2015 HL Desiccant Dryer – HL 6001HGSCHZ01 - Engineering Data Sheet A10051 14 200 Gallon Vertical Air Receiver Tank, Skirted (bid copy – for information only) 81113-DM-0700 1 Blast Media Data Sheets – System B1 81113-DM-0667 2 Coatings System Data Sheets – System 1112 81113-DM-0664 2 Coatings System Data Sheets – System 3301 81113-DM-0665 2 Coatings System Data Sheets – System 3311 The documents listed above represent the latest design documents and are for information purposes only. They are not to be used for construction. Source: 01100, 2014, v.2.0 Scope of Work Page 7 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 01621 - Purchaser-Furnished Mechanical Equipment and Materials 01621.1 General 01621.1.1 Scope of Supply Scope of supply shall include all necessary labor, materials, hardware, and consumables as defined in the section of these contract documents titled 01100 Scope of Work for the erection/assembly of the following Purchaser-furnished mechanical equipment and materials. Installation/assembly shall conform to the requirements of the referenced installation/erection section: Purchaser's Procurement Specification(s) Item Air Compressor (CCAD-CMP-4) 184710.62.0401 Air Dryer (CCAD-DRY-4) 184710.62.0401 Air Reciever (CCAD-TNK-5) 184710.62.0401 Installation/Erection Section(s) Equipment and material quantities and details are indicated on the attached Purchaser-Furnished Mechanical Equipment and Materials Data Sheet. 01621.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this scope of supply are identified on the attached PurchaserFurnished Mechanical Equipment and Materials Data Sheet. 01621.1.3 Equipment and Material Data Data for Purchaser-furnished mechanical equipment and materials are indicated on the PurchaserFurnished Mechanical Equipment and Materials Data Sheet included at the end of this section. 01621.1.4 Codes and Standards Installation and erection of the equipment and materials described herein shall be done in accordance with the codes and standards referenced in the applicable erection sections of these specifications. 01621.1.5 Materials The following materials shall be used: Component Material Consumables and other materials required for installation and erection of the items described herein shall be as specified in 01100 Scope of Work 01621.1.6 Not Used 01621.1.7 Test Requirements The following testing shall be conducted: Source: 01621, 2014, v2.0 Purchaser-Furnished Mechanical Equipment and Materials Page 8 of 280 Calaveras Coal Yard 186144.77.1000 Tests Testing requirements are specified in the referenced erection sections of these specifications. Bid Issue 2Mar2015 Compressed Air Equipment Construction In Accordance With Conducted By Contractor 01621.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 01621.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 01621.2 Products Unless specifically indicated otherwise in these specifications, the Contractor shall be responsible for furnishing any additional quantities of material, accessories, supports, mounting hardware, equipment, devices, fittings, and any other materials or accessories necessary for the complete installation of Purchaser-furnished material for the work. 01621.3 Execution 01621.3.1 General Requirements The equipment and materials indicated on the Purchaser-Furnished Mechanical Equipment and Materials Data Sheet will be furnished by Purchaser under separate specifications for installation by the Contractor. Except as indicated otherwise herein, all work, materials, and additional equipment required for complete installation of the equipment, including receiving from carriers, unloading, inspection, inventory, and storage prior to installation, shall be provided by the Contractor. Information describing equipment included in this section will give only an approximate scope of the installation work and is not intended to be a detailed itemization of all work to be done as a part of these specifications. The Scope of Work to be provided by the Contractor under these specifications, in conjunction with the installation or erection of Purchaser-furnished equipment, shall be based on equipment furnished in compliance with Purchaser's purchase documents, unless specific modifications to the purchase document scope of supply are stated in items herein. Unless specifically stated otherwise in these specifications, the Contractor shall be responsible for the erection or installation of all miscellaneous equipment or materials furnished with Purchaser-furnished material described herein. To obtain complete information, the manufacturers' drawings and other information may be examined at the engineering offices of Purchaser or at Purchaser's plant site offices. If necessary, supplemental information may be obtained from the manufacturer concerning the extent of field installation work. The weights and dimensions given are approximate and shall not be considered limitations to the Scope of Work. Claims by the Contractor for additional compensation on the basis that the Contractor was not aware of the scope of the erection or installation work required will not be paid. Bidders shall be thoroughly familiar with the extent of field assembly required, manufacturers' installation recommendations, and all miscellaneous equipment and materials that are to be installed with Purchaser-furnished equipment. 01621.3.2 Manufacturer's Shop Drawings Manufacturer's shop drawings will be furnished to the Contractor upon contract award. 01621.3.3 Spare Parts and Maintenance Tools All spare parts and maintenance tools provided with equipment shall be delivered to Purchaser. Source: 01621, 2014, v2.0 Purchaser-Furnished Mechanical Equipment and Materials Page 9 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 01621.3.4 Manufacturer's Field Technical Service Representative If indicated on the Purchaser-Furnished Mechanical Equipment and Materials Data Sheet, Purchaser will provide the services of one or more manufacturer's field technical service representatives to provide technical assistance to Contractor. Technical assistance may include the following: Technical direction during startup and initial operation of the equipment. Direction to Contractor in correcting any design or manufacturing errors. The presence of manufacturer's field technical service personnel shall not relieve Contractor of his responsibility for providing a proper installation. Source: 01621, 2014, v2.0 Purchaser-Furnished Mechanical Equipment and Materials Page 10 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Purchaser-Furnished Mechanical Equipment and Materials Data Sheet Equipment Name Air Compressor Equipment Designation R90i-125 Identification Number CCAD-CMP-4 Quantity Furnished Under the Above Designation 1 Manufacturer Ingersoll Rand, Comments Assembly Requirements Supplied as a skid assembly. Dimensions and Weights of Items To Be Handled by the Contractor Item Air Compressor Enclosure (preliminary) Length, in. Width, in. Height, in. Diameter, in. Weight, lb 106.4 57.7 80 na 5,335 Anticipated Receipt Date of Equipment and Materials Item Early Late Air Compressor with Enclosure (estimated) March 1, 2015 May 1, 2015 Storage Requirements In accordance with the equipment Instruction Manuals and the storage requirements as indicated in Onsite Operation Conditions Manufacturer's Field Service Representative Yes Miscellaneous Information Source: 01621, 2014, v2.0 Purchaser-Furnished Mechanical Equipment and Materials Page 11 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Purchaser-Furnished Mechanical Equipment and Materials Data Sheet Equipment Name HL Heatless Desiccant Air Dryer Equipment Designation HL 500-600 Identification Number CCAD-DRY-4 Quantity Furnished Under the Above Designation 1 (twin tower) Manufacturer Ingersoll Rand, Comments Assembly Requirements Supplied as a skid assembly. Dimensions and Weights of Items To Be Handled by the Contractor Item Length, in. Width, in. Height, in. Diameter, in. Weight, lb Air Dyer Skid (preliminary) 52.62 56.50 82.50 na tbd Anticipated Receipt Date of Equipment and Materials Item Early Late Air Dryer (estimated) March 1, 2015 May 1, 2015 Storage Requirements In accordance with the equipment Instruction Manuals and the storage requirements as indicated in Onsite Operation Conditions Manufacturer's Field Service Representative Yes Miscellaneous Information Source: 01621, 2014, v2.0 Purchaser-Furnished Mechanical Equipment and Materials Page 12 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Purchaser-Furnished Mechanical Equipment and Materials Data Sheet Equipment Name Vertical Air Receiver Equipment Designation CCN 38002754 – 200 GAL Identification Number CCAD-TNK-5 Quantity Furnished Under the Above Designation 1 Manufacturer Ingersoll Rand, Comments Assembly Requirements Supplied as a skirted assembly. Dimensions and Weights of Items To Be Handled by the Contractor Item Length, in. Width, in. Height, in. Diameter, in. Weight, lb Air Receiver (preliminary) na52.62 na 72 30 tbd Anticipated Receipt Date of Equipment and Materials Item Early Late Air Receiver (estimated) March 1, 2015 May 1, 2015 Storage Requirements In accordance with the equipment Instruction Manuals and the storage requirements as indicated in Onsite Operation Conditions Manufacturer's Field Service Representative No Miscellaneous Information Source: 01621, 2014, v2.0 Purchaser-Furnished Mechanical Equipment and Materials Page 13 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 02220 - Earthwork 02220.1 General 02220.1.1 Scope of Work Scope of Work shall include completing earthwork and shall include other services as specified under these technical specifications. 02220.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this Scope of Work include the following: Air compressor (CCAD-CMP-4) foundation Buried electrical lines and signal cables for air compressor power and control. Buried cathodically protected stainless steel compressed air line. 02220.1.3 Performance and Design Requirements Performance and design requirements for earthwork are indicated in Article 02220.3. 02220.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Standard Practice for Classification of Soils for Engineering Purposes (Unified Soil Classification System) ASTM D2487 Standard Practice for Description and Identification of Soils (Visual-Manual Procedure) ASTM D2488 02220.1.5 Materials The following materials shall be used: General Component Material Standard Specification for Concrete Aggregates or Standard Specification for Road and Bridge Construction ASTM C33 or (State) Department of Transportation (DOT) Lime Treated Soil Standard Specifications for Road and Bridge Construction, (State) Department of Transportation 02220.1.6 Acceptable Manufacturers of Components For the following components, the manufacturers listed below provide examples of the quality of workmanship required by these specifications. If the Contractor wants to propose a nonlisted Source: 02220, 2014, v2.0 Earthwork Page 14 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction manufacturer that in considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Purchaser: Component Manufacturer Nuclear Surface Moisture-Density Gauge Troxler Model 3430, 3440, 3450, 3451 Nuclear Surface Moisture-Density Gauge Campbell Pacific Nuclear (CPN) Model MC-3 and MC-1 02220.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. Material, compaction, and testing requirements are found in Table 1. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Contractor unless specifically identified as Purchaser-conducted. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Contractor is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure. Tests In Accordance With Conducted By Standard Test Methods for Laboratory Compaction characteristics of Soil Using 3 Modified Effort (56,000 ft-lbf/ft 3 (2,700 kn-m/m )) ASTM D1557 (Modified Proctor) Contractor Standard Test Method for Density and Unit Weight of Soil in Place by the Rubber Balloon Method ASTM D2167 Contractor Standard Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table ASTM D4253 Contractor Standard Test Methods for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density ASTM D4254 Contractor Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils ASTM D4318 Contractor Standard Test Method for InPlace Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth) ASTM D6938 Contractor 02220.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 02220.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. Source: 02220, 2014, v2.0 Earthwork Page 15 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 02220.2 Not Used 02220.3 Execution 02220.3.1 General This article covers general earthwork; removal and disposal of debris; excavation; the handling, storage, transportation, and disposal of excavated material; sheeting, shoring, and protection work; preparation of subgrades; dewatering; protection of adjacent construction; backfill; construction of fills and embankments; surfacing and grading; and other appurtenant work. All excavations, sheeting, shoring, and temporary excavation support shall be performed in accordance with OSHA 29CFR Part 1926, Subpart P, "Excavations." 02220.3.2 Sheeting and Shoring The stability of previously constructed structures and facilities shall not be impaired or endangered by excavation work. Previously constructed structures and facilities include both structures and facilities existing when this construction began and structures and facilities already provided under these specifications. Adequate sheeting and shoring shall be provided to protect and maintain the stability of previously constructed structures and facilities and the sides of excavations until they are backfilled. Sheeting, bracing, and shoring shall be designed and built to withstand all loads and restrain all settlement caused by earth movement or pressure, and shall maintain the shape of the excavation. 02220.3.3 Removal of Water Adequate dewatering equipment shall be provided to remove and dispose of all surface and ground water entering excavations and other parts of the work. Each excavation shall be kept dry. Control of ground water shall be accomplished in a manner that will preserve the strength of the foundation soils, will not cause instability of the excavation slopes, and will not result in damage to existing structures. Where necessary to these purposes, the water level shall be lowered in advance of excavation, utilizing wells, well points, or similar methods. The water level as measured in piezometers shall be maintained continuously about 1 foot below the prevailing excavation level, or it shall be lowered to within about 1 foot of impermeable strata. Open pumping with sumps and ditches, if it results in boils, loss of fines, softening of the ground, or instability of slopes, will not be permitted. Wells and well points shall be installed with suitable screens and filters so that continuous pumping of fines does not occur. Dewatering shall continue until the construction is no longer affected by ground or surface water. The dewatering system shall only pump water that is clear and free of fines, with a sand content less than 10 ppm. The discharge shall be arranged so that samples can be collected. Surface water shall be diverted to the extent possible to prevent entrance into excavations. Pipe or conduit used for drainage purposes shall be kept clean and free of sediment. Temporary drainage piping that is not a part of the permanent construction shall be removed at the completion of the work. When the work is completed, all parts of the permanent plant drainage system used for water disposal that have been damaged by dewatering operations shall be repaired. Dewatering work shall not overload the plant drainage system. Dewatering discharge shall be routed to local open trench. Header systems may be laid on top of the ground provided they do not obstruct plant operations, construction activity, or traffic. Groundwater systems shall operate continuously, if necessary, to maintain the specified water level. Proposed dewatering systems shall be submitted to the Engineer for review. Source: 02220, 2014, v2.0 Earthwork Page 16 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 02220.3.4 Blasting The Contractor shall be responsible for all damage caused by his blasting operations. Materials lifted by blasting shall be confined within the limits of the excavation. The Contractor shall be responsible for obtaining all blasting permits. 02220.3.4.1 Pre-Blast Survey. Contractor shall perform a pre-blast survey of all utilities, structures, and other facilities adjacent to the blast sites to determine the conditions of each utility, house, building, bridge, overpass, and other structures and facilities susceptible to damage from blasting operations. The pre-blast survey shall include all structures and utilities within a minimum of 500 feet radius of the area to be blasted. The survey notification to all property owners, tenants, utilities, and other agencies and the area of survey shall be in conformity with the requirements of the authority having jurisdiction or as determined by Contractor's insurance company if no local ordinance applies. Contractor shall submit the pre-blast survey report for record purposes to Owner. 02220.3.4.2 Blast Monitoring. Prior to the start of Contractor's blasting, Contractor shall measure background ground vibrations. Seismographs shall be placed on the ground adjacent to structures subjected to ground shock to measure peak particle velocity components in three mutually perpendicular directions during blasting operations. The peak particle velocity, defined as the maximum of the three velocity components of vibration, at any location shall not exceed values that will cause damage to the adjacent structures. Air overpressure shall be measured at adjacent structures. Air overpressure at adjacent structures shall not exceed values that will cause damage to the adjacent structures or personnel. The maximum peak particle velocity and air overpressure values that will not cause damage shall be determined by the blasting engineer retained by Contractor and shall be stated in the blasting procedures. Contractor shall submit measurement records of the blast monitoring within 24 hours after each blast for record purposes to Owner. 02220.3.4.3 Post-Blast Survey. Contractor shall perform a post-blast survey of the same utilities, structures, and other facilities surveyed in the pre-blast survey to determine the effect of the blasting operations. Contractor shall submit the post-blast survey report for record purposes to Owner. 02220.3.5(1) Classification of Excavated Materials No classification of excavated materials will be made. Excavation work shall include the removal and handling of excavated materials regardless of the type, character, composition, or condition. 02220.3.6 Freezing Weather Restrictions Backfill and fill shall not be placed during freezing weather unless acceptable to the Engineer. Earth material shall not be placed on frozen surfaces, and frozen materials, snow, or ice shall not be placed in any fill or backfill. 02220.3.7 Preservation of Trees Trees shall be preserved and protected as much as possible. Unless specifically authorized by the Site Construction Manager, trees shall be removed only from areas within the construction limits. Removal of additional trees may be permitted by the Site Construction Manager when necessary for the effective execution of the work. Trees left standing shall be protected from permanent damage. Construction equipment and vehicles shall be parked outside the drip line of trees designated to remain. Trimming of standing trees shall be as directed by the Site Construction Manager. Source: 02220, 2014, v2.0 Earthwork Page 17 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 02220.3.8 Maintenance of Traffic The Supplier shall conduct his work with as little interference as possible with the work of other suppliers. Whenever it is necessary to cross, obstruct, or close roads, driveways, parking areas, and walks, the Supplier shall provide and maintain suitable and safe bridges, detours, or other temporary expedients at his own expense. 02220.3.9 Unauthorized Excavation Material excavated below the bottom of concrete structures to be supported on the subgrade shall be replaced with concrete placed monolithically with the concrete above. Rock fill or lean concrete may be used, if acceptable to the Engineer. 02220.3.10 Testing Laboratory testing shall be performed by an independent testing laboratory acceptable to the Purchaser. Field sampling and testing shall be performed by NICET Level II Construction Materials Testing technicians or a NICET Level II Construction Materials Testing technician employed by an independent testing company. Field samples shall be taken at locations selected by the Site QA Manager. If, in the opinion of the Site QA Manager, additional field control tests are necessary such tests shall be made. Field density tests shall be taken so as to represent the average density over the depth of the layer. The terms "maximum density" and "optimum moisture content" shall be as defined in ASTM D1557. Relative density for compacted crushed rock materials shall be determined in accordance with ASTM D4253 and D4254. The term "relative density" shall be as defined in ASTM D4254. A copy of each test result shall be furnished to the Purchaser on the day the test is performed. Testing requirements are provided in Table 1. 02220.3.11 Site Preparation Subgrades for permanent construction, including subgrades for fills and embankments, shall be stripped of concrete, asphalt, conduit, pipes and demolition or construction debris. All combustible and other wastes materials shall be removed from the construction areas. Disposal shall be as specified in Section 02231. Open burning is not permitted at the site. Clean soil or gravel may be stockpiled for later reuse. Material containing particles (concrete or rock) greater than 4 inches in dimension shall be wasted at a location designated by Purchaser. 02220.3.12 Roadway and Railroad Roadbeds Roadway and railroad roadbed construction shall include excavation, subgrade preparation, and construction of fills and embankments. In excavated roadbed areas, overburden shall be removed and the subgrade shaped to line, grade, and cross section. Soft, organic, and other unacceptable material shall be removed from the subgrade and replaced. The replacement material shall meet the requirements of Article 02220.3.16. The subgrade shall be compacted in accordance with Table 1 and finished to a uniform surface to allow for proper drainage. The subgrade shall be finished to within 0.1 foot of the elevation indicated on the drawings. Ditches and drains along the subgrade shall be maintained for effective drainage. When ruts of 2 inches or more in depth are formed, the subgrade shall be reshaped and recompacted. Materials shall not be stored or stockpiled on subgrades. Source: 02220, 2014, v2.0 Earthwork Page 18 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 02220.3.13 Fills and Embankments Fills and embankments shall be constructed to lines and grades indicated on the drawings. 02220.3.13.1 Materials. To the maximum extent available, earth materials obtained from excavation shall be used for the construction of fills and embankments. Additional material shall be obtained from borrow areas. Fill and embankment material shall be earth only and shall be free from brush, stumps, logs, roots, debris, and organic or other deleterious materials. Fill and embankment material obtained from off-site sources shall be free of contamination. Free of contamination shall be defined as indicated in EPA, state, and other applicable requirements. The fill/embankment material supplier shall provide documentation that the material is free of contamination. 02220.3.13.2 Subgrade Preparation. The subgrade shall be leveled and compacted in accordance with Table 1. The subgrade surface shall be well bonded to the previous layers of fill. 02220.3.13.3 Placement and Compaction. Fill and embankment materials shall be placed in approximately horizontal layers. Material deposited in piles or windrows shall be spread and leveled before compaction. Water shall be added to meet the moisture content required in Table 1 and worked into each layer using harrow, disk, blade, or other acceptable equipment to provide a uniform moisture content. If the material fails to meet the specified density in Table 1, compaction methods shall be altered. 02220.3.13.4 Borrow Areas. Materials necessary to complete fills and embankments shall be excavated from on-site borrow areas designated by the Purchaser and hauled to the fill or embankment site. Upon completion of borrow activity, the borrow site shall be graded in a manner acceptable to the Purchaser. 02220.3.14 Structure Excavation Excavation for structures shall be completed to the designated lines and elevations. Machine excavation shall be controlled to prevent undercutting the subgrade elevations indicated on the drawings. Excavated materials that meet the specified requirements may be used for the fills, embankments, and backfills. Vertical faces of excavations shall not be undercut to provide for extended footings. 02220.3.15 Structure Subgrades Subgrades for structures shall be firm, dense, free from mud, thoroughly compacted to the specified density in Table 1, and sufficiently stable to remain firm and intact. Structure subgrades that cannot achieve the required density shall be over-excavated and replaced with structural fill. Subgrades that are otherwise solid, but become mucky on top due to construction operations, shall be stabilized by reinforcing them with one or more layers of crushed rock or gravel unless otherwise noted on the drawings. The finished elevation of stabilized structure subgrades shall not be above the subgrade elevations indicated on the drawings. 02220.3.16 Structural Fill Structural fill is fill placed beneath structures. Structural fill shall be mechanically compacted. Structural fill requirements are provided in Table 1. Source: 02220, 2014, v2.0 Earthwork Page 19 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Particular care shall be taken to compact structural fill beneath pipes, drives, roads, or other surface construction. When a trench passes through structural fill, the fill shall be placed and compacted to at least 12 inches above the top of the pipe elevation before the trench is excavated. 02220.3.17 Structure Backfill Backfill around and outside of structures shall be deposited in approximately horizontal layers. Backfill shall be mechanically compacted in accordance with Table 1. Compaction of structure backfill by rolling will be permitted provided the desired compaction is obtained and damage to the structure is prevented. Compaction of structure backfill by inundation with water will not be permitted. Backfill material shall be composed of earth only and, to the extent possible, shall be void of wood, grass, roots, broken concrete, stones, trash, or other debris. No tamped, rolled, or otherwise mechanically compacted backfill shall be deposited or compacted in water. All backfill material shall consist of loose earth having a moisture content required in Table 1 to obtain the specified density (Table 1) of the compacted soil. Moisture content shall be distributed uniformly. Water added for correction of moisture content shall be distributed uniformly prior to compaction. Granular material shall be wet, not just damp, when compacted. 02220.3.18 Compacted Rock Fill Compacted rock fill shall consist of crushed rock. Compaction shall be performed with vibrating mechanical compactors. Crushed concrete meeting gradation and requirements may be used with Engineer’s approval. Crushed rock for compacted fill shall be handled and placed in a manner that will prevent segregation of sizes. The fill material shall have the moisture content specified in Table 1 to achieve compaction required in Table 1. If concrete is to be placed on the compacted rock fill, the fill shall be finished with a thin layer of clean concrete sand to fill all voids and interstices to obtain the required subgrade elevation. 02220.3.19 Compacted Sand Fill Compacted sand fill material shall consist of clean, natural sand. Sand fills shall be placed on undisturbed or compacted subgrade. Sand shall be compacted using mechanical vibrators. Compaction and moisture content shall be in accordance with Table 1. 02220.3.20 Drainage Fills Sand drainage fills and drainage filter material shall be as indicated on the drawings. Unwashed material is unacceptable. Sand drainage fill and drainage filter material shall be compacted with a vibrating compactor. Compaction and moisture content shall be in accordance with Table 1. 02220.3.21 Controlled Low Strength Material Controlled low strength material (CLSM) shall be installed in accordance with Section 02320. 02220.3.22 Maintenance and Restoration of Fills, Embankments, and Backfills Fills, embankments, and backfills that settle or erode before final acceptance of the work, and pavement, structures, and other facilities damaged by such settlement or erosion, shall be repaired. The settled or eroded areas shall be filled, compacted, and graded to conform to the elevation indicated on the drawings or to the elevation of the adjacent ground surface. Damaged facilities shall be repaired in a manner acceptable to the Purchaser. Source: 02220, 2014, v2.0 Earthwork Page 20 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Earth slopes of the roads and railroads constructed under these specifications shall be maintained to the lines and grades indicated on the drawings until the final acceptance of the work. 02220.3.23 Final Grading After all construction work has been completed, all ground surface areas disturbed by construction activities shall be graded. The grading shall be finished to the contours and elevations indicated on the drawings or, if not indicated, to the matching contours and elevations of the original, undisturbed ground surface. The final grading shall provide smooth uniform surfaces and effective drainage of the ground areas. 02220.3.24 Disposal of Materials Surplus earth and materials not suitable for the work shall be spoiled on the site in a manner and location designated by the Owner. Material not suitable for work shall be spoiled separately from surplus material. Stockpiles of surplus material shall be free from brush, trees, debris, or other organic or deleterious materials. Offsite disposal may be used, if allowed by the Owner. Disposal shall be in accordance with all federal, state, and local requirements. Source: 02220, 2014, v2.0 Earthwork Page 21 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Table 1 Materials, Compaction, and Testing Requirements Maximum Density Test Frequency ASTM D6938; and ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) -2% to +2% of optimum water content - - ASTM D1557, Method C or ASTM D698, Method C Fill and embankment subgrade - - Subgrade shall be scarified and rolled to provide for bonding of overlying lifts. Fills and embankments - 3 initial tests; further tests as directed 90% Max. Dry Density One test per 500 sy (420 sm), or as required Roadway and railroad roadbed Maximum Density Field Density Test Required Field Water Content Gradation Requirements Material Required Field Density Field Density Test Frequency Plasticity Requirements Field Water Content Test Required Lift Thickness ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) 8 inches (200 mm) depth Remarks The project geotechnical engineer shall verify the table meets local and state DOT minimum requirements Subgrade preparation shall be witnessed and approved by a qualified soil technician and construction management. Areas identified as soft or excessively disturbed shall be removed and replaced with soil compacted as described in “Fills and Embankments”. Subgrade shall be sealed with a smooth drum roller when inclement weather is expected, then scarified prior to adding overlying lifts. Standing water shall not be permitted. Areas that have been exposed to heavy rain or standing water shall be allowed to dry to within 2 percent of optimum water content prior to adding overlying lifts. 6 inch (150 mm) max; 3 inch (75 mm) max in upper 18 inches (460 mm) Source: 02220, 2010, v.1.7 ASTM D1557, Method C or ASTM D698, Method C 3 initial tests, further tests as directed 95% Max. Dry Density ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) Earthwork One test per 500 cy (380 cm), or as required -2% to +2% of optimum water content ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) 8 inches (200 mm) thick lift prior to compaction (loose lift) Top 1 inch (25 mm) of each lift shall be scarified to promote bonding between lifts. Page 22 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Table 1 Materials, Compaction, and Testing Requirements Material Structure subgrade Plasticity Requirements Gradation Requirements - - Maximum Density ASTM D1557, Method C or ASTM D698, Method C Maximum Density Test Frequency 1 initial test; further tests as directed Required Field Density Field Density Test 95% Max. Dry Density ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) Field Density Test Frequency Required Field Water Content One test per 1,000 sy (840 sm), or as required. Min one per foundation for foundations over 10 sy (8 sm) -2% to +2% of optimum water content Field Water Content Test Required Lift Thickness Remarks ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) 8 in. depth - The project geotechnical engineer must provide the requirements for structural fill. Some examples are as follows: Option 1 Plasticity - Non-plastic Gradation - 3 inch maximum; ≤5 percent minus No. 200 Option 2 - Crushed Rock Structural Fill Size Percent Passing 1/2 inch (12.5 mm) 100 3/8 inch (9.5 mm) 90-100 No. 4 (4.75 mm) 30-60 No. 8 (2.36 mm) 0-10 No. 200 (75 µm) 0-5 Option 3 - Clean Sand Structural Fill Size Percent Passing 3/8 inch (9.5 mm) 100 No. 4 (4.75 mm) 95-100 No. 8 (2.36 mm) 75-90 No. 30 (600 µm) 30-50 No. 100 (150 µm) 2-10 No. 200 (75 µm) 0-5 Source: 02220, 2010, v.1.7 Earthwork Page 23 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Table 1 Materials, Compaction, and Testing Requirements Plasticity Requirements Gradation Requirements Maximum Density Structure backfill Structure backfill placed against below grade walls shall be non-swelling material with a liquid limit (LL) less than 40 and a PI less than 15. 3 inch (75 mm) max ≤85 percent minus No. 200 ASTM D1557, Method C or ASTM D698, Method C Compacted rock fill Non-plastic 1-1/2 in. (38 mm) max. to crusher fines; ASTM C33 or Type ___ per Section ___ of ___ DOT Compacted sand fill Non-plastic ≥75% minus No. 4; ≤10% minus No. 200; ASTM C33 or Type ___ per Section ___ of ___ DOT Material Source: 02220, 2010, v.1.7 Maximum Density Test Frequency Field Density Test Frequency Required Field Water Content ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) One test per 200 cy (150 cm), or as required 70% Relative Density ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) 90% Max. Dry Density ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) Required Field Density Field Density Test 3 initial tests; further tests as directed 95% Max. Dry Density ASTM D4253 and D4254 3 initial tests; further tests as directed ASTM D1557, Method C or ASTM D698, Method C 3 initial tests; further tests as directed Earthwork Field Water Content Test Required Lift Thickness -2% to +2% of optimum water content ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) 8 inches (200 mm) thick lift prior to compaction (loose lift) Compaction by inundation with water will not be permitted. One test per 200 cy (150 cm), or as required As required to achieve field density ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) 8 inches (200 mm) thick lift prior to compaction (loose lift) - One test per 200 cy 150 cm), or as required -2% to +2% of optimum water content ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) 8 inches (200 mm) thick lift prior to compaction (loose lift) - Remarks Page 24 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Table 1 Materials, Compaction, and Testing Requirements Maximum Density Test Frequency Surplus earth and materials not suitable for the work - - Sand drainage fill Non-plastic Uniformly graded from No. 4 to No. 100 sieve ASTM D4253 and D4254 3 initial tests; further tests as directed 65% relative density ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) One test per 500 cy (380 cm), or as required As required to achieve field density Lime treated soil - As specified in ___ DOT ASTM D1557, Method C or ASTM D698, Method C 3 initial tests; further tests as directed 95% Max. Dry Density ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) One test per 500 cy (380 cm), or as required -2% to +2% of optimum water content Source: 02220, 2010, v.1.7 Maximum Density Field Density Test Required Field Water Content Gradation Requirements Material Required Field Density Field Density Test Frequency Plasticity Requirements Earthwork Field Water Content Test Required Lift Thickness Remarks Spread uniformly in approximately 12 inches (300 mm) thick lifts Spoil in a manner and location designated by Purchaser. Disposal shall be in accordance with all federal, state, and local requirements pertaining to construction landfills. ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) 4 inches (100 mm) compacted Clean concrete sand ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) 8 inches (200 mm) thick lift prior to compaction (loose lift) Treat with approximately __% hydrated lime in the top 6 inches (150 mm); mix by rotation til until gradation requirements are met. Page 25 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Table 1 Materials, Compaction, and Testing Requirements Material Drainage filter material Plasticity Requirements Gradation Requirements Non-plastic Uniformly graded from 1-1/2 inch (38 mm) to No. 4 Maximum Density Maximum Density Test Frequency Required Field Density Field Density Test ASTM D4253 and D4254 1 initial test; further tests as directed 65% relative density ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) Field Density Test Frequency Required Field Water Content One test per 500 sy (420 sm), or as required As required to achieve field density Field Water Content Test Required Lift Thickness ASTM D6938; ASTM D1556 or ASTM D2167 (10% of tests to be ASTM D1556 or ASTM D2167) 4 inches (100 mm) compacted Remarks Washed rock or crushed gravel ASTM C33 = Standard Specification for Concrete Aggregates. ASTM D698 = Standard Test Methods for Laboratory Compaction Characteristics of Soil using Standard Effort (12,400 ft-lb/ft³). ASTM D1556 = Standard Test Method for Density and Unit Weight of Soil in Place by the Sand Cone Method. ASTM D1557 = Standard Test Methods for Laboratory Compaction Characteristics of Soil using Modified Effort (56,000 ft-lb/ft³) ASTM D2167 = Standard Test Method for Density and Unit Weight of Soil in Place by the Rubber-Balloon Method. ASTM D4253 = Standard Test Methods for Maximum Index Density and Unit Weight of Soils using a Vibratory Table. ASTM D4254 = Standard Test Methods for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density. ASTM D6938 = Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth). Source: 02220, 2010, v.1.7 Earthwork Page 26 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 02221 - Razing and Alterations 02221.1 General 02221.1.1 Scope of Work Scope of work shall include furnishing materials, labor, incidentals, equipment and other services to perform razing and alteration work identified in this technical specification. Scope of Work Verify the location of existing utilities. Raze and alter the structures and facilities shown on the drawings listed in Article 01100 Scope of Work. Dispose of razed materials by hauling offsite to an approved disposal area. Obtain any and all haul permits, or other required permits and pay all associated fees including inspection and tipping fees. 02221.1.2 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 02221.1.3 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 02221.2 Not Used 02221.3 Execution 02221.3.1 General This article covers razing, removal, and alterations of existing structures and facilities within the limits indicated. Except as otherwise indicated or specified, the repair of surfaces remaining after material and equipment are removed will not be required. 02221.3.1.1 Conditions of Structures. The drawings indicate the approximate locations of existing structures and equipment. The full extent and nature of the work shall be determined by a thorough inspection of the site. The Engineer does not guarantee this data. The inspection shall take place during the bidding period. Dimensions shall be verified, and discrepancies shall be reported to the Engineer. The Purchaser will maintain conditions existing at the time of inspection as long as it is practicable. However, the Purchaser may remove some equipment before razing activities commence. 02221.3.1.2 Protection. Existing utilities shall be protected and service shall not be interrupted except when authorized by the Owner. Existing structures, utilities, and equipment that are designated to remain in place shall be protected from damage. All damaged structures and equipment shall be promptly repaired. Special attention shall be directed to the safety and protection of plant operating personnel and construction personnel engaged on the premises. Source: 02221, 2014, v2.0 Razing and Alterations Page 27 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Dust shall be controlled during material removal operations by water spray, vacuum cleaners, or other methods acceptable to the Owner. In areas where welding or flame cutting is performed, fire protection shall be provided. Areas shall be dust free before flame cutting begins. Flame resistant blankets shall be provided to protect combustible materials and finished surfaces. Dry chemical fire extinguishers shall be provided in these areas, and workmen shall be trained in their use. 02221.3.2 Razing Razing methods shall be in accordance with all codes, ordinances, and requirements of the governing authority and shall assure the safety of persons, equipment, and existing structures. Materials and equipment designated to be salvaged for reuse or turned over to the Owner for future use shall be removed without damage as reasonably as can be performed. 02221.3.2.1 Existing Structures and Foundations. The Contractor shall raze and dispose of all structures within the limits of construction designated on the construction drawings or by the Owner. Combustible materials and non-combustible shall be disposed of as off site by the Contractor. Noncombustible materials shall be disposed as specified herein. Disposal shall be in accordance with all applicable governmental regulations. Unless otherwise indicated by the Owner, foundations designated to be razed shall be completely removed. The space shall be backfilled and compacted in accordance with Section 02220 - Earthwork. 02221.3.2.2 Existing Fencing. Not Used. 02221.3.2.3 Existing Wells. Not Used. 02221.3.2.4 Existing Dams. Not Used. 02221.3.2.5 Existing Roads. Existing roads that are within the Facility's property limits may be used as construction roads. Traffic on public roads shall not be diverted and public roads shall not be razed until the Contractor obtains permission from the authority having jurisdiction. For existing roads that are indicated to be removed, all subgrade materials shall be broken up to a depth of 12 inches, graded, and compacted. All concrete or asphalt pavement materials shall be disposed of as indicated herein. All culverts and other existing structures shall be removed and disposed. 02221.3.2.6 Miscellaneous Underground Facilities. Not Used. 02221.3.2.7 Existing Utilities. Overhead utilities such as telecommunication and power lines will be removed, relocated, or abandoned by their owners as indicated on the drawings. Abandoned overhead utilities indicated on the drawings shall be removed from the Owner's property and disposed of in an acceptable manner. Underground utilities such as gas, water, and power will be removed, relocated, or abandoned in place by their owners. Abandoned underground utilities indicated on the drawings for removal and that interfere with the work shall be removed. These utilities shall be removed from the Owner's property and disposed of in an acceptable manner. Source: 02221, 2014, v2.0 Razing and Alterations Page 28 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 02221.3.3 Alterations 02221.3.3.1 Concrete Modifications. Concrete removal shall be planned and executed according to the plan. Vibration, dust, and rubble shall be kept to a minimum. Sections of concrete designated to be removed shall have the outline of the section scored on the exposed surfaces with a concrete or masonry saw. The cut depth shall be as great as practicable without cutting reinforcing steel and shall be about 1 inch (25 mm). Score lines shall be straight and parallel or perpendicular to the major axis of the structure, unless otherwise designated by or acceptable to the Engineer. After the scores have been made, the concrete shall be removed in the largest pieces possible in a manner that will prevent damage to the remaining structures and facilities. Reinforcing steel designated to remain shall be exposed and cleaned to provide a bonding surface. This reinforcing steel shall not be heated. Bending shall be limited and performed to minimize the effect on the strength and ductility. Reinforcing that is damaged, to the extent that its strength is impaired, shall be replaced with dowels or corrected as directed by the Engineer. Existing concrete surfaces that will be in contact with new concrete shall be rough and clean. Surface mortar shall be removed to expose the aggregate, and all loose particles and foreign substances shall be removed. Immediately prior to placing new concrete, the existing concrete surfaces shall be coated with epoxy bonding compound. The bonding compound shall be applied in accordance with the manufacturer's instructions. Temperature limitations shall be observed. Exposed broken and irregular surfaces of remaining concrete shall be finished to match comparable adjacent exposed concrete surfaces. These surfaces shall be ground and filled with mortar or covered with a mortar cap. Before the mortar fill or cap is applied, the existing surface shall be coated with epoxy bonding compound. Holes for sleeves in hardened concrete shall be made with a core drill. Sleeves shall be grouted in place with setting cement. When new concrete joins existing concrete at joints provided in the existing structure, the existing dowels, keyways, and water stops shall be thoroughly cleaned. Dowels shall be cleaned to expose the bare metal. Water stops shall be cleaned and repaired. Solvents, oil, or other residue shall be thoroughly removed. Keyways shall be cleaned of all coatings, dirt, or other foreign materials to completely expose the concrete surface. Dowels, keyways, and water stops shall be coated with epoxy bonding compound. New dowels and keyways shall be provided in existing concrete where indicated on the drawings. Holes for dowels shall be drilled. Dowels and anchor bolts shall be grouted in place with the specified epoxy anchoring system. Epoxy bonding compound and epoxy anchoring systems shall be in accordance with Section 03311 Cast-In-Place Concrete. Razed concrete and other debris shall be removed from the site. 02221.3.3.2 Masonry Modifications. The removal of masonry shall be planned and executed to allow work to proceed without delay and with a minimum of vibration, dust, and rubble. Removed masonry materials shall be disposed. Use of salvaged masonry materials in lieu of new masonry units will not be permitted except as directed by the Engineer. During removal operations, mortar deposited on steel designated to remain in place shall be removed. Existing anchors welded or otherwise secured to steel shall be removed. Remaining weld metal shall be ground flush with surrounding surfaces. Steel shall be left in a clean, paintable condition. Source: 02221, 2014, v2.0 Razing and Alterations Page 29 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Masonry work shall match the surrounding existing masonry surfaces to the maximum extent practicable. New brickwork shall be keyed into existing brickwork. Brickwork shall be saw cut where indicated. 02221.3.3.3 Structural and Miscellaneous Metal Modifications. Razed metal materials shall be reused only if indicated on the drawings or as specified. Materials not designated or specified to be reused shall be disposed. Steel framing designated to be removed shall be disconnected and removed without impairing the stability of the remaining structure and without damaging the remaining members and connections. To the extent practicable, steel framing shall be removed by the disassembling of bolted or riveted connections. Connection rivets shall be drilled or otherwise removed without damage to holes designated to be reused. Flame cutting of rivets in holes designated to be reused will not be acceptable. Existing structural steel members that remain in place shall be modified for the new structural steel framing connections. Before existing bolts or rivets are removed, the connected members shall be shored and braced to provide support until the existing bolts or rivets are removed and the new bolts are installed. Existing bolts or rivets shall not be removed until the new supports and connecting members are in place. New bolts shall be installed and tightened. Modifications to connections supporting existing framing shall be completed by the end of each day's work. Any penetrations or alterations into the existing building sheeting and support shall be covered and repaired with supports and materials of similar type and quality of the existing building. Cutting or welding shall not be performed until adequate fire control provisions have been made. Welding shall be in accordance with Section 21000. No unauthorized welding shall be performed on existing structures. Paint shall be removed from joint surfaces to be welded. When removing paint, appropriate precautions shall be taken to protect against exposure to materials that may contain lead. Cuts shall be neatly made and ground smooth. Weld metal remaining on existing steel after modifications shall be ground flush with the remaining surfaces. Additional holes that are required in existing columns and beams shall be located and drilled. Burning to make new holes or to enlarge existing holes is not acceptable. 02221.3.3.4 Ductwork and Breeching Modifications. Not Used 02221.3.3.5 Grating Modifications. Where required by new construction, existing floor grating shall be cut, reworked, or removed. Cuts shall be saw or flame cut and ground smooth. Ends of cut bearing bars shall be banded with a steel band securely welded to every fourth bearing bar. Where required, new pipe openings shall be cut in the existing grating and a sleeve shall be installed. Band thickness shall be as specified on the attached Razing and Alterations Specification Sheet and the same depth as the bearing bars. Sleeves shall extend the full depth of the grating and project above the grating as specified on the attached Razing and Alterations Specification Sheet. Where sleeves and other openings through existing grating are no longer required, kickplates, sleeves, and bands shall be removed from the grating and a matching section of grating shall be welded in the opening. The cut ends shall be provided with new supports where necessary to provide a stable platform. 02221.3.3.6 Railing Modifications. Existing railings shall be modified or removed where required by new construction. New or relocated posts shall be installed to provide a safe and substantial installation. Materials shall be reused to the extent practicable. New materials shall match the existing adjacent railings. Posts shall be securely fastened to their supports. Connections shall be welded and ground smooth. All "hand hazards" shall be eliminated to the satisfaction of the Site QA Manager. Source: 02221, 2014, v2.0 Razing and Alterations Page 30 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 02221.3.3.7 Touchup Painting. Damaged paint surfaces and all accessible surfaces of field welds shall be cleaned and painted as specified in Section 09900 - Field Applied Protective Coatings. 02221.3.3.8 Surfacing Modifications. Existing crushed rock surfacing removed for construction operations shall be stockpiled and reused in the base course for resurfacing the disturbed area or for new surfacing, if the materials meet the specified base course material requirements. The top course for resurfacing shall consist of new materials and shall be finished flush with adjacent undisturbed materials. 02221.3.4 Salvage and Rubbish Except for materials or equipment designated to be retained, all razed materials, debris, and rubbish shall be promptly removed from the site and disposed of in accordance with all applicable governmental regulations. 02221.3.5 Cleanup At the completion of razing work, the entire razed area shall be cleaned of all debris and rubbish. Interior areas shall be cleaned of settled dust, mortar, plaster, and contaminants. Source: 02221, 2014, v2.0 Razing and Alterations Page 31 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Razing and Alterations Specification Sheet Name The facilities and materials listed below shall be razed up to the limits indicated on the drawings. These include, but are not limited to, the following: 1. Air Compressor located under Crusher 1. 2. Compressed air pipelines from Crusher-1 to the southwest corner of Crusher-1 3. Air Compressor (CCAD-CMP-2) and dryer (CCAD-DRY-2) in Crusher 2 building. 4. Air Compressor (CCAD-CMP-3) and dryer (CCAD-DRY-3) in Transfer tower T-4 building. 5. Rail Car Maintenance Air Compressor (CCAD-CMP-ALL), dryer (CCAD-DRY-ALL) and air receiver (CCAD-TNK-ALL) at rail car dump building. 6. Rail Car Dust Collector Air Compressor (CCCB-CMP-001), dryer (CCCB-DRY-001) and air receiver (CCCB-TNK-001) at rail car dump building. 7. Air Compressor, dryer and air receiver at rail car dump building. The following facilities shall be altered/modified up to the limits indicated on the drawings: See Article 01100.2.1 for drawings The following materials shall be removed from the structure and placed in onsite storage facilities or turned over to the Owner as directed: Existing steel framing consists of Bolts Grating modifications No Band thickness, in. (mm) Sleeves shall project, in. (mm) Excavations of existing structures shall be filled with compacted earth to match the existing contours Well abandonment shall satisfy all requirements of the following State Department of Health T Existing roads shall be Source: 02221, 2014, v2.0 Not Applicable worked into the subgrade to match the surrounding contours. Razing and Alterations Page 32 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 03311 - Cast-in-Place Concrete 03311.1 General 03311.1.1 Scope of Work Scope of work shall include receiving and placing concrete and reinforcement, constructing required formwork, and furnishing materials, equipment, and labor to complete the cast-in-place concrete work including other services as specified herein. 03311.1.2 Items Furnished by Others and Interfaces Items furnished by others and not included in this scope of work are provided in Section 01500 – Technical Scope and System Performance. The Supplier shall attend a pre-placement meeting at the time and location determined by the Purchaser. This meeting will be for the coordination of the supply, placement, finishing, and control testing of the concrete. Issues impacting the execution of the work will be covered and the procedures for execution shall be finalized and implemented. 03311.1.3 Performance and Design Requirements Performance requirements for the cast-in-place concrete shall be in accordance with Table 1 at the end of this section and as follows: Component Material Mechanical splices shall develop 125 percent of yield strength of spliced bars Cold weather placement Maximum time interval for measuring concrete temperature during the protection period, hours 12 hours Finishes for formed concrete surfaces exposed to view Standard finish (rough form finish) Finishing unformed surfaces Screeding Where indicated on the drawings Floating Flat surfaces and floors not otherwise specified Brooming Roads, sidewalks, and walkways Troweling Where indicated on the drawings Aggregate exposure Where indicated on the drawings 03311.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 33 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Work In Accordance With Mix design and qualification ACI 301, ACI 318, and ACI 350 Concrete proportions ACI 318, Chapter 5 Batch plant and production facilities ASTM C94 and Concrete Plant Standards of the Concrete Plant Manufacturers Bureau Ready-mix concrete ASTM C94 Making, curing, and storing concrete cylinders ASTM C192 Water soluble chloride limits ACI 318, Chapter 4 Structural concrete for buildings ACI 301 Hot weather concreting ACI 305R Cold weather concreting ACI 306R and ACI 301 Building code requirements for reinforced concrete ACI 318 Recommended practice for concrete formwork ACI 347R Splices in reinforcing steel ACI 318 Tolerances AISC Manual of Steel Construction, Code of Standard Practice, ACI 117, ACI 301 Finishes and finishing ACI 301 Sampling and Testing for Strength ACI 318, Section 5.6 03311.1.5 Materials The following materials shall be used: General Component Material Cement ASTM C150; Type as referenced in Table 1 at the end of this section Supplementary Cementitious Materials Fly ash ASTM C618, Class C or F Loss on ignition Class C, 2 percent maximum (Class C not permitted with Type II or Type V cement); Class F, 4 percent maximum Ground granulated blast furnace slag ASTM C989, Grade 100 or 120 Silica fume ASTM C1240 Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 34 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction General Component Material Fine aggregate ASTM C33; clean, natural or manufactured sand Coarse aggregate ASTM C33, Class Designation 4S Chemical Admixtures Water reducing ASTM C494, Type A Retarding ASTM C494, Type B Accelerating, non-corrosive, nonchloride type ASTM C494, Type C Water reducing, normal, mid-range, and retarding ASTM C494, Type D Water reducing, normal, mid-range, accelerating, non-corrosive, nonchloride type ASTM C494, Type E Water reducing, high range (extended slump life type) ASTM C494, Type F Water reducing, high range and retarding (extended slump life type) ASTM C494, Type G Reinforcing Steel Billet steel ASTM A615 Epoxy coating ASTM D3963 Welded wire fabric ASTM A185 or A497 Form ties Removable end, permanently embedded body type. In liquid retaining structures, provide integral water stops. Polyethylene sheeting ASTM D4397, 6 mil (150 µm) Water stops - PVC Construction joints PVC ribbed or serrated, 6 inches by 3/8 inch (150 by 10), with "O" bulb closed center section Expansion or isolation joints PVC ribbed or serrated, 9 inches by 3/8 inch (230 by 10), with "O" bulb closed center section Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 35 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction General Component Material Water stops – hydrophilic Concrete joints and pipe penetrations in doubly reinforced secondary containment concrete walls and slabs 8 inch (200 mm) or greater thickness Expanding preformed rubber strip, expansion pressure greater than or equal to 100 psi (690 kPa) Concrete curbs, 6 inch (150 mm) minimum thickness Bentonite/butyl rubber strip, expansion pressure less than 100 psi (690 kPa) Expansion joint material ASTM D1752, Type 1 sponge rubber or closed cell PVC or polyethylene foam Polyurethane sealant ASTM C920, Type M, Grade P, Class 25, Use T Membrane curing compound and floor sealer ASTM C1315, Type 1, Class A, acrylic copolymer, with a minimum 25 percent solids, nonyellowing, maximum moisture 2 loss 0.40 kg/m in 72 hours Membrane curing compound, dissipating type, where specified herein or indicated on the drawings ASTM C309, Type 1, Class A, maximum 2 moisture loss 0.55 kg/m in 72 hours Epoxy bonding adhesive (joints between existing and new concrete) ASTM C881, Types I and V, moisture insensitive, 100 percent solids Anchor and reinforcing adhesive ASTM C881, Type IV, Grade 3 Anchor rod sleeves Plastic 03311.1.6 Acceptable Manufacturers of Components For the following components, the manufacturers listed below provide examples of the quality of workmanship required by these specifications. If the Contractor wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Engineer: Component Manufacturer PVC water stops - 9 inch (230 mm) Vinylex RB9-38, Greenstreak Style 709, and W. R. Meadows Sealtight Type 9380 PVC water stops - 6 inch (150 mm) Vinylex RB6-316 and Greenstreak Style 716, W.R. Meadows Sealtight Type 6380 Hydrophilic water stops (doubly reinforced secondary containment concrete walls and slabs, 8 inch, [200 mm] or greater thickness) CETCO Akwastop Hydrophilic water stops (concrete curbs, CETCO Volclay RX-102 and Greenstreak Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 36 of 280 Calaveras Coal Yard 186144.77.1000 Component Bid Issue 2Mar2015 Compressed Air Equipment Construction Manufacturer 6 inch [150 mm] minimum thickness) Hydrotite CJ 1020 Anchor and reinforcing adhesive Hilti HIT RE-500-SD Epoxy bonding adhesive (joints between existing and new concrete) Sika Sikadur 32 Hi-Mod, Master Builders Concresive Liquid LPL, Euclid Chemical Duralprep A.C. Form coating Nox-Crete Form Coating, L&M Debond, Richmond Clean Strip Ultra, Symons Magic Kote 03311.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. Testing intervals and execution are specified in Article 03311.3.17. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Contractor unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Contractor is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By Slump test ASTM C143 Contractor Air content ASTM C231 Contractor Concrete test cylinders ASTM C31 Contractor Compression test ASTM C39 Contractor Compression strength test ACI 318, Chapter 5 Contractor Concrete temperature ASTM C1064 Contractor Unit weight of concrete ASTM C138 Supplier 03311.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01500. 03311.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 01400. 03311.2 Products Materials and product requirements are provided in Articles 03311.1.5 and 03311.1.6. 03311.3 Execution 03311.3.1 General Work shall include design and construction of formwork; installation of reinforcing steel and other embedments; concrete placement, finishing, curing and other appurtenant work; and provision of miscellaneous materials and services complete as specified. Concrete supply and reinforcement are also covered. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 37 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 03311.3.2 Placement of Steel Reinforcement Reinforcement shall be delivered to the jobsite packaged in bundles. Each shipment shall contain all bundles required for one or more concrete placements. Each bundle shall be tagged with a sturdy, durable, weatherproof tag which includes the following information: Placement number (according to Purchaser's designation). If bar is a dowel bar, the placement number shall be the first of the two placements. Bar diameter. Number of bars in bundle. Position/Shape number. Bar length. Weight of bundle. Graphical description of bar shape. Each shipment shall contain a complete bundle-by-bundle inventory that duplicates all the information listed on all the tags of all the bundles listed. Each bundle shall be securely bound. Every binding shall be capable of safely holding the entire weight of the entire bundle. Reinforcement shall be accurately positioned and secured in place with wire ties or suitable clips. Bare metal supports shall not be used in contact with forms for exposed concrete surfaces. The clear distance between individual parallel bars shall not be less than 1.5 times the maximum size of coarse aggregate in the concrete; not less than one nominal bar diameter; and not less than 1 inch (25 mm) in beams, 1-1/2 inches (40 mm) in columns, or 2 inches in other locations. Where reinforcements in beams are placed in two or more layers, the bars in the upper layer shall be placed directly above the bars in the lower layer and the clear distance between layers shall not be less than 1 inch (25 mm). Clear distance limitations between individual bars shall also apply to the clear distance between a contact lap splice and adjacent splices or bars. 03311.3.2.1 Splices. Splices shall conform to the specified codes and standards. Lap splice lengths shall permit all bars to be spliced at the splice location with no reduction in splice length due to staggered splice locations or excess reinforcement unless otherwise indicated on the drawings. Splices in horizontal reinforcement placed in vertical wall sections shall be spliced in accordance with top reinforcement requirements. Splices shall not be used in regions of maximum bending stress. Lapped splices shall not be used for bars with a diameter greater than 1-1/2 inches. Splices for bars with a diameter greater than 1-1/2 inches shall be made with mechanical splices. Mechanical splices under tension shall develop the minimum strength specified in Article 03311.1.5. The first four splices made by each operator shall be made in the presence of the mechanical splice manufacturer's representative and the Site Construction Manager. Each operator shall make splices in the same splicing positions (vertical, horizontal, angle, or special) to be made for the project. All procedures used shall be acceptable to the mechanical splice manufacturer's representative and the Engineer. Reinforcing bar splices shall be welded only when directed by the Engineer. Welded chairs and supports may be used. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 38 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 03311.3.2.2 Coatings. Rebar coatings that are damaged during installation shall be repaired as specified by the coating manufacturer's standards. 03311.3.2.3 Reinforcement Installed in Hardened Concrete. Reinforcement installed in hardened concrete shall be anchored with the specified reinforcing adhesive. Holes shall be drilled to a depth sufficient to develop the tensile strength of the reinforcing bar as recommended in the manufacturer's literature. Reinforcement shall be installed in accordance with manufacturer's installation instructions. If reinforcement is encountered while drilling existing concrete, drilling shall stop and the Purchaser shall be contacted. Reinforcement shall not be cut without the Purchaser's consent. 03311.3.3 Formwork Forms shall be designed and constructed to produce hardened concrete having the shape, lines, and dimensions indicated on the drawings. Vertical surfaces of footings extended above finished grade shall be formed. 03311.3.3.1 Construction. Forms shall be sufficiently tight to prevent leakage of mortar and shall maintain position, shape, and alignment during and after placement of concrete. Suspended members supported by concrete columns or piers shall be formed to allow the column or pier forms to be removed without disturbing the supports for the suspended members. 03311.3.3.2 Form Ties. Form ties shall have sufficient strength, stiffness, and rigidity to support and maintain the form in proper position and alignment without the use of auxiliary spreaders. Outer ends of the permanently embedded portions of form ties shall be at least 1 inch back from adjacent outer concrete faces. Permanently embedded portions of form ties that are not provided with threaded ends shall be constructed to allow the removable ends to be broken off by twisting without chipping or spalling the concrete surface. Form ties shall be acceptable to the Purchaser. Form ties in exposed surfaces shall be uniformly spaced. 03311.3.3.3 Edges and Corners. Chamfer strips shall be placed in forms to bevel all salient edges and corners except buried edges and edges that are designated on the drawings to receive special treatment. Equipment bases shall have formed beveled projecting edges for all vertical and horizontal corners unless indicated otherwise on the drawings. Bevel dimensions shall be 3/4 inch by 3/4 inch unless indicated otherwise on the drawings. 03311.3.3.4 Form Removal. Forms shall not be removed from structures until the concrete in the structure has sufficient strength to support the weight of the structure and any superimposed load, including loads from construction operations. The Contractor shall be responsible for limiting any applied loadings. There shall be no evidence of damage to concrete and no excessive deflection or distortion of members due either to the removal of forms or to loss of support. Supporting formwork shall not be removed from horizontal members until the concrete has attained at least 75 percent of the specified 28 day compressive strength as determined by cylinders made and cured in the field. Shores shall not be removed before concrete has attained 28 day compressive strength as specified herein. Shoring shall be left in place and reinforced as necessary to carry any construction equipment or materials placed thereon. When forms are removed before the specified curing is completed, measures shall be taken to immediately continue curing. In cold weather conditions, adequate thermal protection for the concrete shall be provided. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 39 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 03311.3.4 Embedments Anchor rods, castings, steel shapes, conduit, sleeves, masonry anchorages, and other materials embedded in the concrete shall be accurately positioned and securely anchored. Location tolerances for anchor rods, and for structural members, embedded structural steel shapes, and plates, shall be in accordance with AISC Manual of Steel Construction Code of Standard Practice. Tolerances for equipment anchorages shall be as required by Article 03311.3.15.1. Anchor rods shall be provided with sufficient threads to permit a nut to be installed on each side of the form or template. The nuts shall secure the anchor rod in its proper position. Pipe sleeves, conduit, and other embedments shall be within 1/4 inch (6 mm) of their design locations unless specified otherwise on the drawings or other specification sections. Embedments shall not be welded to structural reinforcement. Embedments shall be clean when they are installed. After concrete placement, exposed surfaces of embedments shall be cleaned of all concrete spatter and other foreign substances. Anchor rod sleeves, handrail sleeves, and similar openings in concrete susceptible to filling with water and freezing shall be filled with closed cell PVC expansion joint filler for protection until grouting. The upper neck of plastic anchor rod sleeves shall be cut out and the annular space filled with closed cell PVC expansion joint filler or other means acceptable to the Engineer. 03311.3.4.1 Water Stops. Water stops shall be clean and free from coatings that weaken the bond with concrete. Each PVC water stop shall be continuous throughout the length of the joint. Intersections shall be made using factory prefabricated crosses, tees, and ells. The performance of the splice shall be equal to that of the continuous material and shall be made in strict conformance with the recommendations of the water stop manufacturer. Hydrophilic water stops shall be installed as recommended by the water stop manufacturer. Water stops shall be maintained in proper position until the concrete has been deposited and compacted. 03311.3.5 Placement The handling, depositing, and compacting of concrete shall conform to these specifications. Adjustments may be made for weather or placement conditions. The Purchaser shall be notified at least 24 hours in advance of the times and locations where concrete is being placed. Concrete shall not be pumped through aluminum or aluminum alloy pipe. Construction joints indicated on the drawings shall define the limits of each concrete pour. Subgrades shall be moistened with water prior to concrete placement. The subgrade shall not contain puddles or wet, soft, unstable or muddy areas when the concrete is placed. Concrete placed against rock or existing concrete shall have loose pieces of rock removed and the exposed surface cleaned with a high-pressure hose before concrete is placed. The space receiving concrete shall be clean and clear of debris and standing water, and the entire installation shall be acceptable to the Site Construction Manager before concrete is placed. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 40 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction Surfaces encrusted with dried mortar or concrete from previous placement operations shall be cleaned before placing new concrete. Bid Issue 2Mar2015 Coarse aggregate size for pumped concrete mixtures shall be limited to a maximum of 1-1/2 inches (37.5 mm). The slump of concrete, with or without a superplasticizer, that is discharged into the pump may exceed the specified maximum slump value by the amount of slump loss in the pumping system, up to a maximum of 1 inch . The slump loss shall be determined by tests made at each end of the pumping system. 03311.3.5.1 Bonding to Hardened Concrete. The surface of hardened concrete, upon which fresh concrete is placed, shall be rough, clean, and damp. The hardened surface shall be cleaned of all laitance and foreign substances, shall be washed with clean water, and shall be in a saturatedsurface-dry condition by soaking with potable water for 8 to 24 hours before the fresh concrete is placed. Excess water shall be removed from the surface receiving concrete prior to placement. The surface of hardened concrete shall be prepared by one of the following methods: At the time of the initial concrete placement, a retarding agent shall be applied to the fresh concrete. After hardening, the concrete shall be pressure washed to remove the laitance and to expose the aggregate. The hardened concrete shall be roughened to approximately 1/4 inch amplitude. The concrete may be roughened at the time of the initial concrete placement or by mechanical means after the concrete has hardened. The roughened surface shall expose the aggregate and have an open pore structure. The prepared surface shall receive one of the following surface bonding treatments: A 2 inch (50 mm) thick mortar puddle shall be deposited on hardened concrete in wall and column forms immediately before placing fresh concrete. The mortar puddle shall be the specified concrete mix, at the same water content, with the coarse aggregate omitted. An epoxy bonding adhesive shall be used. The epoxy bonding adhesive shall be installed in accordance with the manufacturer's instructions. Concrete shall be placed before the adhesive sets. 03311.3.5.2 Conveyance and Distribution. Concrete shall be conveyed to the placement location by methods that prevent separation or loss of the ingredients. 03311.3.5.3 Depositing Concrete. Concrete shall be deposited in horizontal layers. The depth of a layer shall not exceed 24 inches (610 mm). Each layer of concrete shall be plastic when succeeding layers are placed. Concrete shall be deposited without moving it laterally in the forms for a distance exceeding 5 feet (1,520 mm), unless otherwise accepted by the Engineer. Plastic concrete is defined as concrete that allows the head of an operating immersion type vibrator head to penetrate its full length into the previously placed concrete by means of its own weight. Concrete that is no longer plastic shall be prepared as specified in Article 03311.3.5.1 and slushed with mortar puddle. Mortar puddle shall be the specified concrete mix with the coarse aggregate omitted. The preparation of the in-place concrete shall be acceptable to the Purchaser before the successive layer of concrete is placed. 03311.3.5.3.1 Underwater concrete placement. Not used. 03311.3.5.4 Consolidation. Concrete shall be compacted using mechanical immersion type vibrating equipment. Mechanical vibrators shall maintain at least 9,000 cycles per minute when Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 41 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 immersed in the concrete. Each vibrator shall be driven by a 1-1/2 hp (1 kW) or larger motor. The number and type of vibrators shall be acceptable to the Site Construction Manager. 03311.3.5.5 Hot Weather Concreting. Hot weather concreting shall be in accordance with the recommendations of the codes and standards specified. At air temperatures of 90° F and above, special procedures shall be used to keep the concrete as cool as possible during placement and curing. 03311.3.5.6 Cold Weather Concreting. Cold weather concreting shall comply with the codes and standards specified. When the average of the highest and lowest temperature during the period from midnight to midnight is expected to drop below 40° F for more than 3 successive days, concrete shall meet the following minimum temperatures immediately after placement and shall be maintained at these temperatures throughout the curing period: 55° F for sections less than 12 inches in the least dimension. 50° F for sections 12 inches to 36 inches in the least dimension. 45° F for sections 36 inches to 72 inches in the least dimension. 40° F for sections greater than 72 inches in the least dimension. Calcium chloride shall not be used. Concrete shall not be placed on frozen ground. If the subgrade is frozen, it shall be removed before concrete is placed. If freezing weather is expected, the subgrade receiving concrete shall be protected from freezing. 03311.3.5.7 Mass Concrete. Concrete for structures indicated on the drawings as mass concrete shall meet the following additional requirements. The temperature of concrete when deposited shall not exceed 70° F nor be less than 35° F , unless the Supplier submits an alternative placement plan for acceptance by the Purchaser. The Supplier shall coordinate with the concrete supplier to meet the temperature requirements for the concrete at the delivery point. The concrete shall be cooled gradually so that the drop in concrete surface temperature during and at the conclusion of the specified curing period does not exceed 20° F in any 24 hour period. Concrete placed in cold weather shall meet the requirements for cold weather placement. 03311.3.6 Joints 03311.3.6.1 Construction Joints. Construction joints shall be located and constructed as indicated on the drawings. If an alternative arrangement of construction joints is desired or if they are not located on the drawings, drawings locating and detailing the proposed joints shall be submitted to the Purchaser before detailing and fabricating reinforcing steel. These joints shall be installed only where acceptable to the Purchaser. All construction joints subjected to differential hydrostatic pressure shall be provided with a water stop. Water stops shall be furnished in other joints as indicated on the drawings. 03311.3.6.2 Movement Joints. Movement joints may be expansion, contraction, or isolation joints. These joints shall be located and constructed as indicated on the drawings. Expansion joint filler Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 42 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 shall be firmly bonded to the previously placed joint face with a suitable adhesive. The new concrete shall be poured directly against the joint filler. Accessible edges of each joint shall be sealed with polyurethane sealant. Movement joints shall be as detailed on the drawings. Joints indicated on the drawings and those subjected to differential hydrostatic pressure shall be provided with a water stop installed as indicated on the drawings. 03311.3.6.3 Slab Control Joints. If sawed control joints are used, sawed joints shall be 1/8 inch to 5/32 inch (3 to 4) wide with a minimum depth of one fourth of the slab thickness but not less than 1 inch (25). Reinforcement shall not be cut during joint sawing. These joints shall be located as indicated on the drawings. Cutting shall begin as soon as the concrete has hardened sufficiently to prevent dislodging aggregate. Sawing shall be completed within 12 hours of completing placement. 03311.3.7 Openings in Concrete Concrete wall and floor openings for piping and other fixtures, installed after the walls and floors are built, shall allow sufficient space to properly compact concrete to fill the space around the pipe or fixture. The top of each wall opening shall be sloped or beveled to provide adequate space for placing and compacting the pipe embedment concrete. Water stops shall be provided around wall openings below grade and floor openings that are exposed to weather or submergence. 03311.3.8 Finishing Formed Surfaces The standard finish shall be a rough form finish. Fins and other surface projections exceeding 1/4 inch (6 mm) shall be removed from all formed surfaces except exterior surfaces that will be covered with earth backfill. Surface finish shall be that imparted by the forms. 03311.3.9 Finishing Unformed Surfaces No surface treatment will be required for buried or permanently submerged concrete. Unformed surfaces, designated as screeded surfaces on the drawings, shall be finished by screeding only. Surfaces designated as floated surfaces and all surfaces not otherwise designated shall be finished by screeding and floating. Surfaces designated as troweled surfaces shall be finished by screeding, floating, and troweling. Float finished and screeded surfaces shall be finished to provide a flat profile within 1/4 inch (6 mm) deviation as measured from a 10 foot straightedge. Trowel finished surfaces shall be finished to form a flat plane. The surface profile shall not deviate more than 1/8 inch (3 mm) when measured from a 10 foot (3.0 m) straightedge. When a level floor is required, such as under electrical switchgear, the elevation of all points on the finished surface shall be within 1/8 inch (3 mm) of the elevation indicated on the drawings. 03311.3.9.1 Screeding. Screeding shall provide a concrete surface conforming to the designated elevations and contours with all aggregates completely embedded in adjacent mortar. Surface irregularities in screeded surfaces shall be limited to the tolerances specified. 03311.3.9.2 Floating. The surfaces shall be screeded and given an initial float finish as soon as the concrete has stiffened sufficiently to work. Coarse aggregate disturbed by the float or causing a surface irregularity shall be removed and replaced with mortar. Initial floating shall produce a surface of uniform texture and appearance. Initial floating shall be followed by a second floating at the time of initial set. The second floating shall produce a smooth float finish of uniform texture and color. Floating shall be performed with hand floats or suitable mechanical compactor floats. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 43 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 03311.3.9.3 Troweling. Surfaces designated on the drawings shall receive a steel trowel finish. Troweling shall be performed after the second floating when the surface has hardened sufficiently to prevent excess cement from being drawn to the surface. Troweling shall produce a dense, smooth, uniform surface free from blemishes and trowel marks. 03311.3.9.4 Brooming. Brooming shall follow the float finish for surfaces so designated on the drawings. Brooming shall be done with an acceptable steel or fiber broom not less than 18 inches wide. Adjacent strokes of the broom shall overlap slightly. Broomed surfaces shall be free of porous spots, irregularities, depressions, and small pockets or rough spots. 03311.3.9.5 Aggregate Exposure. Surface mortar shall be removed and the aggregate exposed from surfaces that will be covered with mortar, concrete, or grout at a later time. The method used shall be effective and acceptable to the Purchaser. 03311.3.9.6 Edging. Unless specified to be beveled, exposed edges of floated or troweled surfaces shall be edged with a tool having a 1/4 inch corner radius. 03311.3.9.7 Finishing Mortar. Finishing mortar shall be added if there is not sufficient mortar available from the concrete mix. The proportions for this finishing mortar shall be 2.4 parts of concrete sand to one part of portland cement, by weight, mixed with enough water for proper application. Slump for finishing mortar shall not exceed 2 inches (50 mm). 03311.3.10 Separate Finishes Certain slab surfaces shall be finished with a separate concrete finish or floor covering as indicated on the drawings. Base slab surfaces shall be ground or filled until each surface is within the specified tolerances and is acceptable to the Purchaser. Low areas shall be filled. High spots shall be ground slightly lower than required and then filled and smoothed to the proper elevation and surface. Surfaces that receive epoxy set quarry tile and resilient tile shall be flat with a profile that shall not deviate more than 1/8 inch from a 10 foot straightedge placed on any part of the surface. These surfaces shall be either trowel finished concrete at the elevation indicated on the drawings or a float finished surface set 1/8 inch low and leveled with trowel finished fill material. Surfaces that receive a mortar set quarry tile, ceramic tile, or terrazzo finish shall be given a smooth, tight, and uniform float finish with a profile tolerance of 1/4 inch as measured from a 10 foot straightedge. 03311.3.11 Curing Concrete shall be protected from loss of moisture for not less than 7 days after the concrete is placed. Concrete with mineral admixtures shall be cured for 14 days. Troweled surfaces, except those that receive a separate finish or coating, shall be cured with a membrane curing compound. Float finished surfaces, except those that receive a separate finish, may be cured with either a membrane curing compound or with water. Only water curing shall be used if the surface receives a separate finish unless the curing compound is compatible with the surface finish that will be installed. 03311.3.11.1 Water Curing. Water saturation of concrete surfaces shall begin as quickly as possible after initial set of the concrete, but not more than 30 minutes. The rate of water application shall be regulated to provide complete surface coverage with a minimum of runoff. The concrete surface shall not be permitted to dry. Water retaining structures shall be water cured. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 44 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 03311.3.11.2 Membrane Curing. Membrane curing compound shall be applied within 30 minutes after final finishing of the surface or as soon as possible after finishing without causing damage to the surface. Membrane curing compound shall be spray applied at a coverage rate recommended by the compound manufacturer. A dissipating curing membrane may be used in lieu of wet curing on surfaces that will be covered at a later date with mortar, concrete, dampproofing, tile, or coating. 03311.3.12 Floor Sealer Where indicated on the drawings, concrete floors shall be given a coat of clear floor sealer in addition to that applied as membrane curing compound. The coating shall be applied at the end of the curing period before any traffic is permitted on the floor. A second coat, if required, shall be applied after the floor has been cleaned in preparation for the final inspection. Floor sealer shall be applied in strict accordance with the manufacturer's recommendations. 03311.3.13 Repairing Defective Concrete Surface defects in formed concrete shall be repaired to the satisfaction of the Purchaser within 24 hours. Concrete that is porous, honeycombed, or otherwise defective to a depth in excess of 1 inch (25 mm) shall be cut out and removed to sound concrete. Edges shall be square cut to avoid feathering. Bonding surfaces shall have the laitance removed and the coarse aggregate exposed. A bonding compound shall be used between the hardened and repair concrete profile. When epoxy bonding adhesive is used, surfaces shall be prepared and the compound applied as recommended by the bonding agent manufacturer. Defective concrete shall be replaced within 48 hours after the forms have been removed. Concrete repair work shall not interfere with the curing of surrounding concrete. Mortar and concrete used in repair work shall be adequately cured and shall be finished to match adjacent surfaces. 03311.3.14 Duct Banks Not used. 03311.3.15 Tolerances Tolerances shall be in accordance with ACI 117 unless specifically noted otherwise. The offset between adjacent pieces of formwork facing material for surfaces exposed to view shall not exceed 1/2 inch(13 mm) and for concealed surfaces shall not exceed 1 inch (25 mm). Embedments shall meet the tolerances of Article 03311.3.4. 03311.3.15.1 Equipment Bases. Concrete bases and their embedments for structures and equipment shall meet the following tolerance requirements in addition to those already specified, unless otherwise specified by the equipment supplier. Concrete form dimensions and placement shall be within 1/2 inch of the dimensions and locations indicated on the drawings. The top of the forms shall be accurately set to the designated elevation and within the specified tolerances. The elevation of all points on all float finished surfaces shall be within 1/4 inch (6 mm) of the elevation indicated on the drawings. The elevation of all points on all trowel finished surfaces shall be within 1/8 inch (3 mm) of the elevation indicated on the drawings. Anchor rods and all other materials that are embedded in the concrete shall be accurately positioned and securely anchored. The center of each anchor rod group or cluster shall be within 1/8 inch (3 mm) of the location indicated on the drawings. The center-to-center dimensions between the anchor rods in a group or cluster shall be within 1/16 inch of the dimensions indicated on the drawings. Elevation of top of anchor rods shall be within 1/4 inch of the elevation indicated on the drawings. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 45 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 03311.3.16 Special Structures Special structures may sustain severe service conditions. These structures require very close tolerances and clearances. If required, special structures covered by these specifications are listed in Article 03311.1.3. Work for these structures shall meet the following requirements in addition to those specified elsewhere. 03311.3.16.1 Forms. Forms shall be designed by a qualified engineer experienced in this work. The forms shall be designed and constructed to a tolerance of 1/4 inch (6 mm) from the locations and elevations indicated on the drawings. The form design shall provide for supporting the weight of the reinforcing bars and all construction loads. 03311.3.16.2 Reinforcing Steel. Longitudinal reinforcing bars in beams and girders shall be supported by mild steel angle or channel frames resting on the bottom form. Each bar shall be securely attached to its supporting frames by a mechanical anchor. A steel bearing plate shall be provided on each upright frame for distributing the frame load over the surface of the bottom form. Bearing plates shall be flat and smooth. 03311.3.16.3 Anchor Rods and Templates. Anchor rods and attachments shall be located to the tolerances required by the equipment manufacturer for the equipment secured, and shall be secured during concrete placement with accurately made steel templates. Templates shall be interconnected and braced with steel members that maintain the anchor rod alignment and position. Alignment of forms, reinforcements, embedments, and anchor rods shall be checked before placing concrete. 03311.3.16.4 Concreting Plan and Construction Operations. A detailed concrete placement plan shall be prepared. The plan shall describe the methods, labor, and equipment used in conveying, depositing, consolidating, and curing the concrete. The plan shall indicate the number, production rates, and deployment of each piece of equipment and each crew of workers. The plan shall provide adequate margins for uncertainty in productivity and adequate backup for breakdown of equipment. In determining the required production rates, the advancing faces of fresh concrete shall be assumed to have a slope of 4 to 1. 03311.3.17 Field Control Testing When the testing specified in Article 03311.1.7 is to be conducted by the Purchaser, the Supplier shall furnish the necessary labor to assist the Purchaser's testing agency in obtaining, handling, and storing samples. When testing is specified to be conducted by the Supplier, tests shall be conducted in accordance with the following. 03311.3.17.1 Sampling. Field control tests shall be made at the point of placement in the presence of the Site QA Manager. Equipment, supplies, and qualified personnel necessary for the field control testing shall be supplied. Tests shall be performed by an acceptable independent testing laboratory or Contractor's qualified QA personnel in accordance with the codes and standards specified in Article 03311.1.7. The frequency specified for each field control test is a minimum. Additional field control tests shall be made if requested by the Purchaser. 03311.3.17.2 Slump. A slump test shall be made from each of the first three batches mixed each day. An additional slump test shall be made for each additional 50 cubic yards (38 cubic meters) of concrete placed that day. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 46 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 When plasticizers and superplasticizers are added at the site, the slump shall be measured and recorded before and after the addition. 03311.3.17.3 Air Content. An air content test shall be made from one of the first three batches mixed each day and from each batch of concrete used to make compression test cylinders. 03311.3.17.4 Concrete Temperature. A concrete temperature test shall be made from one of the first three batches mixed each day and from each batch of concrete used to make compression test cylinders. 03311.3.17.5 Compression Tests. Concrete compression test cylinders shall be made each day 3 3 concrete is placed. A set of five test cylinders shall be made from the same batch at 150 yd (114 m ) intervals required by the referenced standard in Article 03311.1.5 unless alternate intervals are specified by the Engineer. Test cylinders shall be cured on-site under the same environmental conditionals as the placed concrete. Access to cylinders shall be limited to prevent tampering of the samples. Each set of compression test cylinders shall be marked or tagged with the date and time of day the cylinders were made, the location in the work where the concrete represented by the cylinders was placed, the delivery truck or batch number, the air content, and the slump. For each set of cylinders, one cylinder shall be tested at an age of 7 days, two cylinders shall be tested at an age of 28 days, and two cylinders shall be stored until otherwise directed by the Construction Manager. If Type V cement is used in the concrete, two extra cylinders shall be made for each set and tested at an age of 45 days. 03311.3.17.6 Test Reports. Test reports shall contain the information specified by ASTM C39 and the following additional information: Date, time, and ambient temperature of pour. Location of pour. Mix class. All test reports shall be kept by the Site QA Manager. All copies of failed tests shall be submitted to the Engineer. 03311.3.18 Proportioning 03311.3.18.1 Mix Design. A tentative concrete mixture shall be designed and tested in the laboratory for each size and combined gradation of aggregates and for each mix specified for use on the work. Concrete proportions shall be established based on field experience, laboratory trial mixtures, or both. Established mixes with documented historical records meeting the specified requirements for the concrete may be used for the work. The qualification records for these mixes shall be submitted for acceptance prior to beginning the work. If these records are acceptable, additional mix design testing is not required. Mixtures shall be adjusted in the field as necessary, within the limits specified, to meet the requirements of these specifications. 03311.3.18.2 Preliminary Review. Reports covering the source and quality of concrete materials and the concrete proportions proposed for the work shall be submitted to the Engineer for review before performing the required trial mixture designs and before concrete work is started. Review of Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 47 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction these reports will be for general acceptability only, and continued compliance with all contract provisions will be required. Bid Issue 2Mar2015 03311.3.18.2.1 Mix design. Design quantities and test results on each mix shall be accepted before concrete work is started. The report on each tentative concrete mix and on the proposed concrete mixture shall contain the information required in the Schedule of Submittals. 03311.3.19 Batching Aggregates, mineral admixture, and cement shall be measured by weight. Aggregate weights shall be adjusted for the moisture content. Correct proportions of admixtures shall be dispensed automatically. The amount of water required to produce the desired slump shall be batched automatically. Additional water needed to maintain a uniform slump shall be added manually by the mixer operator. This additional site-added water shall be limited to a volume that maintains the total mix water to within the volume defined by the maximum specified water-cement ratio for that mix. Slump shall be kept uniform. Aggregates shall float uniformly throughout the mass. The concrete shall flow sluggishly when vibrated. 03311.3.20 Mixing Concrete shall be mixed until all ingredients are uniformly distributed throughout the batch. Mixers shall not be loaded in excess of their rated capacities. If the mixing water is added at the worksite, only the prescribed amount of mixing water required by the mix design shall be placed in the mixing tank, unless the tank is equipped with a meter allowing the amount of water added to each batch to be verified. If water content does not exceed limiting requirements, water may be added to the concrete at the discharge point. Only one application of water will be allowed. The water shall be incorporated into the mix by at least 30 revolutions of the truck mixer at mixing speed. If a high range water reducer (superplasticizer) is used, slump shall be controlled by the addition of measured amounts of admixture instead of adding water. 03311.3.21 Delivery Delivery tickets shall be prepared for each load of concrete. Tickets shall be presented to the Site QA Manager receiving the concrete to acknowledge receipt of the concrete. These signed delivery tickets shall be distributed as follows: Original and one copy to the Site QA Manager. Delivery tickets shall indicate the following: Serial number of ticket. Truck number. Mix class of concrete. Quantity delivered (include weights of constituent materials). Date and time of delivery. Time when cement was combined with water or wet aggregates. Design slump without superplasticizer. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 48 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Design slump after addition of with superplasticizer. Numerical sequence of delivery. Time of concrete discharge from the truck and time when the truck is released after discharge. Quantity and type of admixtures. Site dispensed admixtures and volume dispensed. Allowable water permitted after batch water added, and quantity of extra water added. Percent moisture compensation for each type of aggregate. Both "heated" or "cooled" concrete checkoffs. Concrete temperature at batch plant. Concrete shall be discharged within 90 minutes or before the drum has revolved 300 revolutions after the introduction of the mixing water to the cement and aggregates, or the introduction of the cement to wet aggregates. In hot weather, or under conditions contributing to quick stiffening of the concrete, a shorter time period may be required by the Site QA Manager. Concrete that does not meet this time requirement may be rejected. 03311.3.22 Evaluation and Acceptance of Concrete Concrete will be evaluated for compliance with all requirements of the specifications. Concrete strength will be only one of the criteria used for evaluation and acceptance of the concrete. The results of all tests performed on the concrete and other data and information concerning the procedures for handling, placing, and curing concrete will be used to evaluate the concrete for compliance with the specified requirements. 03311.3.22.1 Substandard Concrete. Strength of delivered concrete shall meet the minimum compressive strength specified. If a test cylinder indicates that the concrete strength is less than the specified minimum, the concrete represented by the test shall be investigated at the Engineer's option. The investigation shall include sampling and testing of the concrete in place to verify the results of the cylinder test. The Supplier shall cooperate with the Site Construction Manager during sampling and testing and shall pay all associated costs, including the replacement of concrete for the samples removed. If the investigation verifies the existence of defective concrete, the Supplier shall be responsible for the following as determined by the Engineer: The cost of removal and replacement of all defective concrete. The cost of design and construction changes necessary to incorporate the inferior concrete. Satisfactory reimbursement or allowance to the Purchaser for the acceptance of the lower quality concrete. If spare cylinders are available for later age testing, these cylinders shall be used to confirm that the design strength has been achieved. The Supplier shall pay for this Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 49 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction testing and reimburse the Purchaser for the costs associated with the making and storing of these cylinders. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Bid Issue 2Mar2015 Page 50 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Table 1 Mix Criteria and Limiting Requirements Design Strength At 28 Days, psi (kPa) Cement Type Maximum Water/ Cementitious Materials Ratio Air Content, percent Maximum Chloride Ion Content** percent Maximum Coarse Aggregate Size, in. (mm) Max Slump, in. (mm) Maximum Slump with Superplasticizer (HRWR),*** in. (mm) Maximum Exposure Classes * Usage B1 F0 / S0 / P1 / C1 General usage – no freeze/thaw 4,000 I, II, or V 0.50 3-6 0.30 1 (25) 4 (100) 8 (200) B2 F2 / S0 / P1 / C1 General usage – with freeze/thaw 4,500 I, II, or V 0.45 6 0.30 1 (25) 4 (100) 8 (200) C1 F2 S1 P1 C1 Structure in contact with water or exposed to moderate sulfate exposure 4,500 I (C3A<5%), II, or III (C3A<8%), 0.45 6 0.30 1 (25) 4 (100) 8 (200) C2 F2 S2 P1 C1 Structure in contact with water or exposed to severe sulfate exposure 4,500 I (C3A<5%), III (C3A<8%), or V 6 0.30 1 (25) 4 (100) 8 (200) D1 F0 S0 P1 C1 Foundation piers and cased reinforced concrete piling – no freeze/thaw 4,000 I, II, or V 0.50 0 0.30 0.75 (20) 4 (100) 8 (200) D2 F2 S0 P1 C1 Foundation piers and cased reinforced concrete piling – with freeze/thaw 4,500 I, II, or V 0.45 6 0.30 0.75 (20) 4 (100) 8 (200) F1 F2 / S2 / P1 / C1 Sulfur pits 4,500 V (C3A<6%) 0.40 6 0.30 0.75 (20) 3 (75) 6 (150) Mix Class 0.42 Est Quan, yd3 (m3) * Refer to Chapter 4 of ACI 318 for Exposure Classes. Exposure class F3 shall also meet the supplementary cementitious material requirements of Table 4.4.2 in ACI 318. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 51 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Table 1 Mix Criteria and Limiting Requirements Mix Class Maximum Exposure Classes * Usage Design Strength At 28 Days, psi (kPa) Cement Type Maximum Water/ Cementitious Materials Ratio Air Content, percent Maximum Chloride Ion Content** percent Maximum Coarse Aggregate Size, in. (mm) Max Slump, in. (mm) Maximum Slump with Superplasticizer (HRWR),*** in. (mm) Est Quan, yd3 (m3) ** Refer to Chapter 4 of ACI 318 regarding Maximum Chloride Ion requirements. *** High range, water reducing. Source: 03311, 2014, v2.0 Cast-in-Place Concrete Page 52 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 03611 - Grouting 03611.1 General 03611.1.1 Scope of Work Scope of work shall include surface preparation, grout materials, placement, and curing of grout placed under baseplates and soleplates for equipment and structures. 03611.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this scope of work include the following: Not applicable. 03611.1.3 Performance and Design Requirements Unless otherwise specified below, performance and design requirements for the grouting are indicated in Article 03611.1.5. 03611.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Grout mixing and placing Manufacturer's instructions 03611.1.5 Materials The following materials shall be used: General Grouting Application General purpose nonshrinking cementitious grout Structural columns, tank bases, stationary equipment, and pumps and compressors up to 25 hp Precision nonshrinking cementitious grout N/A Epoxy grout N/A Acid resistant grout N/A Prejob grout meeting No Specific Component Material General purpose nonshrinking cementitious grout Grout shall meet ASTM C1107 and the following additional requirements within the temperature range of 50° F (10° C) and 90° F (32° C). Compressive strength shall be a minimum of 5000 Source: 03611, 2014, v2.1 Grouting Page 53 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Specific Component Material psi (35 MPa) at 28 days. Extended working times shall be 30 minutes at a flowable consistency. Grout shall not bleed at the manufacturer's maximum recommended water content. 03611.1.6 Approved Manufacturers of Components For the following components, the manufacturers are listed below provide examples of the quality of product and field support services required by these specifications. If the Contractor wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting data provided. Acceptance of the manufacturer as a substitute is at the discretion of the Engineer: Component Manufacturer General purpose nonshrinking cementitious grout BASF Master Builders "Construction Grout" L & M "Duragrout" Conspec "Enduro 50 Grout" Unisorb "V-2" Euclid "Euco N-S" 03611.1.7 Test Requirements The following testing for cement grouts shall be conducted in accordance with the specified standards listed in the following table. Strength shall meet the requirements of ASTM C1107. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Contractor. Field testing of the grout shall be performed as follows: Field Flow Cone Testing Field flow cone tests shall be performed as specified below to establish the water content that will meet the fluid consistency performance for the grout. The maximum and minimum water content shall be established to confirm the fluid consistency will meet the specified grout strength. Grout cubes shall be made and tested from the same batch that the flow cone measurements are taken at the upper and lower water content range being established for the placement. Contractor may propose a method to establish the water content limits for the fluid consistency as a substitute for the flow cone tests, if acceptable to the Engineer. Adequate documentation shall be provided to substantiate the reliability for this substitute procedure: Flow cone testing shall be performed at the following frequency: Prior to the first grouting operation as directed by the Site Construction Manager. Each new lot of grout material. Compression testing shall be performed at the following frequency: A minimum of one compression test for each individual placement operation each grouting day, if less than 5 cubic feet. Source: 03611, 2014, v2.1 Grouting Page 54 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction One compression test for each additional 5 cubic feet or fraction thereof, for each individual placement operation. Tests In Accordance With Conducted By Field flow cone (20 to 30 seconds reading) ASTM C939 Contractor Field compression test cubes (three 2 inch [50 mm] cubes) ASTM C109 as modified by ASTM C1107 Contractor Bid Issue 2Mar2015 03611.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 03611.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 01400. 03611.2 Products The product shall be as specified in Article 03611.1.5. 03611.3 Execution 03611.3.1 Baseplate Grouting Baseplates shall be grouted in place to obtain a uniform and solid bearing surface. Grouting methods used shall provide complete, void free filling of all space beneath the baseplate. Alignment or level of baseplates shall not be disturbed during grouting procedures. All anchor bolt sleeves shall have closed cell foam and excess water removed prior to grouting operations. 03611.3.2 Surface Preparation Hardened concrete surfaces where grout is to be placed shall be mechanically prepared by chipping or sandblasting to remove laitance, to expose sound surface mortar, and to provide a fractured aggregate surface. Prepared surfaces shall be cleaned to remove oil, grease, curing compound, or other foreign materials that prevent a proper bond between grout and concrete. Surface preparation for epoxy and acid resistant grout shall be in accordance with the manufacturer’s instructions. For cementitious grout, the prepared surface shall be flooded with potable water for 8 to 24 hours prior to grout placement and the surface shall be wet without standing water or puddles immediately prior to grout placement. If compressed air is used to blow off excess water, the air compressor shall have an oil separator. Prepared surfaces shall be in accordance with the grout manufacturer's recommendations. 03611.3.3 Alignment and Leveling Baseplates shall be set in place over anchor bolts, properly aligned, and leveled using three-point control. Leveling shall be accomplished using leveling screws with nuts above and below temporary lugs attached to the base. Steel wedges may be used for leveling in lieu of leveling screws. Precautions shall be taken to prevent steel wedges from being dislodged during grout placement. Steel wedges shall be encapsulated by a minimum of 2 inches (50 mm) of grout. Wood blocking or wood wedges shall not be used. Steel wedges used with cementitious nonshrinking grout may remain in place but must be completely covered with the grout. Source: 03611, 2014, v2.1 Grouting Page 55 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 03611.3.4 Mixing Grout shall be mixed as recommended by the grout manufacturer. 03611.3.5 Placement Proper alignment and level shall be verified and accepted by the Site Construction Manager before placing grout. Grout shall be used immediately after mixing before stiffening occurs. The temperature of the grout at placement shall not exceed the manufacturer's recommendations. Placement methods used shall provide grout surfaces that are completely filled, without voids. Low dams enclosing the base shall be used to contain flowable grout mixtures. Adequate space shall be provided between the dam and base to permit pouring and manipulation of the grout. The top of the dam shall be higher than the bottom of the base. The space below the base shall be completely filled. All air and water pockets shall be eliminated to create a solid grout mass without voids. 03611.3.6 Cementitious Grout 03611.3.6.1 Finishing. Grout shall remain undisturbed after placing until a stiff set is obtained. The dam shall be removed, and the edges shall be finished by removing excess grout. The edges shall be beveled at an angle of approximately 45 degrees. Exposed edges of the foundation and adjacent surfaces shall be cleaned to remove all grout. 03611.3.6.2 Curing. When finishing is completed, wet curing shall be provided by applying liberal amounts of potable water for a minimum of 24 hours unless required otherwise by the grout manufacturer's instructions. Following wet curing, curing compound acceptable to the Engineer may be applied to all exposed surfaces as an alternative to continued wet curing. During wet curing, a covering of wet rags and polyethylene sheets may be used to maintain the grout in a wet environment for the period of time required by the manufacturer's standards. The grout shall not be allowed to freeze during the curing period. Special procedures shall be used to keep the grout cool when air temperatures of 90° F (32° C) or higher are encountered. 03611.3.7 Epoxy and Acid Resistant Grouts Placing, finishing, and curing of epoxy and acid resistant grouts shall be in accordance with the manufacturer's instructions. Source: 03611, 2014, v2.1 Grouting Page 56 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 05310 - Steel Roof Deck 05310.1 General 05310.1.1 Scope of Work Scope of work shall include furnishing and installation of steel roof decks and appurtenances as well as any other related services as specified herein. 05310.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this scope of work include the following: N/A 05310.1.3 Performance and Design Requirements Performance and design requirements for the metal roof deck are indicated in Articles 05310.1.5 and 05310.2. 05310.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser’s specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Basic wind speed In accordance with Technical Supplemental D100 Seismic In accordance with Technical Supplemental D100 Dimensional requirements ASTM A6 Attachment/welding AWS D1.3 Structural Welding Code Sheet Steel SDI MOC2 - Manual of construction with Steel Deck SDI - SPD2 = Standard Practice Details Factory Mutual (FM) Design Steel Deck Institute “Design Manual for Composite Decks, Form Decks and Roof Decks” UL "Fire Resistance Directory" Factory Mutual (FM) 05310.1.5 Materials The following materials shall be used: Source: 05310, 2014, v2.0 Steel Roof Deck Page 57 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction General Component Material Roof deck, coated steel ASTM A1008/A1008M Roof deck, galvanized and shop primed ASTM A 653/A 653M and ASTM A924/A924M Specific Design Building code In accordance with Technical Supplemental D100 Fire rating Class 1 Wind rating Factory Mutual (FM) Global Class 1-90 Vertical loads (live and dead), psf (Pa) 50 psf (2,395 Pa) Wind Importance factor In accordance with Technical Supplemental D100 Exposure In accordance with Technical Supplemental D100 Importance factor In accordance with Technical Supplemental D100 Exposure In accordance with Technical Supplemental D100 Seismic Deflection L/240 System components Base material Galvanized steel Metal grade Grade 33 minimum Gauge 0.0358 in. (0.91 mm) (20 gauge) Depth, in. (mm) 1-1/2 in. (38 mm) Profile (similar to) Manufacturer/profile name Side laps (joints) NRC value Nucor/Vulcraft/Type B Manufacturer’s standard Not required Finish Deck topside Galvanized, G90 Deck underside Galvanized, G90 Attachments – Type/spacing Source: 05310, 2014, v2.0 Manufacturer's standard Steel Roof Deck Page 58 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Welding washers Next heavier thickness (gauge) than metal roof deck gauge Accessories Metal closures Base material Same as metal roof deck Gauge 20 gauge, 0.0358 in. (0.91 mm) Finish Same as metal roof deck Sump pans – Single piece Base material Same as metal roof deck Gauge 16 gauge, 0.0598 in. (1.519 mm) Finish Same as metal roof deck Fasteners Fasteners, shall be powder actuated, pneumatically driven, or self-drilling screws. Side-lap fasteners Manufacturer’s standard Sealant tape Permacel P670 Clips, spacers, and shims Manufacturer's standard 05310.1.6 Acceptable Manufacturers of Components For the following components, the manufacturers listed below provide examples of the quality of workmanship required by these specifications. If the Supplier wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Purchaser: Component Manufacturer Roof deck United Steel Deck, or Metal Dek Group Sealing tape Permacel 05310.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source and the applicable technical supplemental. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Supplier is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By Field welds AWS Supplier Attachments FM and ASTM Supplier 05310.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. Source: 05310, 2014, v2.0 Steel Roof Deck Page 59 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 05310.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 01400. 05310.1.10 Submittals of Vendor Drawings Before fabrication, the Supplier shall prepare detailed drawing covering the steel roof deck for use in the fabrication and installation of the materials. Drawings shall be in accordance with Technical Supplemental Q500 and shall indicate size and location of roof framing supports, as well as depth, profile, uncoated metal thickness, gauge, location, lengths and making of deck units to correspond with the sequence of installation. Drawings shall also indicate fastening methods for deck units, accessories, closure pieces, fittings, auxiliary supports and the type and sequence of welded connections. 05310.2 Products 05310.2.1 General Steel roof deck shall include all closures, filler sheets and required accessories for complete installation. 05310.2.2 Materials Materials shall be new and unused, shall be smooth and free of mill scale and roll marks, and shall be in accordance with the technical specification requirements. 05310.2.3 Fabrication 05310.2.3.1 Steel Roof Deck. Steel roof deck and components shall be designed, detailed, and fabricated to tolerances which, when erected, will ensure proper fit. Steel roof deck components shall be designed, detailed, and fabricated so that the completed systems shall perform in compliance to all specified loads. Panels shall be fabricated in lengths which will minimize joints in the completed construction. Joints shall be located at structural steel member locations. 05310.2.3.2 Closures. Closures shall be furnished for openings required at all piping and other penetrations. 05310.2.4 Finishes Fabricated galvanized steel materials not specified to be otherwise finished shall be cleaned and prepared to receive field applied coating, where required, with no additional cleaning or preparation. Steel roof deck primed surfaces shall be suitable for field finish painting, where required, with no additional surface preparation. Shop primer shall be compatible with finish coat and/or with sprayed-on fireproofing where required. 05310.3 Execution 05310.3.1 Handling and Storage Materials for the construction of the steel roof deck shall be unloaded, handled, hauled, and delivered to storage in such manner to prevent bends, dents, scratches, or damage of any kind. Damaged roof deck or accessories shall be rejected and promptly replaced by and at the expense of the Supplier. Materials shall be stored above ground on shoring, under cover, and in a manner which will provide drainage to prevent moisture accumulation and to provide sufficient ventilation of the panels. Source: 05310, 2014, v2.0 Steel Roof Deck Page 60 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 05310.3.2 Installation Examine support framing and field conditions for compliance with requirements for installation, tolerances, and other conditions affecting performance of work. Do not begin field preparation or installation until unacceptable conditions are corrected. Steel roof deck panels shall be secured at each specified supporting member with 3/4 inch (19 mm) round fusion welds through welding washers, including end joints at 12 inch (300 mm) centers. Welds shall seal the metal completely, leaving no openings through the deck. Welds shall penetrate all layers of the deck material at the point of welding and shall have complete fusion to the supporting member. Side joints shall be button-punched from the underside, or welded with 1 inch (25 mm) long seam welds from the topside at least once between supports, with a maximum spacing of 36 inches (915 mm). If welding is used, care shall be exercised to prevent burning through. After attachment is complete, cover caps shall be placed over welding access holes. The deck attachment shall be secured against a net wind uplift as required by project-applicable building codes and standards. The installed metal roof deck shall be smooth, unbroken, and free of unnecessary openings, holes or crevices which might allow leakage of adhesive or bitumen. Such openings shall be closed and sealed or otherwise repaired to the satisfaction of the Purchaser. Inspect roof deck before placement of roof insulation and covering. Repair as needed for proper installation of roof insulation and covering. 05310.3.3 Cleaning At the completion of installation, all surplus material, rubbish, and any other debris shall be removed from the surface of the steel roof deck and properly disposed. Source: 05310, 2014, v2.0 Steel Roof Deck Page 61 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 05500 – Miscellaneous Metals 05500.1 General 05500.1.1 Scope of Work The scope of work for a purchase order is defined in Section 01100. Work under these specifications shall include furnishing and erecting miscellaneous metals and services complete as specified herein: Scope of Supply (Procurement) Detailing and production of fabrication and erection drawings. Material procurement, fabrication, surface preparation, coating application and shipping in accordance with these specifications and the drawings. Scope of Supply (Erection) Receipt, inspection, unloading, storage and erection of materials furnished under these specifications or furnished by others, in accordance with the specifications and the drawings. Preparation of galvanized slip-critical connection faying surfaces. Supply and install touchup coatings. 05500.1.1.1 Miscellaneous Materials and Services for Procurement. Miscellaneous materials and services not otherwise specifically called for shall be furnished by the Supplier in accordance with the following: Tests and inspections required by the specifications. Document submittals as specified in Technical Supplemental Q500. 05500.1.1.2 Miscellaneous Materials and Services for Erection. Miscellaneous materials and services not otherwise specifically called for shall be furnished by the Contractor in accordance with the following: Supply all fit-up bolts, welding electrodes, welding, and other fasteners not supplied by the Purchaser that are necessary for the completion of the work. Survey and lay out the work from the designated control points. Tests and inspections required by the specifications. Document submittals as specified in Technical Supplemental Q500. 05500.1.2 Items Furnished by Others and Interfaces The items furnished by others and interfaces for a purchase order are defined in Section 01100. 05500.1.3 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and Source: 05500, 2014, v2.0 Miscellaneous Metals Page 62 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Structural steel AISC Steel Construction Manual, Thirteenth Edition Structural steel AISC Code of Standard Practice for Steel Buildings and Bridges, AISC 303-05, March 18, 2005. Articles 1.7.1, 1.7.2, 3.6, 4.4, 4.5, 6.5.1, 6.7.4, 7.1, 7.2, 7.6, 7.7, 7.13.3, 7.16, 7.17, 8.4, 8.5.4, 9.3, 9.4, 9.5, 9.6, and 10.4.2 of the above referenced code shall not apply, nor shall any other requirement of this code which conflicts with the requirements of these specifications and documents. Structural steel AISC Specification for Structural Steel Buildings, AISC 360-05, March 9, 2005, with Commentary and Supplements. AISC Seismic Provisions for Structural Steel Buildings, 341-05, March 9, 2005, with Commentary and Supplements. Structural steel AISC Quality Certification Program for Structural Steel Fabricators Structural steel ASTM A6/A6M Bar grating ANSI/NAAMM MBG 531 Heavy-duty bar grating ANSI/NAAMM MBG 532 Checkered steel floor plate ASTM A786/A786M Steel for banding of panel ends and kickplates ASTM A36/A36M, ASTM A1011/A1011M, or acceptable equal Welding AWS D1.1 Structural Welding Code – Steel Coatings SSPC Paint Application Specification No. 1, "Shop, Field and Maintenance Painting" 05500.1.4 Materials The following materials shall be used: Component Material Structural steel wide flange and WT shapes ASTM A992/A992M Structural steel channels ASTM A36/A36M Structural steel S shapes ASTM A36/A36M Structural steel angles and plates ASTM A36/A36M Source: 05500, 2014, v2.0 Miscellaneous Metals Page 63 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Material Structural steel baseplates and plate over 4 in thick ASTM A36/A36M Structural steel shim plates and fill plates Material to match parent steel material Structural tubes ASTM A500/A500M, Grade B Steel pipes ASTM A53/A53M, Type E or S, Grade B High strength bolts, nuts, and washers ASTM A325, Type 1 bolts 3/4 inch diameter (1-1/8 inch diameter where specially noted) ASTM A325, Type 3 bolts 3/4 inch diameter (1-1/8 inch diameter where specially noted) ASTM F1852, Type 1 bolts 3/4 inch diameter (1-1/8 inch diameter where specially noted) ASTM F1852, Type 3 bolts 3/4 inch diameter (1-1/8 inch diameter where specially noted) Direct tension indicators ASTM F959, compatible with bolts Flat and beveled hardened washers (where required) ASTM F436, compatible with bolts Heavy hex nuts ASTM A563, compatible with bolts Welding electrodes Low hydrogen types, with a minimum tensile strength = 70,000 psi (495 MPa) Shear connectors for composite construction FabriSteel Nelson Stud Welding Headed Stud or acceptable equal Anchor rods (anchor bolts) As noted on Drawings Post-installed adhesive anchors IBC compliant and tested to ICC AC-308 with corresponding ICC ESR report. Adhesives: Hilti HIT RE 500-SD (ICC ESR-2322 report) Anchors: Hilti HAS Standard Rods (A36) Hilti HAS Super Rods (A193 B7) Hilti HIT-TZ Rods Threaded inserts for concrete Hilti HIS and HIS-R Internally Threaded Inserts with HIT-HY 200 Adhesive Pulling-in irons Condux International 12-inch (300 mm) with retaining plate and cross bar, galvanized Abrasive nosings for concrete stair treads Wooster Alumogrit Type 101 or acceptable equal, 3 inch (75 mm) wide with three wing type anchors per nosing. Iron castings for manhole/catch basin access and inlets ASTM A48 Class 35 or better Source: 05500, 2014, v2.0 Miscellaneous Metals Page 64 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Material Manhole steps M. A. Industries steel reinforced copolymer polypropylene steps Floor doors, vault hatches Bilco or acceptable equal Rectangular bar grating Mark W-19-4 (1-1/4 by 3/16 inch) [W-30-102 (31.8 by 4.8)] steel Banding of panel ends Required, size 1 by 1/8 inch (25 by 3) Kickplate 4 inches (100) above top of grating by 1/4 inch (6) thick Fasteners Saddle clips with Nelson, Erico, KSM studs Checkered steel floor plates ASTM A786/A786M, 1/4 inch (6) thick Ladders ASTM A36/A36M 05500.1.5 Additional Requirements Additional requirements for the materials and coatings to be furnished under this section of these specifications are indicated herein: Component Material Connection Requirements Shop welded, field bolted Bolting Requirements Slip-critical connection scope All connections with oversized or longslotted holes in one or more plies, except as noted on the drawings Pretensioned connection scope All structural connections not required to be slip-critical Snug-tightened connection scope Connections to non-structural steel components Slip-critical connections, contact surface class Class A Control of bolt tension Direct tension indicators (DTIs) or Twist-off bolts Coating Requirements Embedded structural steel shapes and plates, threaded inserts, continuous inserts Refer to Technical Supplemental Q300 General Coating Requirements. Anchor rods Refer to Technical Supplemental Q300 General Coating Requirements. Structural steel shapes, plates, tubes and pipes – exterior location Refer to Technical Supplemental Q300 General Coating Requirements. Source: 05500, 2014, v2.0 Miscellaneous Metals Page 65 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Material Structural steel shapes, plates, tubes and pipes - interior location Refer to Technical Supplemental Q300 General Coating Requirements. Ladders – exterior location Refer to Technical Supplemental Q300 General Coating Requirements. Ladders - interior location Refer to Technical Supplemental Q300 General Coating Requirements. Floor doors, vault hatches Manufacturer’s standard coating Iron castings None Shear connectors Galvanized Post-installed anchors Galvanized High strength bolts, nuts, and washers Mechanically galvanized (A325 and F1852 only). All connection components shall receive the same coating process, i.e.,. when bolts are mechanically galvanized, washers and nuts shall also be mechanically galvanized. Rectangular bar grating Hot-dip galvanized Heavy-duty rectangular bar grating Hot-dip galvanized Checkered steel floor plates Hot-dip galvanized Additional Coating Requirements Shop or Field touchup Touchup painting shall be in accordance with Technical Supplementals Q300 General Coating Requirements or Q320 Galvanizing. 05500.1.6 Approved Manufacturers of Components For the following components, the manufacturers identified in Article 05500.1.4 or listed below provide examples of the quality of workmanship required by these specifications. If the Supplier wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Engineer: Component Manufacturer High strength bolts Approved US Supplier Direct tension indicators (DTIs). DTIs using a silicon gel marker to indicate fulltension are not acceptable. TurnaSure LLC Plastic anchor rod sleeves Sinco Anchor Bolt Sleeve as distributed by Sinco/Sala Products, Inc. Rectangular metal bar grating and stair treads and heavy-duty bar grating AMICO or Harsco Industries/IKG or Fisher & Ludlow Source: 05500, 2014, v2.0 Miscellaneous Metals Page 66 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Manufacturer Checkered steel floor plate AMICO or Harsco Industries/IKG or Fisher & Ludlow Iron castings Neenah Foundry 05500.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Supplier is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By Nondestructive Testing of Welds Technical Supplemental Specification Q121 included in Section 21000 Supplier Testing of High Strength Bolts by Bolt Manufacturer, ASTM A325, A490 and F1852 ASTM A325, ASTM A490 and ASTM F1852, Production Lot Method Manufacturer Testing of Direct Tension Indicators ASTM F959, Article 10.2, Production Lot Method Manufacturer 05500.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 05500.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 01400. 05500.2 Products 05500.2.1 Drawing Requirements Supplier-produced drawings shall be in accordance with Technical Supplemental Q500 and the following requirements. Each drawing submitted shall indicate the name of the project, the unit designation, the contract title, the contract number, the name of the building structure, and the Supplier's name. In addition, the Purchaser's identification number will be affixed by the Engineer to each Supplier's initially submitted shop drawing. This number shall be maintained on all subsequent submittals of the drawings in the identical format and location as originally indicated by the Engineer. Erection drawings shall be submitted with, or prior to, the submittal of the corresponding detail drawings. A field bolt list indicating the number and length of each bolt shall be submitted. Details of the proposed typical beam connections shall be submitted with the first package of drawings. Source: 05500, 2014, v2.0 Miscellaneous Metals Page 67 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Each detail drawing shall include a Bill of Material. The total weight, area, or length of material on each sheet in every represented unit price category listed in the Proposal section shall be listed on every detail drawing. Each detail drawing shall indicate the mark number of each fabricated piece as assigned by the Supplier and list any material identification numbers assigned by the Engineer. Detail drawings shall indicate the top elevation of all horizontal members. 05500.2.2 Materials Materials shall be new and unused and shall conform to the following. 05500.2.2.1 Steel Certification. Signed chemical-composition and mechanical-property mill certifications shall be obtained for all steel purchased under this specification. If requested, a copy of the mill certifications shall be provided to the Engineer in accordance with Technical Supplemental Q500. 05500.2.2.2 Bolt Inspection - Manufacturer. High strength bolts shall be tested by the manufacturer prior to shipment in accordance with the Production Lot Method. If requested, a copy of the inspection test reports shall be forwarded to the Engineer in accordance with Technical Supplemental Q500. The Engineer reserves the right to independently test the bolt materials. Should the bolt materials be found to be defective, they shall be replaced at the Supplier’s expense. 05500.2.2.3 Direct Tension Indicators (DTIs) - Manufacturer. DTIs shall be inspection tested by the manufacturer prior to shipment in accordance with the Production Lot Method described in ASTM F959, Article 10.2. If requested, a copy of the inspection test reports shall be forwarded to the Engineer in accordance with Technical Supplemental Q500. The Engineer reserves the right to independently test the DTIs. Should the DTIs be found to be defective, they shall be replaced at the Supplier’s expense. 05500.2.3 Structural Steel Fabrication Structural steel shall be fabricated to the dimensions, arrangements, sizes and weights, or thicknesses indicated on the drawings or required by these specifications. Embedded materials shall be accurately fabricated and assembled. Warped or bent sections, which do not fit into the concrete forms as required, shall be replaced with suitable materials. Structural steel shall be fabricated to tolerances that will permit field erection within AISC tolerances, except that the displacement of any column center line from the established column line shall not be more than 1 inch (25 mm) at any point in the total height of the column. Cuts, copes, and holes shall be clean cut without torn, ragged edges or burrs. Unnecessary bolt holes in structural steel materials less than 1-1/2 inches (38 mm) in thickness shall be filled with weld metal and ground smooth. These repairs shall be made before preparing the member for shop painting or galvanizing. Unnecessary bolt holes in structural steel material 1-1/2 inches (38 mm) or greater in thickness shall be plugged with high strength bolts. The radius of beam copes and weld access holes shall be provided free of notches and shall be in accordance with AWS D1.1. Repair of notches shall be in accordance with AWS D1.1. The locations and details of all welded splices in structural members or components shall be acceptable to the Engineer. Unauthorized splices are not allowed. Splices will not be permitted in areas of high stress. The Engineer's acceptance of splice locations shall be obtained before fabrication. Source: 05500, 2014, v2.0 Miscellaneous Metals Page 68 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Holes and other provisions for field connections shall fit when the units are assembled in the field. Where required by the drawings or by the necessity of proper identification and fitting of field connections, the connections shall be matchmarked. 05500.2.4 Bar Grating Fabrication Grinding of crossbar ends is not required if the spacer bars project no more than 1/8 inch (3 mm) beyond the outside bearing bars and the overall panel width used in laying out the work is adjusted to allow for extensions. Kickplates shall be provided where indicated on the drawings. Where openings are indicated in gratings, such as for the passage of pipes, grating sections shall be laid out so that each opening will be centered on a joint between sections. All openings shall be provided with a kickplate of formed steel plate or standard weight steel pipe welded to the bearing bars. All kickplates attached to grating shall extend 1 inch (25 mm) below the top of grating. 05500.2.5 Bolted Connections Bolt holes shall be standard size, nominally 1/16 inch (2 mm) larger than the nominal bolt diameter unless noted otherwise. Bolt holes in clip angle connections shall be short slotted perpendicular to the length of the angle unless otherwise noted. Holes in gusset plates shall be oversized unless otherwise noted. In the event oversized holes are used in an outer ply, hardened washers shall be installed over the oversized hole. Where long-slotted holes are used in an outer ply, plate washers shall be provided and installed over the long-slotted hole. Contact surfaces of slip-critical connections coated with organic or inorganic zinc are acceptable, provided that the requirements for the specified AISC surface condition (Class A or Class B) are met. All bolts shall be furnished with lubricated nuts. Hardened washers (flat and beveled) shall be furnished in accordance with the recommendations on the Research Council’s Specification for Structural Joints. The Supplier shall furnish a 2 percent overage of each size and length of field bolt, plus an additional five bolts of each size and length. 05500.2.6 Welding Welding of structural steel shall be in accordance with the requirements specified in Technical Supplemental Q121 included in Section 21000. All welds shall receive 100 percent visual inspection. Butt joint splices, complete penetration T-joints, plate girder welds, and built-up column welds shall be tested as described in Technical Supplemental Q121. 05500.2.7 Coatings Coatings shall be in accordance with Section 21000. Shop paint shall not be applied within 3 inches (75 mm) of any field welded connection. When galvanizing is specified for structural steel members, all connection components shall be galvanized. 05500.3 Execution 05500.3.1 General Structural steel and miscellaneous metals shall be erected in a safe and workmanlike manner. Erection shall be in accordance with the requirements of OSHA Standard 29 CFR Part 1926, Subpart R, Steel Erection. Source: 05500, 2014, v2.0 Miscellaneous Metals Page 69 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 The Contractor shall store the miscellaneous metals in a manner that will prevent the materials from being damaged or subject to deterioration prior to erection. Materials shall not be stored in direct contact with the earth. Care shall be exercised to prevent damage of the steel coatings, and to prevent ponding of water that could damage the surfaces of galvanized materials. Fasteners shall be furnished in suitable containers, which shall remain closed until the fasteners are required for erection. Metals to be placed in concrete shall be installed as specified in Section 03311 and located as indicated on the drawings to the tolerances specified in Section 03311 and on the drawings. 05500.3.2 Steel Erection All materials erected under this specification shall be erected in accordance with the specified standards, the Purchaser's drawings, the erection drawings, and these specifications. Shop and field beam connections shall conform to details indicated on the drawings. When a Class A/C Hand Brushed Galvanized surface condition is specified, the faying surfaces of the slip-critical connections shall be roughened by means of hand wire brushing. Power wire brushing shall not be permitted. Full pretensioning of high strength bolts shall be required at all slip-critical and pretensioned connections, and where noted on the drawings. Bolts and bolting components shall be protected from dirt and moisture in closed containers at the site of installation. Only as many fastener components as are anticipated to be installed during the work shift shall be taken from protected storage. Fastener components that are not incorporated into the work shall be returned to protected storage at the end of the shift. The length of high strength bolts installed in field connections will be determined in accordance with the Research Council‘s Specification for Structural Joints. The Supplier shall exercise care in following the field bolt list so as to eliminate the need for additional “long” bolts. Additional “long” bolts shall be provided only at the Supplier’s expense. After steel erection, all lifting lugs used for erection purposes shall be removed and the area around the lug ground smooth and flush with the adjacent area. Open holes due to mismatched connections shall be filled with machine bolts and nuts or by welding. Welding shall be ground smooth. 05500.3.2.1 Bolting. The condition of the contact surfaces of each slip-critical type connection shall be in accordance with the slip-critical connection class requirements specified in the technical requirements. Prior to erecting the steel, the contact surfaces shall be inspected for compliance with the requirements given in the referenced edition of the Research Council's Specification for Structural Joints. Contact surfaces at bearing type field connections may be painted or galvanized, but shall be free of foreign substances. Connections requiring bolts of higher strength than ASTM A325 shall be examined after assembly to verify that the proper strength bolts have been installed. Tightening of bolts shall be controlled using the method indicated in Article 05500.1.5. The work shall be done by competent and experienced bolting crews. Source: 05500, 2014, v2.0 Miscellaneous Metals Page 70 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Bolted connections shall be drifted to proper position and the holes inspected to ensure that bolt threads will not be damaged by forcing the bolts in place. Connections shall be tightly drawn together using not less than 25 percent of the total number of bolts in the completed joints, but never less than two bolts. Bolts for initial tightening shall be distributed uniformly about the joint. Either fit-up bolts or high strength bolts may be used for this purpose. Ungalvanized ASTM A325 bolts that have been tightened no more than one-third turn beyond "snug-tight" may be loosened and retightened. Ungalvanized ASTM A325 bolts tightened more than one-third turn beyond "snug-tight" shall not be reused without inspection by the Engineer. ASTM A490 bolts and galvanized ASTM A325 bolts which have been tightened beyond "snug-tight" shall not be reused. Retightening previously tightened bolts that may have been loosened by the tightening of adjacent bolts is not considered a reuse. Smooth beveled washers shall be used when the bearing faces of the bolted parts have a slope of 1 to 20 or greater with respect to a plane normal to the bolt axis. All bolts and nuts shall be lubricated prior to installation to assure that proper tension can be obtained. 05500.3.2.1.1 Bolting pre-installation verification. Fastener assemblies of each combination of diameter, length, grade and lot to be used in pretensioned connections shall be tested with a tension calibrator at the jobsite prior to commencing bolt installation on the work. Pre-installation verification shall be in accordance with the Research Council’s Specification for Structural Joints. 05500.3.2.1.2 Direct tension indicators (DTIs). When using DTIs, tightening shall be done in accordance with the manufacturer's written instructions, the Research Council’s Specification for Structural Joints, and the following. Special care shall be taken to ensure that each DTI is of the correct capacity and grade for its intended use. Any ASTM A325 or A490 bolt that has been tightened sufficiently to deform the DTI shall not be loosened and retightened. Inspection of the installed DTI shall be in accordance with the manufacturer's written instructions. Bolts found to be undertensioned shall be tightened to the correct tension by the Contractor. DTIs shall be inspected after the connection is snug-tight, but before pretensioning, and inspected again after pretensioning. Inspections shall use the appropriate feeler gauge recommended by the manufacturer. 05500.3.2.1.3 Twist-off bolts. When using twist-off bolts, tightening shall be done in accordance with the manufacturer’s written instructions, the Research Council’s Specification for Structural Joints, and the following. Special care shall be taken to store the bolting components properly. Twist-off bolts shall not be relubricated, except by the bolt manufacturer. Joints assembled with twist-off bolts shall first be snug-tightened. Compacting the joint to the snug-tight condition shall progress systematically from the most rigid part of the joint. If the splined end of a bolt is severed during snug-tightening of the connection, then the bolt shall be replaced. Once the connection has been compacted to a snug-tight condition, the bolts shall be pretensioned using tools and methods recommended by the manufacturer and progressing systematically from the most rigid part of the joint in a manner that will minimize relaxation of previously pretensioned bolts. 05500.3.2.1.4 Tightening – turn-of-nut. The turn-of-nut method for tightening bolts shall be performed in accordance with the Research Council’s Specification for Structural Joints and the following. Source: 05500, 2014, v2.0 Miscellaneous Metals Page 71 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Bolts installed in the work shall be in the same condition as the bolts used in the pre-installation verification procedure. Should the bolt conditions change due to additional corrosion or lubrication, then they shall be retested using the verification procedure. Matchmarks shall be applied to both the nut and the bolt end after the "snug-tight" condition has been attained in each connection. 05500.3.3 Welding Welding of structural steel shall be in accordance with Technical Supplemental Q121 included in Section 21000, and the following. All field welds shall receive 100 percent visual inspection. Butt joint splices, complete penetration T-joints, plate girder welds, and built-up column welds shall be tested as described in Technical Supplemental Q121. All welding of stair stringer miters, closure plates, extension pieces, and similar welding applications shall be continuous welds and shall be ground smooth. 05500.3.4 Bar Grating Installation Each section of rectangular bar grating shall be securely fastened in place with not less than two fasteners at each support. Rectangular grating shall be installed so that spacer bars and load carrying bars in adjacent panels are in alignment. Grating fasteners shall be in accordance with Article 05500.1.4 and shall be installed in accordance with the manufacturer's requirements. The fastener system shall be acceptable to the Engineer. When saddle-clips are supplied, welded stud type bolts including nuts and washers shall be included. Saddle-clips shall be galvanized and as specified in the NAAMM manual. Studs shall be Nelson Stud Welding, Erico Products Blue Arc, KSM Welding Systems, or acceptable equal. Welded stud type bolts shall be size 1/4-20 with pitch diameter base. Stud length after welding shall be approximately 1/8 inch (3 mm) less than the grating depth. Nuts shall conform to ANSI B18.2.2. Studs, washers, and nuts shall be zinc plated in accordance with ASTM B633, service condition SC4. When the Hilti Grating Disk System is used, disks shall be either electro-galvanized Type X-FCM or hotdip galvanized Type X-FCM-F and carbon steel threaded studs shall be electro-galvanized Type EM8-1514FP10. Grating disks shall be sized according to height of grating. 05500.3.5 Touchup Painting The Contractor shall inspect fabricator applied paint films and inform the Site QA Manager of inadequate coatings prior to the erection of the materials. Damaged or inadequate paint films of shop primed structural steel materials, all accessible surfaces of field welds, unpainted surfaces at slip-critical connections, ungalvanized field connection bolts, and damaged galvanized surfaces shall be cleaned and touchup painted. . Touchup paint for shop primed materials, all accessible surfaces of field welds, ungalvanized bolts, and damaged galvanized surfaces shall be in accordance with Technical Supplemental Q300 General Coating Requirements. Source: 05500, 2014, v2.0 Miscellaneous Metals Page 72 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 09900 - Field Applied Protective Coatings 09900.1 General Cleaning, surface preparation, and coating application shall be as specified herein and shall meet or exceed the coating manufacturer's recommendations. When the manufacturer's minimum recommendations exceed the specified requirements, the Supplier shall comply with the manufacturer's minimum recommendations. 09900.1.1 Scope The scope of work is provided in Section 01100. 09900.1.2 Schedule The schedule requirements are provided in Section 01100. 09900.1.3 Items Furnished by Others and Interfaces Items furnished by others and not in this scope of supply are provided in Section 01100. 09900.1.4 Coating Applications and Material Requirements Requirements for the coating materials are indicated on the Coating System Data Sheets included as attachments to these specifications. Except as otherwise noted, the following areas and items shall not be coated: Metal wall panels and flashings (exterior). Glass and glazing. Acoustical ceiling. Aluminum surfaces. Brass and Bronze. Quarry tile, ceramic tile, or ceramic granular flooring. Resilient floor coverings. Hardware. Floor plates. Embedments (galvanized). Grating. Galvanized ductwork, dampers, and fan boxes. Light fixtures, except supports. Electrical conductors, insulated or uninsulated. Electrical conduits, wireways, and junction boxes (except as otherwise specified). Cable trays and supports. Chromium plated metals. Source: 09900, 2014, v3.0 Field Applied Protective Coatings Page 73 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Gauges. Rotating shafts and couplings. Rubber belts, skirting, gaskets, and idler disks 09900.1.4.1 Delivery and Storage. All coating products shall be received and stored in accordance with the coating manufacturer's recommendations. 09900.1.5 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Fabrication details, surface finish requirements, and proper design considerations for tanks and vessels to be lined for immersion service NACE SP0178 Mineral and Slag Abrasives SSPC-AB 1 Cleanliness of Recycled Ferrous Metallic Abrasives SSPC-AB 2 Newly Manufactured or Remanufactured Steel Abrasives SSPC-AB 3 Solvent cleaning SSPC-SP 1 Hand tool cleaning SSPC-SP 2 Power tool cleaning SSPC-SP 3 White metal blast cleaning SSPC-SP 5 / NACE No. 1 Near white blast cleaning SSPC-SP 10 / NACE No. 2 Commercial blast cleaning SSPC-SP 6 / NACE No. 3 Brush-off blast cleaning SSPC-SP 7 / NACE No. 4 Power tool cleaning to bare metal SSPC-SP 11 Surface Preparation and Cleaning of Steel and Other Hard Materials by Highand Ultra-High Pressure Water Jetting Prior to Recoating SSPC-SP 12 Brush Off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels and Non-Ferrous Metals SSPC-SP 16 Surface Preparation of Concrete SSPC-SP 13 Source: 09900, 2014, v3.0 Field Applied Protective Coatings Page 74 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Work In Accordance With Shop, field, and maintenance painting of steel SSPC-PA 1 A guide to safety in paint application SSPC-PA Guide 3 Standard procedure for evaluating painting contractors SSPC-QP 1 Visual standard for abrasive blast cleaned steel SSPC-VIS 1 Visual standard for power and hand tool cleaned surfaces SSPC-VIS 3 Dehumidification and Temperature Control SSPC-TR 3 / NACE 9A192 Surface Preparation of Soluble Salt Contaminated Steel Substrates NACE 6G186 Bid Issue 2Mar2015 09900.1.6 Approved Manufacturers of Components Refer to the attached Coating System Data Sheets for approved manufacturers listed in Article 01100. 09900.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Supplier is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By Indicating moisture in concrete by the plastic sheet method ASTM D4263 Supplier Indicating oil or water in compressed air ASTM D4285 Supplier Measurement of wet film thickness by notch gauges ASTM D4414 Supplier Field measurement of surface profile of blast cleaned steel ASTM D4417 Supplier Pull-off strength of coatings using portable adhesion testers ASTM D4541 Supplier Measurement of dry paint thickness with magnetic gauges SSPC-PA 2 Supplier Source: 09900, 2014, v3.0 Field Applied Protective Coatings Page 75 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Tests In Accordance With Conducted By Discontinuity (Holiday) testing of new protective coatings on conductive substrates NACE SP0188 Supplier Guide for Illumination of Industrial Painting Projects SSPC Guide No. 12 Supplier Field Methods for Retrieval and Analysis of Soluble Salts SSPC-TG 15 Supplier 09900.1.8 Technical Attachments The following attachments accompany these specifications in either paper or electronic format. The information contained in these documents constitutes requirements under the defined Scope of Work: Document Number/Description Title Revision 81113-DM-0607 Coating System Data Sheet 1112 2 81113-DM-0664 Coating System Data Sheet 3301 2 81113-DM-0665 Coating System Data Sheet 3311 2 81113-DM-0700 Blast Media Data Sheet B1 1 09900.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 01100. 09900.1.10 Submittals A coating system submittal shall be provided in accordance with Section 21000. A separate coating system submittal shall be developed and submitted for each variation or change in a coating system or surface to be coated. Protective coating and lining work shall be undertaken by applicators, including supervisors and workers, qualified by commercial experience installing the types of materials specified. To satisfy this experience requirement, the Supplier shall be certified to SSPC-QP 1 or equivalent and shall submit to the Purchaser a work history demonstrating a record of performance of such applications. When the proposed products will be in contact with potable water, the Supplier shall submit certifications that the proposed systems are in compliance with ANSI/NSF 61. Supplier shall submit color cards for all coatings proposed for use, together with specifications to the Purchaser for review and color selection. Approval of the Supplier submittals must be provided by the Purchaser prior to the commencement of work. 09900.1.11 Quality Assurance 09900.1.11.1 Inspector.. The Supplier shall assign an experienced coating inspector to supervise the entire process to ensure that all procedures meet or exceed the specifications or the coating Source: 09900, 2014, v3.0 Field Applied Protective Coatings Page 76 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 manufacturer's recommendations. A third party lining inspector may be provided by the Purchaser to ensure compliance with this specification. 09900.1.11.2 Certification. The Supplier shall review and approve in writing the coating manufacturer's recommendations for the intended service. Any variations from these specifications or the coating manufacturers published recommendations shall be submitted in writing and approved by the Purchaser. 09900.1.11.3 Manufacturer’s Services. The services provided by the coating manufacturer shall include review of the project before surface preparation; certification, in writing, of the applicator and the coating materials to be used. 09900.1.11.4 Work Experience. Work experience submittal shall be provided in accordance with Supplemental Specification Section 21000. 09900.1.12 Receiving, Handling, Storage and Cleaning The Supplier shall promptly receive, unload, and place into storage all equipment, materials, and supplies arriving at the Jobsite for the Work under this Contract. Expired units of paint or linings delivered to the Jobsite shall be returned to the manufacturer. Storage areas on the Jobsite will be allocated for the Supplier's use by the Purchaser. Equipment and materials shall be stored in assigned lay-down areas. Before unloading any materials or equipment, the Supplier shall advise the Purchaser as to the requirements for the storage area. Paints, linings, and thinners awaiting application are the responsibility of the Supplier and must be stored appropriately to insure proper quality when used. Supplier shall properly dispose of paint damaged by improper storage or exceeded shelf life, and shall provide acceptable replacements. Catalysts and resins shall be stored in isolation from each other. The Supplier shall provide all required storage facilities. All platforms, enclosures, shoring, and weatherproof coverings for storage use shall remain the property of the Supplier and shall be removed upon completion of the work. Prior to acceptance by Purchaser, the Supplier shall remove all dirt and other material that has been spilled, misplaced, or otherwise allowed to mar the finished surfaces. All debris shall be removed from the Jobsite and disposed of. The Supplier shall dispose of used or leftover containers, thinners, rags, brushes, and rollers in accordance with applicable regulations. The Supplier shall abide by all EPA, OSHA, and state regulations regarding storage, handling, and use of flammable and combustible liquids. All employees who will be using chemicals (solvents, cleaners, lubricants, linings, etc.) shall be knowledgeable and skilled in the proper use of and the hazards associated with these chemicals. The Supplier shall manage all hazardous waste generated by the Work in accordance with the requirements as stated elsewhere within the Contract Documents. 09900.2 Products 09900.2.1 Materials All coating materials shall be delivered to the job in original, unopened containers, with labels intact. Coating materials shall be maintained during transportation, storage, mixing and application within the temperature range required by the coating manufacturer. No adulterant, unauthorized thinner, or other material not included in the coating formulation shall be added to the coating for any purpose. All coatings shall conform to the air quality regulations applicable at the location of use. Coating materials that cannot be guaranteed by the manufacturer to conform, whether or not specified by product designation, shall not be used. Source: 09900, 2014, v3.0 Field Applied Protective Coatings Page 77 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Coatings used in successive field coats shall be produced by the same manufacturer. The first field coat over shop coated or previously coated surfaces shall cause no wrinkling, lifting, or other damage to underlying coats. 09900.2.2 Approved Manufacturers Except as otherwise acceptable to the Purchaser, coatings shall be manufactured, formulated, and compounded by coating manufacturers named in the Coating System Data Sheets. Abrasive blast media shall be supplied by abrasive blast materials manufacturers named in the Blast Media Data Sheets. 09900.3 Execution 09900.3.1 Surface Preparation Coating work shall include the protection of surfaces not to be coated and surface preparation, furnishing and applying materials, and other work incidental to coating that is required to properly execute the work. All exposed surfaces of the equipment shall be coated as directed on the Coating System Data Sheets. The remainder of the plant equipment will be coated under separate specifications. All surfaces to be coated shall be clean and dry and shall meet the recommendations of the coating manufacturer for surface preparation. Oil and grease shall be completely removed by using techniques described in SSPC-SP 1 before mechanical cleaning is started. Surfaces shall be free of cracks, pits, projections, or other imperfections that would interfere with the formation of a smooth, unbroken coating film. Freshly coated surfaces shall be protected from dust and other contaminants. The gloss on previously coated surfaces shall be dulled if necessary for proper adhesion of topcoats. When applying touchup coating or repairing previously coated surfaces, the surfaces to be coated shall be cleaned as recommended by the coating manufacturer and the edges of the repaired area shall be feathered by sanding or wire brushing to produce a smooth transition that will not be noticeable after the coating is applied. All coatings made brittle or otherwise damaged by heat of welding shall be completely removed. The quality of compressed air shall be verified in accordance with ASTM D4285 prior to performing abrasive blasting. The test will be carried out at the beginning of each shift and witnessed by the coating inspector. The surface preparation specified herein are minimums, and if the requirements published in the coating manufacturer's data sheets exceed the limits specified, the value published on the data sheets shall become the minimum requirement. 09900.3.1.1 Galvanized Surfaces. Galvanized surfaces shall be prepared for coating by following the cleaning procedures specified n SSPC-SP 16, Brush-off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels and Non-Ferrous Metals and the instructions of the coating manufacturer. Any chemical treatment of galvanized surfaces shall be followed by thorough rinsing with clean water. 09900.3.1.2 Ferrous Metal Surfaces. Ferrous metal surfaces shall be prepared for coating by using one or more of the following cleaning procedures as specified: solvents (SSPC-SP1); hand tools (SSPC-SP2); power tools (SSPC-SP3 or -SP11); abrasive blasting (SSPC-SP5, -SP6, -SP7, or -SP10); or water jetting (-SP12). Oil and grease shall be completely removed in accordance with SSPC-SP1 before beginning any other cleaning method. Surfaces of welds shall be scraped and ground as necessary to remove all slag and weld spatter. Source: 09900, 2014, v3.0 Field Applied Protective Coatings Page 78 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Unless specified in the Coating System Data Sheets, all ferrous metal surfaces shall have all welds ground smooth and free of all defects in accordance with NACE Standard SP0178, Appendix C, Designation D. All blasting residue, waste, and accumulation shall be removed before coating application. Cleaned surfaces shall be coated or lined with the specified coating, primer, or touchup coat within 6 hours of cleaning, or before rust bloom occurs. No blast cleaned surfaces shall stand overnight before coating. The surface preparation specified herein are minimums, and if the requirements printed in the coating manufacturer's data sheets exceed the limits specified, the value printed on the data sheets shall become the minimum requirement 09900.3.1.3 Stainless Steel Surfaces. Stainless steel surfaces shall be prepared for coating by following the cleaning procedures specified in SSPC-SP 16, Brush-off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels and Non-Ferrous Metals. 09900.3.1.4 Concrete Surfaces. Concrete surfaces shall be prepared in accordance with SSPC-SP 13. Concrete surfaces shall be prepared until they are acceptable to the coating manufacturer. Surfaces shall be free of cracks, pits, projections, or other imperfections that would interfere with the formation of a smooth, unbroken coating film. Concrete surfaces, including those with bug holes less than 1 inch in any dimension, shall be prepared using an epoxy repair mortar or as recommended by the coating manufacturer. If any repairs to existing concrete are required, they shall be made as part of the surface preparation in accordance with the concrete repair section. New concrete shall be cured for at least 28 days before lining is applied and shall be ready to receive the lining as determined by the coating manufacturer. Concrete surfaces shall be tested for capillary moisture in the concrete in accordance with ASTM D4263. There shall be no capillary moisture migration after 24 hours as determined by the test method. Before the lining is applied, the surfaces shall be thoroughly washed or cleaned by air blasting to remove all dust and residue. The surface tensile strength of concrete shall be measured after the surface has been prepared. Surface tensile strength tests shall be performed in accordance with the requirements of SSPC-SP 13. The measured surface tensile strength of the concrete shall comply with the requirements of SSPC-SP 13, Table 1, for severe service. All penetrations, i.e. anchor bolts, electrical conduit, etc…, through concrete coating systems shall be sealed with a chemically resistant caulking compound as recommended by the coating manufacturer. 09900.3.2 Mixing and Thinning Coating shall be thoroughly mixed each time any is withdrawn from the container. Coating containers shall be kept tightly closed except while coating is being withdrawn. Coating shall be factory mixed to proper consistency and viscosity for hot weather application without thinning. Thinning will be permitted only as necessary to obtain recommended coverage at lower application temperatures. In no case shall the wet film thickness of applied coating be reduced, by addition of coating thinner or otherwise, below the thickness recommended by the coating manufacturer. Thinning shall be done in compliance with all applicable air quality regulations. Uniform suspension of coating pigments shall be maintained during application. Source: 09900, 2014, v3.0 Field Applied Protective Coatings Page 79 of 280 Calaveras Coal Yard 186144.77.1000 Jobsite tinting will not be permitted. Bid Issue 2Mar2015 Compressed Air Equipment Construction 09900.3.3 Application Coating shall be applied in a neat manner that will produce an even film of uniform and proper thickness, with finished surfaces free of runs, sags, ridges, laps, and brush marks. In no case shall coating be applied at a rate of coverage greater than the maximum rate recommended by the coating manufacturer. A skid resistant additive shall be incorporated into the top layer of coating systems which are applied to permanent walking surfaces. Each layer of the coating system shall be of a visibly different color or shade from the preceding coat. Coatings shall be factory tinted. Ventilation in the work area shall be adequate to remove all particulates and solvent vapors. Where natural ventilation is inadequate, a mechanical ventilation system shall be employed. The ventilation system shall provide a clean air supply during all phases of coating operations. Coating failures will not be accepted and shall be entirely removed down to the substrate and the surface recoated. Failures include but are not limited to checking, cracking, teardrops, fat edges, fisheyes, or delamination. Coating materials shall be applied in accordance with the manufacturer's recommendations by competent and experienced applicators. 09900.3.4 Protection of Surfaces Throughout the work, proper dropcloths, masking tapes, and other protective measures shall be provided to protect surfaces from accidental spraying, splattering, or spilling of coatings. Damage resulting from coating operations shall be corrected and repaired. Coatings deposited on surfaces not being coated shall immediately be removed. The Supplier shall remove and reinstall, or provide adequate in-place protection for, valve and equipment identification tags, gauges, installed hardware, accessories, lighting and electrical components, factory finished materials, plumbing fixtures and fittings, and other materials that may become splattered or damaged by coating materials. 09900.3.5 Environmental Conditions Coatings shall not be applied, except under environmentally controlled conditions, during wet, damp, or foggy weather, or when windblown dust, dirt, debris, or insects will collect on freshly applied coating. o Do not install coating or lining material if substrate temperature is within 5 F of the dewpoint temperature or if the relative humidity is greater than 95 percent. Coatings shall not be applied at temperatures less than the minimum temperature recommended by the coating manufacturer, or to metal surfaces where conditions are likely to cause condensation, regardless of the air temperature. Where necessary, a temporary enclosure shall be provided to maintain the temperature within acceptable temperature limits during surface preparation and coating application activities and until the coating has fully cured. Coatings shall not be applied at temperatures greater than the maximum temperature recommended by the coating manufacturer. Where coatings are applied during periods of elevated ambient temperatures, the Supplier shall ensure that proper application is performed including adherence to all re-coat window requirements. Precautions shall be taken to reduce the surface temperature during application below 100°F, including shading the application area from direct sunlight, applying coating in the evening or at night, and ventilating the area to reduce the humidity and temperature. Source: 09900, 2014, v3.0 Field Applied Protective Coatings Page 80 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Coatings shall not be applied when the relative humidity is greater than the maximum or less than the minimum values recommended by the coating manufacturer. Where necessary, a temporary enclosure shall be provide to maintain the relative humidity within acceptable temperature limits during surface preparation and coating application activities and until the coating has fully cured. Concrete that is expelling air, or increasing in temperature, shall not be coated. 09900.3.6 Field Quality Control The following inspection and testing shall be performed as required herein: visual inspection, surface profile, wet and dry film thickness, spark testing, and adhesion testing. The Purchaser shall be responsible for review of all Supplier testing documentation and shall also establish hold points indicating periodic on-site review of the Supplier’s test procedures. The Supplier shall provide daily documented quality control reports to the Purchaser. The reports and forms may vary each day depending on the point in the preparation and application process. At a minimum, in addition to inspection and testing the following shall be documented for all coats, including putty/scratch and coat/stripe: Material storage: • • • Confirmation of catalyst and resin isolation Storage temperatures Product batch numbers and expiration dates Surface preparation: • • • • • Weld profile Method and materials used for dust, dirt, grease, and soluble salts removal Abrasive used Surface standard achieved Anchor profile and method used Environmental conditions: • All environmental conditions shall be recorded at least every 2 hours during lining application, between coats and until lining cure is complete. Atmospheric temperature, relative humidity and dew point on the lined surface, lining and surface temperatures shall be the minimum information recorded. Temperature checks shall occur at multiple substrate locations. Mixing: • • • Batch numbers Mixing time Mixing ratios Application times and locations: • • When and where lining work began When and where lining work concluded Personnel performing or supervising the inspection of surface preparation, coating application and quality control testing shall be qualified as a Certified Coating Inspector in accordance with the requirements of NACE International or previously approved equivalent program. The Supplier shall immediately notify the Purchaser of any non-conformance and shall prepare a nonconformance report. Source: 09900, 2014, v3.0 Field Applied Protective Coatings Page 81 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 09900.3.6.1 Surface Profile Testing. The surface profile for ferrous metal surfaces shall be measured for compliance with the specified minimum profile in accordance with ASTM D4417. The surface profile for concrete shall comply with SSPC-SP 13, Table 1, for severe service. 09900.3.6.2 Visual Inspection. The surface of the protective coatings shall be visually inspected. 09900.3.6.3 Film Thickness. Coating film thickness shall be verified by measuring the film thickness of each coat as it is applied and the dry film thickness of the entire system. Dry film thickness shall be measured in accordance with SSPC-PA 2. Wet film thickness shall be measured with a gauge that will measure the wet film thickness within an accuracy of ±0.5 mil in accordance with ASTM D4414. 09900.3.6.4 Holiday Testing. Where specified on the Coating System Data Sheets (CSDS), coatings shall be holiday tested using an acceptable electrical spark tester set at the recommended voltage. The Purchaser shall observe the spark testing and shall verify the testing equipment is working properly before the spark testing of the coating is started. The electrode movement shall be continuous and shall proceed in a systematic manner that will cover 100 percent of the coated surface. The electrode shall maintain continuous contact with the coated surface. Holiday testing for coatings on metal shall be done in accordance with NACE SP0188. All detected holidays and pinholes shall be marked and repaired. Repairs shall be performed in accordance with the coating manufacturer’s published recommendations. 09900.3.6.5 Coating Adhesion Testing. Where coated surfaces contain visible defects that could adversely affect the adhesive or cohesive properties of the film, an adhesion test shall be conducted to validate the integrity of the coating system. Defects visible in the film that require performance of an adhesion test include overspray, cratering, runs or sags, solvent blistering, dirt or debris in the film, flaking, lifting or cracking. Prior to performance of the adhesion test, the test area shall have been coated and allowed to cure completely according to the coating manufacturer’s published recommendations. A minimum of one adhesion test shall be performed in accordance with ASTM D4541 for steel substrates and SSPC-SP 13 for concrete substrates. The resultant coating adhesion strength shall meet or exceed the minimum value specified in the coating manufacturer’s published literature or, in the case of concrete, exceed the minimum surface tensile strength of the substrate. If the surface tested fails to comply with the minimum specified adhesion strength, adhesion testing shall be expanded to adjacent surfaces until sound coating, e.g., coating adhesion strength meets or exceeds the minimum value specified in the coating manufacturer’s published literature, if obtained. Coating materials shall be removed, down to the substrate, from surfaces that exhibit adhesion values less than the specified minimum and replaced. Coating removal shall be accomplished by mechanical means, e.g., hand/power tool and/or abrasive blasting. The coating shall be reapplied in accordance with the applicable coating system data sheet. Treatment of interfaces and tie-ins between the previously coated surfaces and surfaces that have been replaced shall comply with recommendations stated in the coating manufacturer’s published literature. Source: 09900, 2014, v3.0 Field Applied Protective Coatings Page 82 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 13110 - Galvanic Anode Cathodic Protection 13110.1 General 13110.1.1 Scope of Supply Scope of supply shall include furnishing the cathodic protection equipment as specified herein. 13110.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this scope of supply shall include the following: Air Compressor Air Dryer Air Receiver 13110.1.3 Performance and Design Requirements Performance and design requirements for the equipment to be furnished under this section of these specifications are as indicated herein. 13110.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Cathodic protection equipment The applicable NACE International Standards. 13110.1.5 Materials See Section 13110.2 and Section 01100.1.2 (Drawing E2701) 13110.1.6 Approved Manufacturers of Components For the following components, the manufacturers listed below provide examples of the quality of workmanship required by these specifications. If the Supplier wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Purchaser: Component Manufacturer Cathodic Protection Equipment Corrpro Companies, Inc.; Norton Corrosion Limited; Mesa Products, Inc. 13110.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Supplier is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Source: 15225, 2014, v2.0 General Service Pipe Page 83 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Tests In Accordance With Conducted By Startup Article 13110.3.2, Testing Purchaser 13110.1.8 Technical Attachments The following attachments accompany these specifications in either paper or electronic format. The information contained in these documents constitutes requirements under the defined Scope of Work: Document Number/Description Title Revision 186114-1CPU-E2701 Galvanic Anode – Cathodic Protection Details A 186114-1CPU-E2702 Insulated Flange – Cathodic Protection Details A : 13110.1.9 Supplemental Specifications Not Used 13110.2 Products 13110.2.1 Galvanic Anodes 13110.2.1.1 Packaged Magnesium Anodes. High potential magnesium anode material shall be Grade M1C, UNS Alloy M15102, complying with ASTM B843. Anodes shall be furnished as a packaged assembly. The packaged assembly shall consist of a permeable cloth bag containing the anode, centered in and completely surrounded by compacted backfill. The backfill shall have the following composition in percent by weight: Material Percent Ground hydrated gypsum 75 Powdered bentonite 20 Anhydrous sodium sulfate 5 High potential magnesium anode shall be furnished with Type TW insulated, solid copper lead wire. 13110.2.1.2 Packaged Zinc Anodes. Not Used 13110.2.1.3 Cast Magnesium Anodes. Not Used 13110.2.2 Aboveground Test Stations Test stations shall consist of a terminal block contained in a cast aluminum enclosure. Terminal blocks shall include five nickel-plated marine brass terminals and one nickel-plated marine brass jumper strap. The enclosure cover fastener shall be stainless steel. The enclosure shall have a threaded hub suitable for connection to 2 inch rigid galvanized steel (RGS) conduit. 13110.2.3 Test Station Identification Tags Test station identification tags shall be 2 inch width by 1-1/4 inch (32 mm) height by 20 gauge Type 304 stainless steel plate. One 3/32 inch diameter hole shall be drilled in each corner of the plate. Lettering shall be 3/16 inch square. Source: 15225, 2014, v2.0 General Service Pipe Page 84 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 13110.2.4 Copper Sulfate Reference Electrodes Reference electrodes shall be the saturated, gelled, copper-copper sulfate type. Reference electrodes shall be furnished as a packaged assembly. Packaged reference electrodes shall be furnished with Type HMWPE insulated, stranded copper lead wire. 13110.2.5 Exothermal Welding Materials Welding charge formulation and equipment selection shall be appropriate for the size, shape, and composition of the material being welded. Weld molds shall be supplied complete with appropriate handles. 13110.2.6 Exothermal Weld Coating Repair Materials Coating repair material shall be a preformed plastic sheath filled with an encapsulation compound. 13110.2.7 Compression Ring-Tongue Terminals Compression ring-tongue terminals shall be constructed of corrosion-resistant copper, bronze, or nickelplated brass. Terminals shall be single hole, uninsulated, compression type. 13110.2.8 Cathodic Protection Cable Cable Type CP shall be stranded copper cable with low density, high molecular weight polyethylene insulation (HMWPE). 13110.2.9 Nondetectable Underground Marking Tape Underground marking tape shall be a minimum 3 inches in width, red in color, with the following words printed in black: "Caution - Electric Line Buried Below," or "Caution - Cathodic Protection Cable Buried Below," or similar. Marking tape shall be supplied on 1,000 foot rolls. 13110.2.10 Wire and Cable Markers Markers for wire and cable circuits shall be an opaque nylon material consisting of a marker board, nonreleasing holding device, and cable fastening tail. 13110.2.11 Marking Pens Marking pen ink shall be suitable for marking on nylon and shall be black, permanent, and waterproof. 13110.2.12 Solder Solder shall be 50/50 tin/lead solid wire with nonacid flux. 13110.2.13 Insulated Flange Kits Insulated flange kits shall consist of the following components: One 1/8 inch thick Type "E," full-faced insulating and sealing flange gasket containing a precision tapered groove to accommodate the controlled compression of the sealing element. The full-faced flange insulating gasket shall be 1/8 inch less in inside diameter (ID) than the ID of the flange in which it is installed. One 1/32 inch thick full length bolt insulating sleeve per flange bolt. Two 1/8 inch thick insulating washers per flange bolt. Two 1/8 inch thick zinc-plated steel backing washers per flange bolt. Steel backing washer ID and outside diameter (OD) shall be identical to that of the insulating washer. Insulating material selection shall be based on the application as indicated below: Fluid Retainer Seal Washer Washer Air G-10 Nitrile Phenolic Mylar Source: 15225, 2014, v2.0 General Service Pipe Page 85 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction G-10 insulating sleeves and washers shall be provided for flange diameters greater than 24 inches or ANSI class ratings greater than or equal to 600. 13110.2.14 Insulated Flange Identification Tags Insulated flange identification tags shall be 3-1/2 inch width by 1-1/4 inch height by 20 gauge Type 304 stainless steel plate. One 3/32 inch diameter hole shall be drilled in each corner of the plate. Lettering shall be 3/16 inch square. 13110.2.15 Polyethylene Mesh Polyethylene mesh shall be medium density polyethylene extruded into a diamond shaped pattern. Polyethylene mesh shall be approximately 0.156 inch thick. Polyethylene mesh shall be furnished in 60 inch wide by 100 foot long rolls. 13110.2.16 Silver Brazing Materials Silver brazing filler shall be AWS classification BAg-7 or BAg-36 per AWS SFA A5.8. Brazing flux shall be chloride-free and water-washable, AWS classification FB3-A per AWS SFA A5.31. 13110.3 Execution 13110.3.1 Installation All cathodically protected piping and piping components shall be installed free of foreign material and construction debris. The Supplier shall electrically isolate cathodically protected piping from pipe supports, concrete reinforcing steel, structural steel, grounding conductors, interconnecting piping and equipment, and all other plant items where contact with the protected pipe will create a conductive path to ground. Prior to placement of concrete, the Supplier shall wrap all concrete encased carbon steel, stainless steel, and copper piping with a single layer of polyethylene mesh to prevent contact with reinforcing steel. Polyethylene mesh shall be held in place with plastic tape unless otherwise indicated on the drawings. 13110.3.1.1 Packaged Anodes. Anodes associated with underground piping shall be installed as indicated on the drawings and as specified herein. The minimum burial depth shall be such that the uppermost part of the anode is located beneath the invert of the pipe being protected. Should geological conditions, such as solid rock, preclude installation of the packaged anode in the prescribed manner, the anode shall be installed in a horizontal position. Caution shall be exercised to ensure that the permeable cloth backfill packaging remains intact. 13110.3.1.2 Wire and Cable. Installation of anode lead wires, pipe lead wires, reference electrode lead wires, and all other cathodic protection wire and cable shall be in accordance with the drawings and as specified herein. Connection of lead wires to the pipe shall be as specified in the article titled Exothermal Weld Connections. Connection of the lead wires in the test station terminal block shall be as specified in the article titled Test Station Terminations. Splices in pipe lead wire shall be subject to the approval of the Engineer. At all times, pipe lead wires shall be clearly identified with regard to the pipe with which they are connected. 13110.3.1.3 Test Station Terminations. Wire terminations shall be installed on the test station terminal block as shown on the drawings and as specified herein. Source: 15225, 2014, v2.0 General Service Pipe Page 86 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction A calibrated crimping tool shall be used to attach a compression ring-tongue terminal to the end of each conductor. The compression terminal shall not release from the conductor when pulled or twisted. In addition to crimping, solid conductors shall be soldered to the compression terminal. Wire and cable markers shall be attached to each lead wire in the test station terminal block. Pipe lead wire shall be identified by pipe diameter and service, as a minimum. In the test station terminal block, remove and retain the solid brass jumper strap located between the anode lead wire(s) and Pipe Lead Wire 1. All test station lead wires should be initially terminated on individual lugs in the terminal block. Test station terminal block lugs should not be interconnected until directed during performance of Underground Piping Cathodic Protection System Tests. 13110.3.1.4 Exothermal Weld Connections. Exothermal weld connections shall be used to attach cathodic protection lead wire to protected ductile iron and steel structures where the minimum structure wall thickness is 0.145 inch (4 mm). Soldering and silver brazing shall be used to attach cathodic protection lead wires to protected copper and stainless steel structures, respectively. Exothermal weld connections shall be performed using weld molds, cable sleeves, and weld cartridges sized in accordance with the equipment manufacturer's recommendations. Completed welds shall be capable of withstanding moderate hammer blows. Porous or deformed welds shall be rejected. Exothermal weld connections shall not be covered until inspected by the Supplier. Following inspection, completed weld connections shall be covered with coating repair material as shown on the drawings. 13110.3.1.5 Aboveground Test Stations. Test stations shall be installed in a manner and at the locations indicated on the drawings and as specified herein. When a proposed test station location will interfere with the normal use of an area, the test station shall be relocated to a nearby protected location. 13110.3.1.6 Copper Sulfate Reference Electrodes. Reference electrodes shall be installed in a manner and at the locations indicated on the drawings and as specified herein. Reference electrodes shall be stored and maintained in a dry environment. Reference electrode storage temperature shall be continuously maintained above 32° F. Prior to installation, reference electrodes shall be activated by immersion in freshwater for a period of time prescribed by the manufacturer. 13110.3.1.7 Insulated Flange Kits. Insulated flange kits shall be installed in a manner and at the locations indicated on the drawings and as specified herein. Unless otherwise indicated, all insulated flange kits shall be installed above grade. Sufficient clearance shall be provided around the insulated flange to allow for maintenance and testing. Flange gasket seating surfaces shall be free from tool marks, scratches, pits, deposits, and other defects. Stud tensioning shall be performed using a torque wrench or other tensioning device such as a hydraulic wrench. Torque settings shall not exceed the maximum value specified by the insulated flange kit manufacturer. Insulated flange kits shall be installed as follows: 1. Inspect the gasket kits. Verify that the material is as specified and provided in a new and undamaged condition. Source: 15225, 2014, v2.0 General Service Pipe Page 87 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction 2. Clean the bolting materials. Apply lubricant or antiseizing compound to all threads required for engagement with nuts and nut facings. Bid Issue 2Mar2015 3. Align flange faces so that they are parallel and concentric with each other within 0.010 inch without external loading or springing. 4. Line up bolt holes by driving two tapered drift pins in opposite directions to each other into two diametrically opposite bolt holes. 5. Insert insulating sleeves into the bolt holes. If they do not slide in easily, the flanges are not lined up properly. Do not force sleeves into bolt holes as sleeve damage may result. 6. Assemble the studs (or bolts) as follows: a. Run one nut on each stud so that two full threads are showing beyond the nut. b. Slide a steel washer onto stud and insert into bolt hole. (If the flange requires two sided insulation, add an insulating washer after the steel washer.) c. From the opposite end of the stud, place an insulating washer, a steel washer, and then a nut. Hand tighten. 7. Torque studs to a maximum of 30 percent of the final torque value specified. Replace the two drift pins with stud assemblies. Torque the remaining studs to 30 percent of the final torque value in a star pattern sequence. 8. Repeat steps in Procedure 7, increasing the torque to approximately 60 percent to 80 percent of the final torque value. 9. Continue torquing all studs in the sequence using the specified torque setting (100 percent) until there is no further rotation of nuts. 13110.3.1.8 Cast Magnesium Anodes. Cast magnesium anodes shall be installed as indicated on the drawings. 13110.3.2 Testing After installation of all cathodic protection equipment is complete, field testing shall be performed to evaluate and document the cathodic protection system performance. Insulated flanges shall not be disassembled or reworked after final testing. 13110.3.2.1 Test Equipment. 8 inch saturated copper-copper sulfate solution portable reference electrode, M. C. Miller Model RE7, available from the M. C. Miller Co. Inc., Ringwood, New Jersey; or acceptable equal. The reference electrode copper rod shall be cleaned and the reference electrode shall be charged with a saturated copper-sulfate solution within 30 days of test performance. High input impedance dc voltmeter, Fluke Model 87 handheld multimeter available from John Fluke Mfg. Co., Everett, Washington; or acceptable equal. High frequency flange insulation tester, Gas Electronics Model 601 available from M. C. Miller Co. Inc, Ringwood, New Jersey. Source: 15225, 2014, v2.0 General Service Pipe Page 88 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Miscellaneous flexible test leads as required. 13110.3.2.2 Test Procedures. Procedures for testing system components shall be as described herein. Test data shall be recorded and submitted to the Purchaser. Electrical isolation of cathodically protected piping is a prerequisite for performance of the cathodic protection system. Electrical isolation of all mechanical and electrical connections to the cathodically protected piping shall be completed prior to testing the cathodic protection system. Insulated flange testing shall be performed using the high frequency tester specified. Prior to testing, calibrate and "zero" the insulation tester as recommended by the manufacturer. When properly calibrated and ready to use, the instrument meter should be deflected to full scale. Firm metal-to-metal contact should be established between each instrument probe and flange face across the insulator being tested. The instrument meter should be observed. An effective insulator is indicated if the instrument meter remains deflected to full scale. Any deflection less than full scale indicates a shorted insulator. Electrical insulation tests shall be performed at 6 inch (150 mm) intervals around the circumference of the insulated flange. Failure of the insulation test at any location around the circumference shall qualify as a failed insulator. Failed insulators may result from deficient installation of the flange gasket or one or more of the associated flange bolts. Defective components shall be identified and replaced by the Supplier. Underground Piping Cathodic Protection System Test Procedure  Testing shall be performed using a Fluke Model 87 handheld multimeter. Alligator clip type multimeter lead wires shall be connected to the specified test station terminals. Personnel shall not contact multimeter lead wires or test station terminals while measuring dc voltage and current values. Test Procedures 1 through 6 shall be performed in sequence, as follows: Tests 1 and 2 shall be performed to measure “native” pipe-to-soil potentials. These tests shall be performed before any anodes are jumpered to pipe lead wires in the field test stations. Test 1: Set the multimeter to the dc volts (V) scale. Connect the positive terminal (V Ω) multimeter test lead wire to the Pipe Lead Wire 1 lug in the test station terminal block. Connect the negative terminal (COM) multimeter test lead wire to the reference electrode lead wire lug in the test station terminal block. Observe and record the dc voltage and polarity (should be negative) displayed by the multimeter. Test 2: Set the multimeter to the dc volts (V) scale. Connect the positive terminal (V Ω) multimeter test lead wire to the Pipe Lead Wire 2 lug in the test station terminal block. Connect the negative terminal (COM) multimeter test lead wire to the reference electrode lead wire lug in the test station terminal block. Observe and record the dc voltage and polarity (should be negative) displayed by the multimeter. In the test station terminal block, verify that the solid brass jumper strap located between the anode lead wire(s) and Pipe Lead Wire 1 is removed. All test station lead wires should now be terminated on individual lugs in the terminal block. Test station terminal block lugs should not be interconnected. Source: 15225, 2014, v2.0 General Service Pipe Page 89 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction Test 3: Set the multimeter to the dc volts (V) scale. Connect the positive terminal (V Ω) multimeter test lead wire to the anode lead wire lug in the test station terminal block. Connect the negative terminal (COM) multimeter test lead wire to the reference electrode lead wire lug in the test station terminal block. Observe and record the dc voltage and polarity (should be negative) displayed by the multimeter. Bid Issue 2Mar2015 Test 4: Set the multimeter to the dc milliamperes (mA/A) scale. Connect the positive terminal (mA μA) multimeter test lead wire to the Pipe Lead Wire 1 lug in the test station terminal block. Connect the negative terminal (COM) multimeter test lead wire to the anode lead wire lug in the test station terminal block. Observe and record dc milliamperes and polarity (should be positive) displayed by the multimeter. Test 5: Set the multimeter to the dc milliamperes (mA/A) scale. Connect the positive terminal (mA μA) multimeter test lead wire to the Pipe Lead Wire 2 lug in the test station terminal block. Connect the negative terminal (COM) multimeter test lead wire to the anode lead wire lug in the test station terminal block. Observe and record dc milliamperes and polarity (should be positive) displayed by the multimeter. After completion of Test 5, replace the solid brass jumper strap between the anode lead wire(s) and Pipe Lead Wire 1. Test 6: Set the multimeter to the dc volts (V) scale. Connect the positive terminal (V Ω) multimeter test lead wire to the Pipe Lead Wire 2 lug in the test station terminal block. Connect the negative terminal (COM) multimeter test lead wire to the reference electrode lead wire lug in the test station terminal block. Observe and record the dc voltage and polarity (should be less than -0.850 volt) displayed by the multimeter. Test Station Number Below Grade Pipeline Code Test 1 Native PTS Potential, Pipe Lead Wire 1 (Volts) Test 2 Native PTS Potential, Pipe Lead Wire 2 (Volts) Source: 15225, 2014, v2.0 Test 3 Anode Open Circuit Potential (Volts) Test 4 Anode Current Output, Pipe Lead Wire 1 (mA) General Service Pipe Test 5 Anode Current Output, Pipe Lead Wire 2 (mA) Test 6 Protected PTS Potential, Pipe Lead Wire 2 (Volts) CP System No. Page 90 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 15225 - General Service Pipe 15225.1 General 15225.1.1 Scope of Supply Scope of supply shall include furnishing materials for non-boiler external piping systems as indicated in the attachments listed in Article 15225.1.8. Materials shall include straight lengths of pipe, fittings, flanges, and unions. Gaskets and flange bolting materials shall be furnished if indicated in the attachments. Special welding adapters shall be furnished if indicated in the attachments. If the general service pipe to be furnished under this specification is part of the scope of the work under a larger procurement package to be designed and furnished by the Supplier, the scope of piping and accessories to be furnished will be determined by Supplier's overall design. 15225.1.1.1 Pipeline List or Pipe Class. The Pipeline List or Pipe Class, if included, specifies the operating and design conditions and types of pipe to be used with each piping system. The Pipeline List or Pipe Class designates the pipeline identification code; line description; operating, design, and test pressures and temperatures; pipe material, nominal sizes, and corresponding schedule or wall thickness; valve class rating, end preparation requirements, and material; insulation class; remarks; and special features. 15225.1.1.2 Quantity Spreadsheet. The quantity spreadsheet, if included, is a bill of quantities or other spreadsheet listing the quantities to be furnished for each type, size, and material of piping component. It may also serve as the instrument by which the Supplier submits proposed total pricing and unit pricing information, if so indicated in Article 15225.1.8. If the bill of quantities shows a zero quantity for a given component, the item is included only for the securing of a unit price against possible future need. 15225.1.1.3 Piping Isometric Drawings. Piping isometric drawings, if included, indicate the routing of the piping systems for which materials are to be furnished under this Contract. The Supplier shall use the isometric drawings to determine the quantities of straight lengths of piping, fittings, flanges, gaskets, bolting, etc., required for each system. 15225.1.1.4 Plan and Section Drawings. Plan and section drawings, if included, indicate the routing of piping for which materials are to be furnished under this Contract. The Supplier shall use the plan and section drawings to determine the quantities of straight lengths of piping, fittings, flanges, gaskets, bolting, etc., to be furnished for each section of pipeline. 15225.1.1.5 Piping and Instrument Diagrams/Flow Diagrams. Piping and instrument diagrams or flow diagrams, if included, indicate the materials and line sizes of piping systems for which materials are to be furnished under this Contract. 15525.1.1.6 Additional Scope. Welding rod and other associated consumables for welded joint piping systems furnished Yes 15225.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this scope of supply include the following: Instrument piping and all instruments except as otherwise indicated. 15225.1.3 Performance and Design Requirements Performance and design requirements for the general service pipe to be furnished under this section of these specifications are as follows: Source: 15225, 2014, v2.0 General Service Pipe Page 91 of 280 Calaveras Coal Yard 186144.77.1000 Acceptable Types of Pipe Bid Issue 2Mar2015 Compressed Air Equipment Construction ASTM A106 Grade B (above ground) 31CC2X ASTM A312, Type 304 (buried) 31SANX Coatings Data Sheet 81113-DM-0667 81113-DM-0667 81113-DM-0665 Coatings System Data Sheets – System 1112 Coatings System Data Sheets – System 3301 Coatings System Data Sheets – System 3311 15225.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Materials for piping and application of piping materials The most current edition of the ASME Code for Pressure Piping, B31.1, Power Piping, including all addenda thereto Sizes, schedule numbers, and dimensions of carbon steel and alloy steel pipe, and stainless steel pipe schedules not covered by ANSI B36.19M ANSI/ASME B36.10M Sizes and dimensions of stainless steel pipe designated as Schedule 10S, 40S, or 80S ANSI/ASME B36.19M Wall thickness tolerances for carbon steel and alloy steel pipe ASTM A530 Manufacturing standard for mechanical joint and push-on joint ductile iron pipe Manufacturing standard for flanged ductile iron pipe ANSI/AWWA C151/A21.51 ANSI/AWWA C115/A21.15 Polyethylene tubes for protection of ductile iron pipe that will be installed underground ANSI/AWWA C105/A21.5 Cement linings for ductile iron pipe ANSI/AWWA C104/A21.4 Manufacturing standards for plastic lined pipe and fittings Polypropylene (PP) lining Source: 15225, 2014, v2.0 ASTM F492 General Service Pipe Page 92 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Work In Accordance With Polyvinylidene fluoride (PVDF) lining ASTM F491 Polytetrafluoroethylene (PTFE) lining ASTM F423 Manufacturing standard for polyvinyl chloride (PVC) pipe ASTM D1785 Manufacturing standard for chlorinated polyvinyl chloride (CPVC) pipe ASTM F441 (Schedules 40 and 80) or ASTM F442 (SDR and PR) High density polyethylene (HDPE) pipe ASTM F714 Butt weld fitting manufacturing standard ANSI/ASME B16.9 and ANSI/ASME B16.28 Socket-weld and threaded forged steel fittings manufacturing standard and minimum pressure class ratings ANSI/ASME B16.11 Carbon steel flanged fittings ANSI B16.5 Steel castings for pipe system components In accordance with Technical Supplemental Specification Q400 Cast iron fittings for use with plastic lined or rubber lined pipe ANSI B16.1, Class 125 Ductile iron fittings for use with plastic lined or rubber lined pipe ANSI/AWWA C110/A21.10 Welding adapters Paragraph 104.3 of ANSI/ASME B31.1 Manufacturing standard for cast iron fittings for use with lined steel pipe ANSI B16.1 Manufacturing standard for ductile iron fittings for use with lined steel pipe ANSI/AWWA C110/A21.10 Manufacturing standard for cast iron and ductile iron flanged fittings ANSI/AWWA C153/A21.53 Manufacturing standards for mechanical joint and push-on joint ductile iron and cast iron fittings ANSI/AWWA C153/A21.53 and ANSI/AWWA C111/A21.1 Petroleum asphaltic coatings for cast iron and ductile iron pipe fittings ANSI/AWWA C153/A21.53 Cement linings for cast iron and ductile iron pipe fittings ANSI/AWWA C104/A21.4 PVC fittings ASTM D2466 or ASTM D2467 corresponding to the pipe schedule with which they will be used CPVC fittings ASTM F438 or ASTM F439 corresponding to the pipe schedule with which they will be used Source: 15225, 2014, v2.0 General Service Pipe Page 93 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Work In Accordance With Socket weld fittings for use with stainless steel tubing ANSI B16.11 Braze joint fittings for use with copper tubing ANSI B16.22 Steel flange construction requirements ANSI/ASME B16.5 Cast iron and ductile iron flange construction requirements ANSI/AWWA C115/A21.15 Compressed fiber gaskets and elastomeric gaskets ANSI B16.21 Ring joint gaskets ANSI B16.20 Flange bolting requirements - alloy steel bolting ANSI/ASME B16.5 Flange bolting requirements - carbon steel bolting ANSI B16.1 Carbon steel bolting dimensional standards ANSI B18.2.1 and ANSI/ASME B18.2.2 Cleaning interior surface of carbon steel pipe The Society for Protective Coatings (SSPC) Abrasive shot blast cleaning The Society for Protective Coatings (SSPC) and PFI Standard ES-29 (sand or silica bearing blasting materials are not allowed) Piping and materials used for potable water service NSF 61 15225.1.5 Materials The following materials shall be used: Component Material Steel pipe Carbon steel ASTM A106 Grades A, B, C; ASTM A53 Type S Grades A or B; ASTM A53 Type E Grade B; ASTM A134 Grades A283 A, B, C, D and A285 A, B, C; ASTM A139, Grade B; ASTM A333; API 5L Grade B seamless, Schedule 40 minimum for 2 inch (50 mm) and smaller, or as indicated on attachment(s) Nickel alloy steel ASTM B464-UNS 08020 Other alloy steel As indicated on attachment(s) Stainless steel Source: 15225, 2014, v2.0 General Service Pipe Page 94 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Material 304 stainless steel ASTM A312, Type 304 or 304L, Schedule 10S minimum for 2 inch (50 mm) and smaller, or as specified on attachment(s) 316 stainless steel ASTM A312, Type 316 or 316L, Schedule 10S minimum for 2 inch (50 mm) and smaller, or as specified on attachment(s) Ductile iron pipe push-on joint gaskets Neoprene or other synthetic rubber. Natural rubber will not be acceptable. Steel pipe to be lined with PP, PVDF, PTFE, or rubber ASTM A53 for pipe sizes greater than 8 inch (200 mm); ASTM A587 for pipe sizes 8 inch (200 mm) and smaller PP lining material ASTM D2146 PVDF lining material ASTM D3222 PTFE lining material ASTM D1457 Rubber lining material Synthetic rubber which does not contain polyisoprene or other substances subject to biological attack PVC pipe ASTM D1785, Cell Class 12454-B HDPE pipe ASTM D3350, with a cell classification of 345434C AWWA C906 (fire water mains) Copper tubing Oxygen free copper, UNS No. C10800 or phosphorus deoxidized copper, UNS No. C12200 Copper tubing for use with flareless bite type fittings ASTM B75 Copper tubing for use with braze joint fittings ASTM B88, Type K Copper tubing for use with Viega ProPress® System ASTM B88, Type K Stainless steel tubing ASTM A213, fully annealed Type 316 with carbon content greater than 0.04 percent Cast iron fittings for use with plastic lined or rubber lined steel pipe ASTM A126, Class A or B, lined with lining material equivalent to that of the pipe Ductile iron fittings for use with plastic lined or rubber lined steel pipe ASTM A395, lined with lining material equivalent to that of the pipe Carbon steel flange material standards, ANSI Pressure Classes 150 and 300 ASTM A181/A181M or ASTM A105/A105M Carbon steel flange material standards, ANSI Pressure Class 600 and higher ASTM A105/A105M Source: 15225, 2014, v2.0 General Service Pipe Page 95 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Component Material Chromium alloy and stainless steel flange material standards (all ANSI pressure classes) ASTM A182/A182M Carbon and alloy steel butt weld fitting material standards ASTM A234/A234M Stainless steel butt weld fitting material standards ASTM A403/A403M Bid Issue 2Mar2015 Alloy steel bolting materials for use with piping with design temperatures of 800° F and above Studs ASTM A193/A193M Grade B16 ASME SA-193/SA-193M Grade B16 Nuts ASTM A194/A194M Grade 3 ASME SA-194/SA-194M Grade 3 Alloy steel bolting materials for use with piping with design temperatures less than 800° F Studs ASTM A193/A193M Grade B7 ASME SA-193/SA-193M Grade B7 Nuts ASTM A194/A194M Grade 2H ASME SA-194/SA-194M Grade 2H High-strength stainless steel bolting materials Studs ASTM A453/A453M, Grade 660 ASME SA-453/SA-453M, Grade 660 Nuts ASTM A453/A453M Grade 660 ASME SA-453/SA-453M Grade 660 Low-strength stainless steel bolting materials Studs ASTM A193/A193M Grade B8M ASME SA-193/SA-193M Grade B8M Nuts ASTM A194/A194M Grade 8M ASME SA-194/SA-194M Grade 8M Carbon steel bolting materials Studs ASTM A307 Grade B ASME SA-307 Grade B Nuts ASTM A563 Grade B ASME SA-563 Grade B Bolt coating (applies to alloy, stainless steel, and carbon steel bolting) Piping design temperatures of 450° F and above Source: 15225, 2014, v2.0 No coating General Service Pipe Page 96 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Material Piping design temperatures less than 450° F PTFE coating Bolt plating (applies to alloy and carbon steel bolting Piping design temperatures of 450° F and above No plating Piping design temperatures less than 450° F Cadmium plating in accordance with ASTM B766 or zinc plating in accordance with ASTM A153 Nonmetallic flanges without backing ring Follow nonmetallic flange manufacturer’s recommendation Stainless steel Victaulic Vic-Press® fittings material standards ASTM A312, Type 304/316 Copper Viega Pro-Press® fittings material standards ASTM B88, Type K 15225.1.6 Approved Manufacturers of Components For the following components, only the listed manufacturers are recognized as maintaining the level of quality of workmanship required by these specifications. If the Supplier wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Purchaser: Component Manufacturer PP lined, PVDF lined, and PTFE lined pipe and fittings Dow Chemical Company Resistoflex Corporation Peabody Dore Rubber lined pipe and fittings Dow Chemical Company FRP pipe and fittings Centrifugally cast Fibercast Company - Fibercast Filament wound Ameron Corrosion Control Division Bondstrand Reinforced Plastics Systems Inc. - ABCO Plastics Division Smith Fiberglass Products Inc. Fibercast Company - Fibercast HDPE pipe and fittings Factory Mutual (FM) approved Source: 15225, 2014, v2.0 Phillips Petroleum Company - Driscopipe 1000 FM Class 200 Amsted Industries - Plexco EHMW - Class 200 - FM Bluestripe - Class 200 - FM Redstripe - Class 200 - FM Poly Systems Incorporated, KWH Class 200 General Service Pipe Page 97 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Manufacturer Non-FM applications Phillips Petroleum Company - Driscopipe 1000 Amsted Industries - Plexco PE 3408 Poly Systems Incorporated, KWH Sclairpipe Nickel alloy steel pipe Carpenter Steel Company - Carpenter 20Cb-3 pipe Tubing fittings Crawford Swagelok Parker Hannifin Integrally reinforced forged branch outlet fittings Bonney Forge WFI Compressed fiber gaskets Richard Klinger, Inc. - Klingersil Garlock, Inc. - Blue-Gard Spiral wound gaskets Flexitallic Gasket Company Garlock Spiral wound gasket filler Flexitallic Gasket Company - Flexite Super Garlock Cloth inserted elastomeric gaskets Manville Stainless steel pressed fit fittings Victaulic Vic-Press® system Copper pressed fit fittings Viega ProPress® system Abrasive blast cleaning media Ervin Industries, AMASTEEL Cast Steel Abrasives 15225.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Supplier is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By Testing of mechanical joint and push-on joint ductile iron pipe ANSI/AWWA C151/A21.51 Supplier Source: 15225, 2014, v2.0 General Service Pipe Page 98 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Tests In Accordance With Conducted By Hydrotests of piping components, except as provided for in the above referenced standard for ductile iron pipe, are not required as part of the piping material supply, but may be required as part of piping erection Work if included in this Contract. N/A N/A Bid Issue 2Mar2015 15225.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 15225.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 15225.2 Products 15225.2.1 Piping Material Requirements All pipe shall be in accordance with the applicable codes and standards designated in Article 15225.1.4 and the attachments thereto. Except as otherwise specified, schedule numbers, sizes, and dimensions of piping shall conform to the applicable standards specified in Article 15225.1.4. Material substitutions, except as specified on the attachments listed in Article 15225.1.8, shall not be made without written approval by the Purchaser. 15225.2.1.1 Steel Pipe. Carbon steel and alloy steel pipe shall be ungalvanized seamless type unless otherwise specified. Steel plate piping, where allowed by these specifications, shall be of the straight seam welded type unless otherwise specified. 15225.2.1.2 Ductile Iron Pipe. Ductile iron pipe shall be of the mechanical joint or restrained push-on joint type as indicated on the attachments listed in Article 15225.1.8. Unless otherwise specified, interior surfaces of ductile iron pipe shall be cement lined. Unless otherwise specified, the exterior surface of all ductile iron pipe shall be coated before shipment with a bituminous material. Ductile iron piping systems shall be provided with restrained mechanical joints. Where specified on the attachments listed in Article 15225.1.8, polyethylene tubes shall be furnished by the Supplier as required to allow field wrapping of buried ductile iron pipe in accordance with ANSI/AWWA C105/A21.5 Method A. 15225.2.1.3 Pipe Lined with Plastic or Rubber. Pipe to be lined with plastic or rubber shall be steel pipe of the material specified in Article 15225.1.5 and of the schedule either specified in the attachment(s) or as required by Supplier's overall design. Lined pipe shall have flanged connections, an applied liner of the specified material, and molded raised face joints. Flanges shall be Class 150 forged steel flat faced slip-on or socket-weld type, or Class 150 ductile iron flat faced. Source: 15225, 2014, v2.0 General Service Pipe Page 99 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Plastic lining materials shall be as specified in Article15225.1.5. The Supplier shall submit information on rubber lining materials and rubber lining application methods for the Purchaser's acceptance. Lined pipe shall be shop fabricated and lined. 15225.2.1.4 Fiberglass Reinforced Plastic Pipe. Not Used. 15225.2.1.5 High Density Polyethylene Pipe. Not Used. 15225.2.1.6 Polyvinyl Chloride Pipe. Not Used. 15225.2.1.7 Chlorinated Polyvinyl Chloride Pipe. Not Used. 15225.2.2 Tubing Tubing for instrument compressed air service shall be in accordance with Technical Supplementals in 21000. The following tubing requirements do not apply for compressed air service. Copper tubing 3/4 inch and smaller for use with flareless grip type tubing fittings shall be light drawn temper tubing conforming to the material specification indicated in Article 15225.1.5. All light drawn copper tubing smaller than 3/4 inch for use in instrument air service shall be shipped to the jobsite in coils of at least 50 foot length and shall be dehydrated and sealed. Copper tubing 1 inch and larger, and short instrument drop runs of 3/4 inch and 1/2 inch tubing, for use with braze joint fittings, shall conform to the material specification in Article 15225.1.5. The tubing shall be in lengths of at least 10 feet and shall be capped at both ends. Copper tubing shall conform to the material specifications included in Article 15225.1.5. Oxygen bearing tough pitch copper tubing shall not be substituted. Stainless steel tubing shall conform to the material specification indicated in Article 15225.1.5. Stainless steel tubing for use with tubing fittings shall not exceed Rockwell B80 hardness. Wall thickness for tubing 3/4 inch and smaller shall not be less than the following. The thicknesses indicated are the minimum acceptable: Wall Thickness, in. Outside Diameter of Tubing, in. Copper, ASTM B75 Stainless Steel 1/4 0.030 (0.762) 0.035 3/8 0.049 (1.245) 0.065 1/2 0.065 0.065 5/8 0.083 0.095 3/4 0.109 0.109 Wall thickness of Type K copper tubing shall be in accordance with ASTM B88. Source: 15225, 2014, v2.0 General Service Pipe Page 100 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 15225.2.3 Fittings If a quantity list is included as a part of this specification, fittings shall be constructed of materials indicated on the list. If the Supplier determines that the fittings are to be furnished based on pipe routing and piping system design conditions, the materials for pipe fittings shall be equivalent to the material of the pipe with which they are used, except that plastic or rubber lined cast iron or ductile iron fittings shall be used with plastic or rubber lined steel pipe, as indicated on the attachment(s). 15225.2.3.1 Steel Fittings. Unless otherwise indicated on the attachment(s), steel fittings 2-1/2 inches and larger shall be butt welding type and steel fittings 2 inches and smaller shall be socket welding type. Butt Welding Fittings. Butt welding fitting wall thicknesses shall be equal to the pipe wall thickness with which they are used. Fittings shall be manufactured in accordance with the applicable standards listed in Article 15225.1.4. Unless otherwise indicated on the drawings, elbows shall be of the long radius type and conform to the applicable standards listed in Article 15225.1.4. Forged Steel Fittings - Socket-Welded and Threaded. Forged steel fittings shall be used for socketwelded and threaded connections. Socket-welded and threaded fittings shall conform to the applicable standards listed in Article 15225.1.4. Metal thicknesses of fittings shall be adequate to provide actual bursting strengths equal to or greater than those of the pipe with which they are to be used. Minimum pressure class rating of socket-welded and threaded fittings shall be in accordance with the applicable standard listed in Article 15225.1.4. Integrally Reinforced Forged Branch Outlet Fittings. Specially designed integrally reinforced forged branch outlet fittings shall be furnished if so indicated on the attachment(s). For piping systems designed and routed by the Supplier, specially designed integrally reinforced forged branch outlet fittings (weldolets or sweepolets) may be furnished in lieu of reducing outlet tees when the main run pipe wall thickness does not exceed 3/4 inch. Unless otherwise specified, all branch connections 2 inches and smaller shall be made with specially reinforced welding adapters, sockolets (SOL), or threadolets (TOL). These adapters shall be integrally reinforced forged branch outlet fittings. Integrally reinforced forged branch outlet fittings shall be manufactured by a manufacturer listed in Article 15225.1.6. Stainless Steel Pressed Fittings. Stainless steel pressed fittings shall conform to the standards listed in Article 15225.1.4 and Article 15225.1.5. O-rings for pressed fittings shall be suitable for potable water, compressed air and water service. Copper Pressed Fittings. Copper pressed fittings shall conform to the standards listed in Article 15225.1.4 and Article 15225.1.5. Seals and gaskets for pressed fittings shall be suitable for compressed air service. 15225.2.3.2 Plastic or Rubber Lined Ductile Iron Fittings. Ductile iron fittings for use with lined steel pipe shall be flanged fittings. The lining material shall be the same as that specified for the pipe. 15225.2.3.3 Plastic Lined Piping System Spacers. PP spacers shall be used as recommended by the manufacturer. An adequate supply of extra PP spacers shall be supplied to compensate for normal fabrication and erection tolerances. 15225.2.3.4 Fiberglass Reinforced Plastic Fittings. Fittings for use with FRP pipe shall have cementing type joints. Source: 15225, 2014, v2.0 General Service Pipe Page 101 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 15225.2.3.5 High Density Polyethylene Fittings. Fittings for HDPE piping systems shall have pressure ratings equivalent to the straight pipe sections with which they will be used. Fittings shall be of the molded or mitered type as indicated on the drawings. If not indicated on drawings, fittings shall be molded type unless otherwise accepted by the Engineer. Fittings shall be of the butt fusion weld, socket fusion weld, or saddle type as recommended by the pipe manufacturer for the point of application within the system. 15225.2.3.6 Polyvinyl Chloride Fittings. PVC pipe fittings shall have socket ends with internal shoulders designed for solvent cementing and shall conform to the standards referenced in Article 15225.1.4. 15225.2.3.7 Chlorinated Polyvinyl Chloride Fittings. CPVC pipe fittings shall have socket ends with internal shoulders designed for solvent cementing and shall conform to the standards referenced in Article 15225.1.4. 15225.2.3.8 Ductile Iron Fittings. Fittings shall conform to the standards listed in Article 15225.1.4. Except as otherwise specified, interior surfaces of ductile iron pipe fittings shall be cement lined. Except as otherwise specified, the exterior surfaces of all ductile iron pipe fittings shall be coated with a bituminous material. 15225.2.3.9 Tubing Fittings. Brass fittings shall be used with ASTM B75 copper tubing and shall be of the flareless grip type. Braze joint fittings shall be used with ASTM B88 Type K copper tubing and shall be wrought oxygen free or phosphorus deoxidized copper, bronze, or brass. Stainless steel fittings shall be used with stainless steel tubing. Fittings for use with stainless steel tubing in sizes smaller than 3/4 inch (20 mm) shall be of the flareless grip type, and fittings for use with tubing in sizes 3/4 inch (20 mm) and larger shall be socket-weld type. Fitting material and bursting strength shall be equivalent to the tubing with which they are used. 15225.2.4 Flanges Flanges shall conform to applicable standards indicated in Article 15225.1.4. Unless otherwise specified, flanges shall be as follows: For the case where the Supplier determines flanges to be furnished based on attached drawings or based on the Supplier's overall design, flanges mating with flanges on piping, valves, and equipment shall be of sizes, drillings, and facings that match all connecting flanges. Flange class ratings shall be adequate to meet the design pressure and temperature specified in the attachment(s) for the piping with which they are used. Flange materials shall be equivalent to the pipe with which they are used. 15225.2.4.1 Steel Flanges. All steel flanges 2-1/2 inches and larger shall be of the weld neck type and all steel flanges 2 inches and smaller shall be of the socket type-except as indicated on the attachment(s). Steel flanges shall have raised face flange preparation-except as specified otherwise herein. Flat face flanges shall be used to mate with cast iron, ductile iron, FRP, PVC, CPVC, and plastic or rubber lined flanges. All steel flanges shall conform to the design and manufacturing standards and the material specifications indicated in Article 15225.1.5. Source: 15225, 2014, v2.0 General Service Pipe Page 102 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 15225.2.4.2 Spectacle Flanges. Unless otherwise specified, the spectacle flanges shall be constructed of materials equivalent to the flanges with which they are used and shall be suitable for the pressure class rating of the mating flanges. 15225.2.5 Gaskets Gaskets shall be furnished if so indicated on the attachment(s). Unless otherwise specified, elastomeric or compressed fiber gaskets shall be used with flat face flanges. Compressed fiber gaskets shall be used for slip-on raised face flanges and ANSI CL 150 socketwelded raised face flanges. Spiral wound gaskets shall be used with all raised face flanges other than slip-on or ANSI CL 150 socketwelded flanges. Gaskets are not required for lined pipe-to-lined pipe connections unless otherwise recommended by the manufacturer. Gaskets containing asbestos are not acceptable. 15225.2.5.1 Compressed Fiber Gaskets. Compressed fiber gasket materials shall be suitable for a maximum working pressure of 600 psi (and a maximum working temperature of 750 F. Gaskets shall be dimensioned to suit the contact facing. They shall be full faced for flat face flanges and shall extend to the inside edge of the bolt holes on raised face flanges. Gaskets for plain finished surfaces shall be not less than 1/16 inch thick and for serrated surfaces shall be not less than 3/32 inch thick. 15225.2.5.2 Spiral Wound Gaskets. Spiral wound gaskets shall be constructed of a continuous stainless steel ribbon wound into a spiral with nonasbestos filler between adjacent coils. The gasket shall be inserted into a steel gauge ring whose outside diameter shall fit inside the flange bolts properly positioning the gasket. The gauge ring shall serve to limit the compression of the gasket to the proper value. Compressed gasket thickness shall be 0.130 inch ±0.005 inch. 15225.2.5.3 Elastomeric Gaskets. Elastomeric gasket materials shall be cloth inserted sheet elastomer. They shall be full face and 1/16 inch thick unless otherwise specified. Elastomeric gaskets shall be used for temperatures up to 150 °F and EPDM type elastomeric gaskets for temperatures up to 215 °F. 15225.2.6 Bolting Flange bolting shall be furnished if so indicated on the attachments listed in Article 15225.1.8. Alloy steel bolting shall be used for joining all raised face, weld neck, alloy or carbon steel flanges when used in conjunction with spiral wound gaskets, regardless of the design pressure rating of the flanges. Carbon steel bolting may be used with raised face, weld neck, alloy or carbon steel flanges of Class 150 design pressure rating, provided that compressed fiber gaskets are used, but alloy steel bolting is acceptable as well. In general, carbon steel bolting should be used with all other flanges not constructed of stainless steel or “exotic” materials. Examples would include steel slip-on flanges, threaded steel or iron flanges, flanged connections making use of elastomeric gasketing, backing rings for HDPE piping joints, etc. Alloy steel bolting may be used in lieu of carbon steel bolting in these cases as long as appropriate torquing procedures and values are utilized to ensure that the flanges, gaskets, and flange-topipe joints are not damaged by over-tightening. High strength stainless steel bolting shall be used for all raised face, weld neck stainless steel flanges when used in conjunction with spiral wound gaskets, regardless of the design pressure rating of the flanges. Low-strength stainless steel bolting may be used with raised face, weld neck stainless steel flanges of Class 150 design pressure rating, provided that compressed fiber gaskets are used, but high strength stainless steel bolting is acceptable as well. In general, low strength stainless steel bolting should be used for all other stainless steel flanges. Stainless steel bolting may also be appropriate for flanges constructed of nickel based alloys or “exotic” materials. Examples of such materials would include Inconel, Alloy 20, C276, titanium, etc. Bolting for bolt diameters 1-3/4 inches (45 mm) and larger shall consist of threaded studs and two nuts. Bolting for bolt diameters less than 1-3/4 inches (45 mm) may be threaded studs and nuts or bolts and Source: 15225, 2014, v2.0 General Service Pipe Page 103 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 nuts. Bolts and nuts shall be heavy hexagonal heads conforming to the standards listed in Article 15225.1.4. All bolting shall be plated in accordance with the material specifications indicated in Article 15225.1.5. 15225.2.7 Unions All piping unions shall be of the ground joint type constructed of materials equivalent in alloy composition and strength to other fittings in the piping systems in which they are installed. Union pressure classes and end connections shall be the same as the fittings in the piping systems in which they are installed. Steel unions shall have hardened stainless steel seating surfaces on both faces. 15225.2.8 Coating and Wrapping of Pipe To Be Installed Underground Exterior surfaces of carbon and stainless steel pipe to be installed underground shall be provided with a shop applied fusion bonded epoxy (FBE). No coating shall be applied within 4 inches of field weld connections. Underground carbon and stainless steel pipe and fittings shall be provided with the CSA 245.20, shop applied, FBE coating system 3M Scotchkote 206N. Except as specified otherwise herein, all pipe surface preparation, material, coating application, inspection, and repairs for the shop applied FBE coating system; and marking, handling, storage, and shipping of the coated pipe shall be in accordance with Canadian Standard Association Standard Z245.20-98, or latest revision for all steel piping. FBE coating thickness shall be 14 mils minimum, 16 mils average, and 20 mils maximum. Polyethylene compatible adhesive tape shall also be furnished by the Supplier as required. 15225.2.9 Cleaning Interior and exterior surfaces of all piping shall be thoroughly cleaned of sand, mill scale, greases, oils, dirt, and other foreign materials. 15225.2.9.1 Interior Cleaning. Interior surfaces of all piping shall be cleaned in accordance with the Cleaning Code specified for fabrication on the Pipeline List or Pipe Class (if included) and as described in the applicable standards indicated in Article 15225.1.4. Interior surfaces specified to be prepared in accordance with Cleaning Code SP3 shall be cleaned with rotary tools or wire brushing as described in Society for Protective Coatings (SSPC) SSPC-SP 3, Power Tool Cleaning. All interior surfaces shall be thoroughly cleaned. The Supplier may perform a SSPC-SP-6 blasting in lieu of the specified SP3 rotary tool and wire brushing cleaning. Interior surfaces specified to be prepared in accordance with Cleaning Code CP6 shall be thoroughly shotblast cleaned as described in SSPC-SP 6, Commercial Blast Cleaning, using a nonsiliceous steel blasting material as described in SSPC-AB 3. Use of sand or silica bearing material on these surfaces is not acceptable, and shall result in the rejection of the piping by the Purchaser. Nonsteel blasting materials, (e.g., Black Beauty) that contain silica, shall not be used. Steel blasting material shall be confirmed by testing to contain not more than 1.2 percent complexed silica and no free silica by weight. After cleaning, interior surfaces of all piping shall be thoroughly air blown, coated in accordance with the specification, Pipeline List or Pipe Class, and sealed. Preservative coatings shall be applied within 4 hours of completion of cleaning or the pipe shall be recleaned. Interior surfaces specified to be prepared in accordance with Cleaning Code SP8 shall be thoroughly cleaned by immersion in hot alkaline cleaning solution or by alkaline steam jet cleaning. Refer to SSPCSP 8, Pickling, Article 5.2.2. After cleaning, the pipe shall be immersed in hot dilute hydrochloric or Source: 15225, 2014, v2.0 General Service Pipe Page 104 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 sulfuric acid to which a suitable inhibitor has been added to prevent attack on the bare metal. The piping shall then be thoroughly rinsed for removal of acid and dried. After drying, an oil soluble rust preventive shall be applied as indicated on the spool drawings. Interior surfaces specified to be prepared in accordance with Cleaning Code NO require no special cleaning. The following requirements apply to the mechanical cleaning of austenitic stainless steel components: Mechanical cleaning entails the removal of debris, foreign articles, loose soil, unacceptable rust, etc., by grinding, brushing, vacuum cleaning, and similar processes. Wire brushing and grinding should not be performed on internal surfaces not accessible for hand cleaning and visual examination unless the item is completely free of crevices. Mechanical cleaning tools such as grinding, polishing, filing, deburring, and brushing tools shall be clean and shall not have been used on aluminum, copper, lead, or materials containing lead or lead compounds, or other low melting point materials. Stainless steel surfaces may be blast cleaned to remove heavy rust. Material used on stainless steel shall be clean and iron free. Tools and material used on carbon steel surfaces shall not be used on stainless steel surfaces. Filing and deburring shall be performed with carbide-tipped or tool-steel tools. Rotary files used on austenitic stainless steel shall be faced with tungsten carbide or titanium carbide. Wire brushes shall have stainless steel bristles and shall be identified and controlled for use on stainless steel only. Grinding of stainless steel shall be performed with resin bonded aluminum oxide or silicon carbide grinding wheels identified and controlled for use on stainless steel only. 15225.2.10 Coatings All carbon and alloy steel piping shall be coated as specified herein and in the Supplemental Specifications in Section 21000. Underground stainless steel piping shall be coated. 15225.2.10.1 Interior Surface Coatings. Protective coatings shall be furnished and applied to the interior surfaces of piping where specified on the attachments listed in Article 15225.1.8. Coating requirements for shop applied pipe interior coating systems shall be in accordance with Section 21000 and any Coating System Data Sheets referenced and included as attachments. Interior surfaces of all shotblast cleaned piping shall be thoroughly air blown, coated with water soluble preservative as specified on the drawings and in the Pipeline List or Pipe Class (if included), and sealed. Interior surfaces of all oil piping cleaned by the pickling method shall be coated with an oil soluble rust preservative as specified on the drawings and in the Pipeline List or Pipe Class (if included). 15225.2.10.2 Exterior Surface Coatings. Piping exteriors, parts, and appurtenances shall be prepared and coated in accordance with the following. All exposed surfaces shall be prime painted except for piping internals (including internal surfaces of branch connections), stainless steel, flange faces, threaded surfaces, external surfaces within 3 inches (80 mm) of field welded connections, and external surfaces of insulated pipe. Source: 15225, 2014, v2.0 General Service Pipe Page 105 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Piping shall be painted using the coating system that is specified on the drawings and in the Pipeline List or Pipe Class (if included). Painting shall be in accordance with Section 21000. 15225.2.10.3 Weld End Coatings. Machined weld end preparations for field welds on carbon and alloy steel piping shall be coated with a weldable consumable coating as specified on the drawings and in the Pipeline List or Pipe Class (if included) to prevent surface corrosion prior to welding. 15225.2.10.4 Flange Face/Threaded Connection Coating. Flange faces on shotblast cleaned pipe shall be given an application of a water soluble preservative coating as specified on the drawings and in the Pipeline List or Pipe Class (if included). Flange faces on piping cleaned by the pickling method shall be given an application of an oil soluble preservative coating as specified on the drawings and in the Pipeline List or Pipe Class (if included). 15225.2.11 Jointing Materials and Tools Where specified in Article 15225.1.1.6, the Supplier shall furnish welding rod, flux, solvent cement, or any other consumable materials required for proper erection of the pipe and fittings furnished under these specifications. Welding rod and related materials shall be in accordance with the Supplemental Specifications in Section 21000. Solvent cement and related materials shall be in accordance with the recommendations of the manufacturer of the pipe with which they will be used. The Supplier shall provide any special tools required for joining plastic or pressed fit pipe for the use of the erecting contractor. These tools shall remain the property of the Supplier and will be returned upon completion of erection. 15225.2.12 Preparation for Shipment Interior and exterior surfaces of piping and accessories shall be cleaned and shall have preservative coatings applied prior to shipment to the jobsite in accordance with the Supplemental Specifications in Section 21000. Open ends and branches of piping shall be securely closed as follows to protect the interior cleanliness and end surfaces during shipment: Weld end larger than 2 inches--Attach a plastic cap or metal cap lined in the end with 3/4 inch (20 mm) soft wood and seal with waterproof tape. Female opening 2 inches and smaller, such as Sock-o-let--Press in a light metal or plastic insert and seal with waterproof tape. Miscellaneous loose items shall be suitably packed in heavy wooden boxes with waterproof linings to prevent entry of dirt and moisture. 15225.3 Execution Piping erection shall be in accordance with the requirements of Section 15052 - Pipe Erection. Source: 15225, 2014, v2.0 General Service Pipe Page 106 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 15226 - Underground Pressure Piping 15226.1 Schedule of Submittals after Purchase Order Award The following documents or notices shall be required as deliverables upon Purchase Order Award: Submittal Item Schedule Copies of certified test and inspection reports/data 15 days after test or inspection Certified material test reports With each shipment Shipment notice and materials list 2 days before each shipment Hazardous materials documentation With each shipment and materials list Detailed final packing list With each shipment Storage and handling requirements 30 days before delivery of materials Manufacturer's data for piping materials and piping accessories 30 days after award Cutsheets with fabricated and molded fitting dimensions for HDPE pipe 15 days after award 15226.2 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. The version that is latest adopted, published, and effective at the date of this document shall apply unless specifically stated otherwise. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Materials for piping The most current edition of the ASME Code for Pressure Piping, B31.1, Power Piping, including all addenda thereto Sizes, schedule numbers, and dimensions of carbon steel pipe ANSI/ASME B36.10M Sizes, schedule numbers, and dimensions of stainless steel pipe ANSI/ASME B36.19M Sizes and dimensions of stainless steel pipe 12 inches (300 mm) NPS and smaller designated as Schedule 5S, 10S, 40S, or 80S, and 14 inches (350 mm) NPS and larger designated as Schedule 5S or 10S ANSI/ASME B36.19M Wall thickness tolerances for carbon steel ASTM A530 Manufacturing standard for mechanical joint and push-on joint ductile iron pipe ANSI/AWWA C151/A21.51 Manufacturing standard for flanged ductile iron pipe ANSI/AWWA C115/A21.15 Source: 15226, 2014, v2.0 Underground Pressure Piping Page 107 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Work In Accordance With Polyethylene tubes for protection of ductile iron pipe that will be installed underground ANSI/AWWA C105/A21.5 High density polyethylene (HDPE) pipe AWWA C906 Cement linings for ductile iron pipe fittings ANSI/AWWA C104/A21.4 Manufacturing standard for polyvinyl chloride (PVC) pipe ASTM D1785 Manufacturing standard for chlorinated polyvinyl chloride (CPVC) pipe ASTM F441 (Schedule 40 and 80) or ASTM F442 (SDR and PR) Butt weld fitting manufacturing standard ANSI B16.9 and B16.28 Over 7/8 inch (22 mm), Figure 3, Detail C Ductile iron fittings for use with plastic lined or rubber-lined pipe 6 inch NPS and smaller Schedule 80 and less, Figure 2, Detail B Carbon steel flanged fittings ANSI B16.5 Manufacturing standard for ductile iron fittings used with lined steel pipe ANSI/AWWA C110/A21.10 Manufacturing standard for cast iron and ductile iron flanged fittings ANSI/AWWA C153/A21.53 Manufacturing standards for mechanical joint and push-on joint ductile iron and cast iron fittings ANSI/AWWA C153/A21.53 and ANSI/AWWA C111/A21/1 Polyvinyl chloride (PVC) fittings ASTM D2466 or ASTM D2467 corresponding to the pipe schedule with which they will be used Chlorinated polyvinyl chloride (CPVC) fittings ASTM F438 or ASTM F439 corresponding to the pipe schedule with which they will be used Cast iron and ductile iron flange construction requirements ANSI/AWWA C115/A21.5 Flange bolting requirements - carbon steel and stainless steel ANSI B16.1 Bolting dimensional standards for carbon and stainless steel ANSI B18.2.1 and ANSI/ASME B18.2.2 Weld end prep requirements for stainless and carbon steel pipe (greater than 2 inches) Over 7/8 inch (22 mm), Figure 3, Detail C 7/8 inch (22 mm) and less, Figure 2, Detail C 5/8 inch (16 mm) to 7/8 inch (22 mm), Figure 2, Detail C Under 5/8 inch (16 mm) Valves - Figure 2, Detail B Pipe and fittings - Figure 2, Detail A Source: 15226, 2014, v2.0 Underground Pressure Piping Page 108 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Work In Accordance With Clean interior surface of carbon steel pipe PFI Standard ES-5, Articles 4.2.1 and 4.2.2 Piping and materials used for potable water service NSF 61 15226.3 Material Specifications The following materials shall be used: Component Materials Carbon steel ASTM A106 Grade B Pipe General service ASTM F714 and ASTM D3350, with a PE 3409 designation and a cell classification of 34534C Fire protection FM approved Potable In accordance with NFS61 Fittings FM approved suppliers CPCHEM Performance Pipe Driscoplex™ 1500 Class 200 Poly Systems Incorporated, KWH Class 200 Non-FM approved suppliers CPCHEM Performance Pipe Driscoplex™ 4100 Poly Systems Incorporated, KWH Sclairpipe Carbon steel flange material standards, ANSI Pressure Class 150 and 300 ASTM A181/A181M or ASTM A105/A105M Carbon steel flange material standards, ANSI Pressure Class 600 and higher ASTM A105/A105M Carbon steel butt weld fitting material standards ASTM A234/A234M Ductile iron pipe push-on joint gaskets Neoprene or other synthetic rubber. Natural rubber will not be acceptable. Ductile iron fittings for use with plastic lined or rubber lined pipe ASTM A395, lined with lining material equivalent to that of the pipe Stainless steel butt weld fitting material standards ASTM A403/A403M Carbon steel bolting materials ASTM A307 Grade B 15226.4 General Material Descriptions 15226.4.1 Ductile Iron Pipe and Fittings Ductile iron pipe and fittings shall conform to the standards referenced in Article 15226.2. Source: 15226, 2014, v2.0 Underground Pressure Piping Page 109 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Interior surfaces of ductile iron pipe and fittings shall be coated before shipment with a bituminous material. Ductile iron piping systems shall be provided with restrained joints. Fire protection piping shall utilize mechanical joint type restraints and shall be U.L. Listed and FM approved. All other restrained joints shall be American Pipe - fasttite with fastgrip gaskets or U.S. Pipe - Field Lok. Where specified in Article 15226.2, polyethylene tubes shall be furnished by the Supplier as required to allow field wrapping of buried ductile iron pipe in accordance with ANSI/AWWA C105/A21.5 Method A. 15226.4.2 High Density Polyethylene Fittings Fittings for HDPE piping systems shall have pressure ratings equivalent to the straight pipe section with which they will be used. Fittings shall be of the molded type unless otherwise accepted by the Purchaser. Fittings shall be of the butt fusion weld, socket fusion weld, or saddle type as recommended by the pipe manufacturer for the point of application within the system. Preference shall be given to molded fittings. If fittings other than Y-laterals are fabricated by mitering pipe material, SDR of fitting material shall be increased accordingly to meet the requirements of this pipe section. The ends of the increased SDR fittings shall be machined to matching adjoining piping. Flanged fitting shall include ductile iron convoluted backup rings. Molded fittings shall be provided for pipe sizes 8 inches and smaller. Fabricated fittings may be used for sizes 10 inches and larger. HDPE piping shall be fabricated in 40 foot straight lengths and shall not be furnished in rolls. Three segment fabricated fittings shall be used for pressure system piping 10 inches and larger. Five segment fabricated fittings shall be used for gravity systems for all sizes 4 inches to 12 inches. The HDPE pipe list identifies the pressure and gravity drain systems. All underground reducers shall be eccentric reducers. 15226.4.3 Carbon and Stainless Steel Pipe and Fittings Steel piping shall be fabricated in 40 foot lengths. Pipe will have weld end preps for both ends. Steel Fittings. Unless otherwise indicated in the attachment(s), steel fittings 2-1/2 inches and larger shall be butt welding type and steel fittings 2 inches (50 mm) and smaller shall be socket welding type. Fittings and flanges manufactured in the People's Republic of China shall be in accordance with the 1994 (or later) quality assurance program that has been implemented by the CVPVI and shall be stamped with the mark of the CBPVI, shall have markings as required by the applicable standard, and shall bear the official stamp of CBPVI on all relevant quality inspection reports. Butt Welding Fittings. Butt welding fitting wall thickness shall be equal to the pipe wall thickness with which they are used. Fittings shall be manufactured in accordance with the applicable standards listed in Article 15226.2. Unless otherwise indicated on the drawings, elbows shall be of the long radius type and conform to the applicable standards listed in Article 15226.2. Forged Steel Fittings - Socket-Welded and Threaded. Forged steel fittings shall be used for socketwelded and threaded connections. Socket-welded and threaded fittings shall conform to the applicable Source: 15226, 2014, v2.0 Underground Pressure Piping Page 110 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 standards listed in Article 15226.2. Metal thickness of fittings shall be adequate to provide actual bursting strengths equal to or greater than those of the pipe with which they are to be used. 15226.4.4 Steel Flanges All steel, flat face flanges shall be used to mate with cast iron, ductile iron, FRP, HDPE and plastic or rubber lined flanges. All steel, raised face flanges shall be supplied for carbon and stainless steel pipe. 15226.5 Coating of Pipe to be Installed Underground Exterior surfaces of carbon and stainless steel pipe to be installed underground shall be provided with a shop applied fusion bonded epoxy (FBE) in accordance with Coating System 3301 or 3311 (Complete). Painting and surface preparation shall be in accordance with Section 21000. No coating shall be applied within 4 inches of field weld connections. Underground carbon and stainless steel pipe and fittings shall be provided with the specified shop applied coating systems. Except as specified otherwise herein, all pipe surface preparation, material, coating application, inspection, and repairs for the shop applied FBE coating system; and marking, handling, storage, and shipping of the coated pipe shall be in accordance with AWWA C213-07, or latest revision for all FBE coated piping. 15226.6 Cleaning Interior and exterior surfaces of all piping shall be thoroughly cleaned of sand, mill scale, greases, oils, dirt, and other foreign materials. 15226.7 Weld End Coatings Machined weld end preparations for field welds on carbon steel piping shall be coated with a weldable consumable coating as specified to prevent surface corrosion prior to welding. Preservative coating materials shall be in accordance with provisions Section 21000. Other materials may be proposed provided manufacturer's data is submitted to the Purchaser for acceptance prior to application: 15226.8 Preparation for Shipment Open ends and branches of piping shall be securely closed as follows to protect the interior cleanliness and end surfaces during shipment: Weld End. Attach a plastic cap or metal cap seal with waterproof tape. Weld end larger than 2 inches (50 mm)--Attach a plastic cap or metal cap lined in the end with 3/4 inch (20 mm) soft wood seal with waterproof tape. Female opening 2 inches (50 mm) and smaller, such as Sock-o-let-Press in a light metal or plastic insert and seal with waterproof tape. Miscellaneous loose items shall be suitably packed in heavy wooden boxes with waterproof linings to prevent entry of dirt and moisture. All pipe shall be clearly labeled with the system and line code. Source: 15226, 2014, v2.0 Underground Pressure Piping Page 111 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 15262 - Steel Valves 2 Inches and Smaller 15262.1 General 15262.1.1 Scope of Supply Scope of supply shall include furnishing steel valves 2 inches and smaller as specified in Article 15262.2 and contained in the following valve list: No. ID Number Client ID Description Valve Type Class* Material* Service* Compressor/dryer (CMP-1) Valve Size (inch) 2 1 CCAD-BV-298 Ball CL 150 150 psi/130F CCAD-BV-128 Compressor/dryer (CMP-1) 2 Ball CL 150 3 CCAD-BV-299 2 Ball CL 150 4 CCAD-BV-300 Compressor/dryer (Crossover) Compressor/dryer (CMP-4) 2 Ball CL 150 5 CCAD-BV-301 Compressor/dryer (CMP-4) 2 Ball CL 150 6 CCAD-BV-302 Compressor/dryer (TNK-1) 2 Ball CL 150 7 CCAD-BV-302 2 Ball CL 150 8 CCAD-BV-344 Compressor/dryer (portable compressor connection) Supply to Railcar Dump (T-1) 2 Ball CL 150 9 CCAD-BV-345 2 Ball CL 150 10 CCAD-BV-346 Supply to Railcar Dump (Tunnel) Drain at Drainage Trench 1 Ball CL 150 11 CCAD-BV-347 1 Ball CL 150 12 CCAD-BV-348 1 Ball CL 150 13 CCAD-BV-349 1 Ball CL 150 14 CCAD-BV-350 1 Ball CL 150 15 CCAD-BV-351 1 Ball CL 150 16 CCAD-BV-352 Railcar Dump Air Receiver Inlet Railcar Dump Air Receiver Outlet Railcar Dump Air receiver Trap Inlet Railcar Dump Air Receiver Trap Outlet Railcar Dump Air Receiver Trap Bypass Railcar Dump Maintenance 2 Ball CL 150 17 CCAD-BV-353 Railcar Dump Dust Collector 2 Ball CL 150 CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim SS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim CS Body w/316 SS Trim 2 * see Pipe Class documents 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 150 psi/130F 15262.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this scope of supply include the following: Per Section 01100. Source: 15262, 2014, v2.0 Steel Valves 2 Inches and Smaller Page 112 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 15262.1.3 Performance and Design Requirements Performance and design requirements for the equipment to be furnished under this section of these specifications are indicated herein: Air operated valve identification number(s) none Locking devices 01100 Material 01100, Pipe Class attachment Pressure class 01100, Pipe Class attachment 15262.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Valves (including ratings and tests) and associated equipment design ANSI B16.34, ASME B31.1, ASME Boiler and Pressure Vessel Code, UL/FM Personnel protection OSHA Valve end preparation socket weld ANSI B16.11 Valve end preparation threaded ANSI B1.20.1 15262.1.5 Materials The following materials shall be used: Component Material Valve body Carbon steel ASTM A105 or SA105 5 percent chromium alloy steel ASTM A182 Grade F5 or ASME SA182 Grade F5 2-1/4 percent chromium alloy steel ASTM A182 Grade F22 or ASME SA182 Grade F22 Stainless steel Type 316 ASTM A182 Grade F316 or ASME SA182 Grade F316 Type 316L ASTM A182 Grade F316L or ASME SA182 Grade F316L Type 304 ASTM A182 Grade F304 or ASME SA182 Grade F304 Type 304L ASTM A182 Grade F304L or ASME SA182 Grade F304L Source: 15262, 2014, v2.0 Steel Valves 2 Inches and Smaller Page 113 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Material Note: Valves specified as "Boiler Code" in the valve list shall be of SA materials. Valve trim materials Stem Stainless steel, AISI Type 416 or Type 410 Gate or disk Stainless steel or material acceptable to Purchaser Seating surfaces (including gate or disk seating surfaces) Stellite faced except ANSI Pressure Class 600, which may have hardened stainless steel Bonnet bolting studs ASTM A193 Grade B7 Bonnet bolting nuts ASTM A194 Grade 2H 15262.1.6 Approved Manufacturers of Components For the following components, only the listed manufacturers are recognized as maintaining the level of quality of workmanship required by these specifications. If the Supplier wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Purchaser: Component Manufacturer Manual Valves By Supplier, Owner approved 15262.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Supplier is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By All tests required by ANSI B16.34 ANSI B16.34 Supplier 15262.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 15262.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 15262.2 Products This article covers the design and construction requirements for the steel valves 2 inches and smaller. Steel valves 2 inches and smaller shall have forged steel bodies. The valves shall be furnished in the body types specified on the Valve List. Source: 15262, 2014, v2.0 Steel Valves 2 Inches and Smaller Page 114 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Wye pattern type bodies shall be provided for lift check and stop check valves unless an alternate body style is specified in the Valve List. 15262.2.1 Service Condition The valves shall be guaranteed for safe and reliable operation at high velocities and at operating pressures and temperatures up to the maximum pressure-temperature ratings of the valves. All valves shall provide tight shutoff over a range of differential pressures up to the maximum pressure rating coincident with operating temperatures and up to the maximum temperature rating of the valve. All valves shall have Standard Class, Special Class, or Intermediate Rating Special Class pressuretemperature ratings meeting or exceeding the design pressure and design temperature specified in the Valve List. Valves shall be Standard Class unless Special Class or Intermediate Rating Special Class is specified in the Valve List. If a class rating is indicated in the Valve List, it is the anticipated pressure class rating only. In all cases, it shall be the responsibility of the Supplier to properly and economically select valves with pressure-temperature ratings meeting or exceeding the design pressure and temperature specified in the Valve List. Valves with class ratings lower than those listed in the Valve List will not be acceptable. In addition to the above requirements, all valves (including valves seats) shall be suitable for hydrostatic shell and closure tests at 100° F. Tests may be performed under separate specifications in the field in conjunction with system hydrostatic tests with the valve disk in the open or closed position, at a test pressure of 1-1/2 times the design pressure listed in the Valve List unless a special hydrostatic test pressure is specified in the Valve List. In that case, the hydrostatic shell and closure tests will be at the specified hydrostatic test pressure. The Supplier shall be responsible for the suitability of the valves for the specified shell and closure test conditions, and shall guarantee that there are no functional limitations to so testing the valves. If the pressure-temperature rating of a valve meets the specified design pressure and design temperature, but the specified hydrostatic test pressure exceeds the code required closure test pressure, then a special shop hydrostatic closure test of not less than the specified hydrostatic test pressure shall be performed on both sides of the seat with the valve closed. The test pressure shall be applied successively on each side of the closed valve. Packing seal leakage and seat leakage shall be measured and recorded. This test shall be in addition to the hydrostatic shell test performed on the body forging. All valves shall be stamped with 100° F rating that meets or exceeds the specified hydrostatic shell and closure test pressure. 15262.2.3 Valve Design All valves shall have socket-weld or threaded ends as indicated on the Valve List. ANSI pressure Class 600 and lower valves shall have pressure seal, integral, welded, or bolted type bonnet joints. Valves over ANSI pressure Class 600 shall have pressure seal, integral, or welded bonnet joints. Gate, globe, and angle valves shall be of outside screw and yoke construction. All valves except flow control valves and gate valves shall have integral type seats. Gate valves and flow control valves shall have renewable type seats. All integral bonnet type valves shall be of fixed back seat design. The back seat on bolted, welded, and pressure seal type bonnet gate, globe, and angle valves shall be integral with the bonnet. All flow control valves shall have a V-port disk and a stem position indicator. Flow control valves shall be designed for severe service continuous high-pressure drop throttling applications. Source: 15262, 2014, v2.0 Steel Valves 2 Inches and Smaller Page 115 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 ANSI pressure Class 1500 and higher globe valves of the Y-pattern type shall be designed for rodthrough cleaning unless otherwise indicated. Lift and stop check valves shall be of the guided piston type. All check valves shall be designed for installation in either horizontal piping or vertical piping with upward flow. The valve bodies and bonnets shall be designed to support the valve operators (hand wheels, gear, electric motor, or diaphragm) in any position without external support and without stem deflection. 15262.2.4 Materials Stainless steel valves shall be of the grade specified in the Valve List, with the exceptions that valves specified as Type 304 or Type 304L may be offered as Type 316 or Type 316L, respectively, at the Supplier's option. Valves specified as Type 316 or Type 316L shall not be substituted with valves made of Type 304 or Type 304L, respectively. Valves with stainless steel stems shall be provided with special inhibited packing for storage in high humidity environments. No copper or copper bearing alloys shall be used for any valve parts, including the packing glands, which may come in contact with contained fluid. This requirement applies to all valves, regardless of the system in which the valves are used. All packing and gaskets shall be non-asbestos. 15262.2.5 Special Features Special features such as motor or pneumatic operators, locking devices, limit switches, vacuum service, boiler code, and UL/FM rating shall be furnished as indicated on the Valve List and as specified herein. 15262.2.5.1 Motor Operators. Electric motor operators shall be furnished in accordance with the Valve List and the requirements of the Supplemental Specifications in Section 21000. The maximum differential pressure for selection of operators to meet torque requirements shall be considered to be the same as the design pressure rating of the valves unless specified otherwise in the Valve List. The maximum differential pressure for valves specified for vacuum service shall be considered to be the same as the valve design pressure plus 15 psi (100 kPa), unless specified otherwise. Unless specified otherwise in the Valve List, valve stem linear travel speed shall be 12 inches (300 mm) per minute. 15262.2.5.2 Pneumatic Operators. Not Used. 15262.2.5.3 Locking Devices. Locking devices shall allow the valve to be locked in either the open or closed position by use of a standard padlock. 15262.2.5.4 Limit Switches. Limit switches shall be furnished as indicated on the Valve List and shall be as specified in Supplemental Specifications. 15262.2.5.5 Vacuum Service. Where specified in the Valve List, valves shall have packing designed to minimize air leakage into the valve at pressures down to minus 30 inches (760 mm) of mercury. Water seals will not be accepted as a means to stop air leakages for achieving vacuum rating. 15262.2.5.6 Boiler Code. When boiler code is specified in the Valve List, the valves shall be designed in accordance with the ASME Boiler and Pressure Vessel Code. Mill test reports of the physical and chemical properties of the valve body materials shall be submitted to the Purchaser. 15262.2.5.7 Underwriters' Laboratories Listed and Factory Mutual Approved. Where specified in the Valve List, valves shall be Underwriters' Laboratories Listed and Factory Mutual approved. Valves with this requirement will have "UL/FM" listed in the remarks column of the Valve List. Source: 15262, 2014, v2.0 Steel Valves 2 Inches and Smaller Page 116 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 15262.2.6 Installation Instructions Installation instructions for field welding the valves into the piping shall be provided. The instructions shall state valve plug or disk position during welding, disassembly requirements, and all other precautions, recommendations, or special instructions for proper installation. 15262.2.7 Identification Each valve assigned a valve number in the Valve List shall be provided with a permanent stamped stainless steel tag bearing the "Valve Number" which can be securely attached to the valve with 20 gauge stainless steel wire. Each accessory item furnished with the valve, but not securely attached to the valve, shall be provided with an identical identification tag. Shop drawings and all correspondence shall be identified by the "Valve Number." Tags shall be shipped separate for attachment to the valves in the field, except special valves shall have tags attached at the factory. Special valves are those valves specified in the Valve List to have any of the following special features: Motor operator. Pneumatic operator. Locking device. Limit switch. Position transmitter. The valves which do not have tags attached in the factory shall be crated separately so that like components (grouped by size, type, pressure class, and material) remain together and are undamaged through handling, shipment, and covered storage. Each crate shall be durably and clearly tagged with its identifying nomenclature, valve type, size, material, pressure class, and all other applicable information. Valves specified in the Valve List to be suitable for vacuum service or in compliance with the boiler code shall be shipped in separate crates, which are clearly marked, as tags will be attached in the field. 15262.2.8 Drawing Requirements Valve and accessory outline drawings shall indicate overall dimensions, weights (including operators and accessories), direction of flow, location of operator, operator removal clearance, and a list of materials of construction for each component. 15262.3 Execution Not used. Source: 15262, 2014, v2.0 Steel Valves 2 Inches and Smaller Page 117 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction Steel Valves 2 Inches (50 mm) and Smaller Specification Sheet Bid Issue 2Mar2015 Valve Pneumatic Operator Data Air operated valve identification number(s) Operator manufacturer Type Size Model Number Weight Speed of operation, closed to open, seconds At maximum air pressure At minimum air pressure Maximum differential pressure against which operator is capable of operating Required stem thrust at maximum differential pressure Available stem thrust at minimum air supply pressure of 60 psig (400 kPa) Source: 15262, 2014, v2.0 Steel Valves 2 Inches and Smaller Page 118 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 15901 - Mechanical Equipment Erection 15901.1 General This section covers the general erection requirements for all mechanical equipment to be erected by the Supplier. When applicable, additional detailed requirements for erection of specific items of equipment are covered in separate sections as listed in Article 15901.1.3. 15901.1.1 Scope of Work Equipment erection shall include all work required for complete installation, from unloading to placing the equipment in successful operation. 15901.1.2 Scope Responsibilities The following items shall be furnished by the Supplier or will be furnished by the Purchaser as indicated: Item By Supplier Concrete equipment bases X Post-installed mechanical anchors for equipment that will not have cast-in-place anchor bolts X Grouting materials X Shims and wedges X Dowels X Anchors and supports X Bolting for structural attachments X Bolting for connecting pipe flanges to flanged equipment connections X Gaskets X Packing X Welding rod X Consumable gases X All other miscellaneous materials required for complete erection of the equipment X By Purchaser 15901.1.3 Detailed Erection Requirements Additional detailed requirements for erection of some equipment items are covered in the the Air Compressor Supplier Manuals In addition, the following sections apply to some or all of the mechanical equipment erection work under these specifications: 03311 - Cast-in-Place Concrete. 03611 - Grouting. 09900 - Field Applied Protective Coatings. 15921 - Piping Erection. 15941 - Insulation and Lagging Installation. Source: 15901, 2014, v2.0 Mechanical Equipment Erection Page 119 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 15901.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Equipment Erection ASME B31.1 Code for Pressure Piping ASME Boiler and Pressure Vessel Code 15901.1.5 Materials The following materials shall be used: Component Material Bolting for structural attachments ASTM A490 Bolting for pipe connection flanges In accordance with Section 15921 Post-installed mechanical anchor bolts Hilti Kwik-Bolt TZ or acceptable equal meeting Federal Specification A-A-1923A, Type 4, IBC, and ACI 318, Appendix D 15901.1.6 Approved Manufacturers of Components Not Used. 15901.1.7 Test Requirements Not Used. 15901.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 15901.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 15901.2 Products Not Applicable. 15901.3 Execution 15901.3.1 General Erection procedures shall be in accordance with the recommendations of the equipment manufacturers. If requirements contained herein are in conflict with equipment manufacturer requirements, the issue shall be referred to the Purchaser for resolution. Equipment shall be checked prior to its installation to ensure that it is in conformance with the manufacturer's drawings. Any discrepancies shall be reported to the Purchaser. When equipment to be erected by the Supplier is shipped unassembled, the complete assembly of such equipment shall be a part of the work included under these specifications. Source: 15901, 2014, v2.0 Mechanical Equipment Erection Page 120 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 If the equipment to be erected by the Supplier includes electric motors or other equipment that has electrical connections, the electrical connection work will be performed by others, or the requirements for electrical connection work will be covered in other sections of these specifications. Setting and all other erection work for this equipment shall be performed under this section. 15901.3.2 Code Requirements All erection procedures shall be in conformance with accepted good engineering practice, the latest applicable requirements of the codes and standards listed in Article 15901.1.4, and all relevant laws and local regulations. 15901.3.3 Location Tolerances All equipment shall be located within 1/8 inch of the dimensioned locations indicated on the drawings. 15901.3.4 Piping Connections All equipment that has piping connections shall be leveled, aligned, and shimmed in place and shall have piping initially fit before being grouted, except as approved by the Construction Manager. Boiler feed pumps shall be bolted to the base and grouted, then piping shall be carefully and accurately fit to the pump nozzles. Equipment shall be grouted or bolted to its foundation prior to final bolting or welding of the connecting piping. 15901.3.5 Leveling and Grouting The metal bases of all equipment installed under these specifications shall be grouted in place in accordance with the equipment manufacturer's instructions and recommendations when available, and in accordance with Section 03611 when the manufacturer has not provided any direction. Prior to placing of grout, each base shall be set in place over its anchor bolts and shall be carefully aligned in proper position and then brought to accurate level, preferably by means of leveling screws with nuts above and below temporary lugs attached to the edges of the base. Steel shims may be used for leveling small bases, if permission is given by the Purchaser. Such shims shall be of a type that cannot be easily or accidentally dislodged. The use of wood blocking or wood wedges to hold the base in position will not be permitted. 15901.3.6 Equipment Piping All piping, valves, and fittings furnished with the equipment shall be installed in accordance with the requirements of Section 15921. All equipment drains shall be piped to bell-ups or floor drains. Water drains shall be open to atmosphere to allow verification of correct discharge and flow. When connecting piping of the same size to a bell-up, the connection shall be caulked. When connecting steel pipe to an HDPE stub, the connection shall be made with a sleeve clamp. When one or more smaller pipes drain into a larger pipe, the bell-up shall remain open to allow visible verification of flow. Equipment oil drain points shall be provided with a bronze plug cock of the same size as the connection and a screwed cap or plug. 15901.3.7 Pump Suction Strainers All pump suction strainers shall be installed before starting the associated equipment. 15901.3.8 Welding When welding to equipment that is assembled, separate ground leads shall be attached to the equipment, pipes, or components to prevent stray welding currents from arcing the internals of the equipment. 2 Wherever possible, the ground lead shall be 2/0 AWG (70 mm ) cable or larger, directly and mechanically connected adjacent to the welding area, and returned directly to the welding power source. 15901.3.9 Shaft Alignment The alignment of rotating machinery shafts shall meet the equipment suppliers' recommendations. Parallel offset measurements shall be made with a dial indicator. Angular offset measurements shall be Source: 15901, 2014, v2.0 Mechanical Equipment Erection Page 121 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 made with a dial indicator. Feeler gauges may be used to measure angular offset when the coupling is on a motor that has sleeve bearings, and when the use of a dial indicator is not practical. Laser technology measurement methods may be used at the Supplier's discretion. Machinery shall operate without excessive vibration, overheating bearings, or other conditions that would tend to shorten machinery life. Before starting, all bearings, shafts, and other moving parts shall be checked for proper alignment, cleaned, and lubricated in accordance with the manufacturer's recommendations. Copies of final alignment measurement records shall be furnished to the Purchaser. 15901.3.10 Motors All motors shall be checked for proper rotation before connection to the driven equipment. A record shall be kept of all motor rotation checks. Stainless steel shims (1/8 inch thick), cut to fit under the motor foot, shall be installed beneath each motor wherever practicable when aligning shafts, so that future realignment may be performed without grinding the motor baseplate. No more than five shims shall be used under each foot of the equipment. Motor space heaters shall be energized upon receipt of the equipment on site. When the motor or equipment is set in the erected position, the motor space heater shall be connected and remain energized until it is connected into and energized by the permanent plant electrical system. 15901.3.11 Equipment Checkout All equipment shall be cleaned. Rotating machinery shall be lubricated and checked for freedom of movement by hand if possible, and all prerequisite operating conditions shall be established before the application of motive power. Equipment subject to pressure shall be checked for leakage. 15901.3.12 Miscellaneous Equipment Miscellaneous equipment such as fire hose and racks, locally mounted pressure and flow transmitters, pilot controls for control valves, and similar items shall be installed in locations in accordance with the drawings if shown. Such items not shown on the drawings shall be installed in easily accessible locations and subject to the acceptance of the Purchaser. All such items shall be rigidly supported from the building structure by means of suitable brackets. 15901.3.13 Defects All defects in erection shall be corrected to the satisfaction of the Purchaser. The dismantling and reassembly of Supplier-furnished equipment to remove defective parts, replace parts, or make adjustments shall be included as a part of the work under these specifications. 15901.3.14 Maintenance Tools Except as otherwise specified, all tools purchased with equipment for maintenance purposes shall not be used for erection purposes. All such tools shall be stored as directed by the Purchaser. Source: 15901, 2014, v2.0 Mechanical Equipment Erection Page 122 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 15921 - Piping Erection 15921.1 General 15921.1.1 Scope of Work The work shall include erection of all piping, fittings, valves, supports, and piping specialties, as called for on the drawings and specifications, and by the codes and standards. Erection of piping systems designated by the system codes and indicated on the drawings listed in Article 15921.1.8 are included, except as otherwise specified herein. The Contractor shall furnish all required materials and perform all related work for completion of the work included under these specifications. If furnishing any piping or fittings; installing insulation and lagging; furnishing and installing freeze protection, chemical cleaning, steam blow cleaning, trenching, and earthwork for underground piping; or furnishing and/or installing control and instrument piping is included in the Scope of Work, it shall be done in accordance with separate sections included in these specifications: Additional Scope The additional Scope of Work for this package includes the following items: System Name System Code Category* CAD 2 *Categories are as follows: 1. Noncold sprung critical piping system. 2. Noncritical piping system. The systems listed above include the following: Above grade piping Yes Below grade piping Yes In addition to erection of the piping systems defined above, the Scope of Work includes the following services and materials: Routing of miscellaneous 2 inch and smaller pipe, fittings, and valves Yes Installation of instrument and control piping and tubing as indicated on the attachments Yes Hydrostatic testing of piping erected under these specifications Yes Hydrostatic testing of the following piping systems erected by others: Furnish water for hydrotest Source: 15921, 2014, v2.0 Yes Piping Erection Page 123 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Furnish chemicals for treatment of hydrotest water No 15921.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this Scope of Work include the following: Refer to Section 01100. Construction and miscellaneous services and materials not specified in Article 15921.1.1. 15921.1.3 Performance and Design Requirements Not used. 15921.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Installation of mechanical joint piping ANSI/AWWA C111/A21.11 Field applied coatings for underground piping AWWA C209 Repair of damaged shop applied coatings for underground piping AWWA C203 Repair of damaged field applied coatings for underground piping AWWA C209, Section 3.4 Polyethylene tubing for underground ductile iron pipe Material ANSI/AWWA C105/A21.5 Installation ANSI/AWWA C105/A21.5 Dimensions and installation of restrained push-on type joints AWWA C606 Sterilization of piping and equipment AWWA C651, AWWA C652 Installation of pipe supports MSS-SP-58 15921.1.5 Materials The following materials shall be used: Component Material Flexible weatherproofing Nylon reinforced neoprene fabric with compatible adhesive Source: 15921, 2014, v2.0 Piping Erection Page 124 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Material Clamps for attaching flexible weatherproofing to pipe and sleeve Stainless steel worm drive clamps Nonfire rated penetration seals Field applied protective coating for underground pipe Nylon reinforced hypalon with closure zipper and stainless steel worm drive clamps Tape and primer system Metal pipe identification signs Aluminum sheet, No. 5005 H-16, with engraved legends filled with paint Pipe identification labels Pressure sensitive vinyl cloth Flange bolting shall be furnished as indicated in the table below. Alloy steel bolting shall be used for joining all steel flanges having a design pressure rating of Class 150 or greater, except steel slip-on flanges. Carbon steel bolting shall be used for joining all other flanges including steel slip-on flanges. Bolting for bolt diameters 1-3/4 inches and larger shall consist of threaded studs and two nuts. Bolting for bolt diameters less than 1-3/4 inches may be threaded studs and nuts or bolts and nuts. Bolts and nuts shall be heavy hexagonal heads conforming to the applicable standard. Bolting Material Alloy steel bolting materials for use with piping with design temperatures of 750° F and above Studs ASTM A193/A193M Grade B16 Nuts ASTM A194/A194M Grade 3 Alloy steel bolting materials for use with piping with design temperatures less than 750° F Studs ASTM A193/A193M Grade B7 Nuts ASTM A194/A194M Grade 2H Carbon steel bolting materials ASTM A307 Grade B, ASTM A563 Grade A heavy hex nuts Bolt coating (applies to alloy and carbon steel bolting) Piping design temperatures of 450° F and above No coating Piping design temperatures less than 450° F PTFE Teflon coating Bolt plating (applies to alloy and carbon steel bolting Source: 15921, 2014, v2.0 Piping Erection Page 125 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Piping design temperatures of 450° F and above No plating Piping design temperatures less than 450° F Cadmium plating in accordance with ASTM B766 or zinc plating in accordance with ASTM A153 15921.1.6 Acceptable Subsuppliers For the following components, only the listed manufacturers are recognized as maintaining the level of quality of workmanship required by these specifications. If the Contractor wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Purchaser: Component Manufacturer Flexible weatherproofing fabric and adhesive DuPont (Fairprene 5798 material with Fairprene 5128 adhesive) Clamps for attaching flexible weatherproofing to pipe and sleeve Aero-Seal (QS 200) Shrink sleeves for underground piping Raychem Corporation Pipe identification labels Brady Corporation (Type B500) 15921.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Contractor unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Contractor is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By Hydrostatic and pneumatic testing of piping ASME B31.1, Paragraph 137 Contractor Hydrostatic testing of underground fire protection piping NFPA 24 Contractor Pressure testing of nonmetallic piping ASME B31.1, Paragraph 137; and as supplemented by Article 15921.3.29 Contractor Holiday testing of shop applied coatings for underground pipe AWWA C203 Contractor Holiday testing of field applied coatings for underground pipe Coating manufacturer's recommendations Contractor Holiday testing of field installed shrink sleeves for underground piping Manufacturer's recommendations Contractor Source: 15921, 2014, v2.0 Piping Erection Page 126 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Tests In Accordance With Conducted By Testing of electrical isolation flange kits Manufacturer's recommendations Contractor Bid Issue 2Mar2015 15921.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 15921.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 15921.2 Products 15921.2.1 Pipeline List The Pipeline List and piping isometric drawings included with these specifications detail the requirements for the various major piping systems to be erected under these specifications. The information included on the Pipeline List and/or isometric drawings designates the pipeline identification number; line description; operating, design, and test pressures and temperatures; pipe material, nominal sizes, and corresponding schedule or wall thickness; valve class rating, end preparation requirements, and material; insulation class; welding remarks; gasket types; and special features. 15921.3 Execution All piping, valves, fittings, and piping specialties shall be erected in accordance with the requirements of this section. Any piping installation not specified herein shall be done in accordance with good engineering practice. The drawings indicate the dimensions of the major lines. These dimensions are subject to change to accommodate the equipment, valves, and fittings actually furnished and the variations in equipment as actually installed. If the equipment, valves, fittings, and other components of the piping systems actually furnished differ in dimensions from those indicated, the piping systems shall be altered as required to accommodate these changes. If, due to some unforeseen circumstance, the installation of the piping as indicated would result in an interference, the modifications or corrections required to install the piping free from interferences shall be made. A field check of all connections to equipment and existing pipe, valves, or fittings for location, size, butt weld end preparation or flange drilling and facing shall be made prior to erecting interconnecting piping. Allowances in fit-up and modifications to piping spools shall be made as required prior to completion of field welds and hoisting pipe spools into place as applicable. Pipe, fittings, valves, and accessories shall be handled in a manner that will ensure installation in a sound, undamaged condition. Equipment, tools, and methods used in unloading, reloading, hauling, and laying pipe and fittings shall be such that the pipe and fittings are not damaged. Particular care shall be taken to prevent damage to protective coatings and concrete pipe joint rings. Slings shall be nonabrasive and located between the ends of each pipe section when lifting. Bare wire rope slings or the use of hooks to lift pipe will not be permitted. 15921.3.1 Welding Field welding shall be in accordance with the requirements of the Supplemental Specifications in Section 21000. Source: 15921, 2014, v2.0 Piping Erection Page 127 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 15921.3.2 Miscellaneous Piping Miscellaneous piping is defined as piping 2 inches and smaller which is not shown on the detailed piping drawings. All miscellaneous piping shall be given special attention such that it is routed and installed in a neat, rectangular form. All piping shall be installed perpendicular or parallel to the major equipment, building structure, and floor levels except in special cases consented to by the Purchaser. If routing of miscellaneous piping is included under these specifications, all piping, including tubing, not located on the drawings shall be routed and installed in accordance with the following requirements: Pipe routing shall allow unobstructed maintenance of plant equipment. Piping shall not be installed above, or within a horizontal distance of 3 feet from, electrical equipment such as switchgear, switchboards, control panels, motor controls, contactors, communication equipment, batteries, battery chargers, and motor generators unless written consent of the Purchaser is obtained. Improperly located piping shall be removed and relocated. All branch piping shall be provided with shutoff valves at the main headers. Valves shall be installed in such a manner that they can be operated from the main operating floors or platforms without the use of ladders or special operating devices. Piping shall be installed with a minimum of 7'-6" headroom over passageways and walkways. Pipe runs that require condensate drainage shall be installed so that they pitch toward the point of drainage. Piping subject to freezing shall not be routed in the vicinity of large doors which could be open for the moving of mobile equipment or maintenance. Where building expansion walls are indicated on the drawings, piping shall not be supported from or located on columns or beams on these walls. Piping indicated on P&IDs or other drawings as having a connection for the future extension of the piping to another unit shall be routed to a convenient point along the column row adjacent to the unit or the location for a future unit. Routings shall be selected to avoid interference with planned and dimensioned locations for lighting fixtures, electrical trays, raceways, or conduit. The Contractor shall review the Purchaser's drawings for electrical construction to avoid such interferences before routing the piping. Sketches of the proposed routing of all piping not located on the drawings shall be submitted to the Purchaser. The Purchaser's acceptance of all routings shall be obtained before the piping is erected. 15921.3.2.1 Vents and Drains. Vents and drains for system filling and draining may not be shown on the drawings for miscellaneous pipe. The Contractor shall furnish and erect all required vents and drains to allow miscellaneous piping to be filled and drained. Each vent and drain shall be sized and shall include a shutoff valve and a screwed cap in accordance with the vents and drains shown on the associated P&ID for piping 2-1/2 inches and larger. All piping and fittings for vents and drains shall be provided in accordance with the Pipeline List. 15921.3.3 Temporary Piping All equipment, piping, and valves of a temporary nature shall be installed in a safe and workmanlike manner. This shall include such lines as temporary vents for steam blowing, hydrostatic test lines, Source: 15921, 2014, v2.0 Piping Erection Page 128 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 chemical cleaning lines, and all other temporary lines required to successfully complete the work. When the temporary piping is no longer required, any Contractor-furnished temporary piping shall be dismantled and removed from the site. Temporary piping furnished by others shall be dismantled and stored as directed by the Purchaser. Temporary piping shall ordinarily be removed prior to startup and operation of the facility. If for some reason the temporary piping must remain in place for a time after startup, the piping shall be designed and installed in accordance with the codes/specifications used with the permanent piping to which the temporary piping is attached. 15921.3.4 Piping in Existing Areas Before installation of piping in existing areas, the routings of new piping to be installed shall be walked down to verify that the piping, insulation, and supports can be installed as designed without interference. If the piping as designed would interfere with existing facilities, the pipe routing shall be reviewed with the Engineer and shall then be altered or existing piping shall be relocated. All pipe routings shall be subject to acceptance by the Purchaser. 15921.3.5 Alterations and Cut-ins All alterations and cut-ins to existing piping and equipment indicated on the drawings shall be made as specified herein and as required for proper installation of the new piping and equipment. All cut-ins shall be done by sawing, machining, or careful flame cutting as directed by the Purchaser. Flame cut holes shall be ground smooth. The interior of the piping shall be thoroughly cleaned after cutting. Whether indicated on the drawings or not, existing miscellaneous piping shall be revised as required to permit installation, without interference, of new piping and equipment. Existing miscellaneous piping that interferes with walkways or presents an unsightly appearance after modification of existing buildings, structures, equipment, or piping shall be relocated as directed by the Purchaser. The alterations to existing piping shall include any required revisions, additions, or replacements of insulation and pipe supports. Any piping materials and valves removed and not reused shall be disposed of as directed by the Purchaser. All alterations and cut-ins to existing systems shall be made on a time schedule acceptable to the Purchaser. After alterations and cut-ins to existing coated equipment or coated piping have been made, the damaged coating shall be repaired. All welds and sharp edges shall be finished smooth and all weld spatter shall be removed. The metal shall be prepared and the coating system applied in strict accordance with the instructions and recommendations of the coating manufacturer. 15921.3.6 Thermal Expansion All piping shall be installed so that excessive or destructive expansion forces will not exist either in the cold condition or under conditions of maximum temperature. 15921.3.6.1 Critical Piping Systems. Not used. 15921.3.6.2 Noncritical Piping Systems. The Contractor shall install the pipe in a stress free condition. Cold spring shall not be used to close the final joint in runs of piping between equipment and anchors. The methods used to erect the piping shall result in an installation which is true to plan. Starting from an established reference point, successive piping spools or piping sections shall be erected such that the installed end is within the established tolerance from the dimensioned drawings for the NPS being erected. Once a spool or piping section is properly located to within the required tolerance steps shall be taken to maintain the location of that piping. Successive spools or piping sections may then be erected Source: 15921, 2014, v2.0 Piping Erection Page 129 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 while maintaining the required tolerance for the NPS being erected. As erection of the piping system progresses, individual spools or piping sections shall be shifted to match the proceeding section so that the dimensions accumulate into a final weld fit up gap tolerance based on the NPS being erected. The following lists allowable spool or piping sections ends and the final weld fit up gap. Description Erected Tolerance From Drawings Final Weld Fit Up NPS 2 inch and smaller +/- 1 inch +/- ½ inch NPS 12 inch and smaller +/- ¾ inch +/- 3/8 inch NPS greater than 12 inch +/- ½ inch +/- ¼ inch Note the final weld fit up gap may only be closed by moving the ends of the pipe together if there is at least two unrestrained dead weight spans available perpendicular to the direction of the gap being closed. This restriction prevents excessive loading of nearby lateral and axial restraints. Dead weight spans are as defined in ASME B31.1 Table 121.5, Suggested Pipe Support Spacing. Where expansion joints are indicated on the drawings, anchors shall be installed as required to prevent damage from the forces generated by the fluid pressure of the line. Care must be taken in installing expansion joint anchors to make certain that full design movement is allowed at all times from maximum to minimum temperatures. 15921.3.7 Pipe Supports Welding of pipe supports to structural steel forming a part of the building supporting structure shall be in accordance with the requirements of Supplemental Specifications in Section 21000. Generally, welds shall run parallel with the length of the beam and all welding of lugs or attachments shall be staggered on the sides, with cooling allowed between subsequent weld bead deposits. Loaded beams shall be unloaded or properly shored prior to field welding if 10 percent or more of the flange width or web depth should be heated to over 500 F at any one time. The support assemblies shall not be used for the attachment of rigging to hoist the pipe into place. The piping shall be securely held in place by other means until the pipe support is completely assembled and attached to the pipe and building structures and the spring support set to take care of pipe sway. All rigging shall be removed in such a manner as not to impose a sudden load on the pipe support. Spring supports on gas filled systems shall not be used during hydrostatic testing of piping systems unless they are pinned or blocked to act as rigid supports. All piping having such supports that are not pinned or blocked shall be held securely in place by other temporary means throughout the testing. After successfully passing the hydrostatic test, the pin or blocking device shall be removed. After the piping has been completely installed, insulated, and filled with its normal operating medium, the springs shall be adjusted to the "C" or cold position. Critical piping systems such as HP Steam, Hot Reheat, Cold Reheat, and LP Steam shall be checked after being thermally cycled a minimum of two times and shall be readjusted to the “C” or cold position after the line has cooled below 150 F. 15921.3.8 Cutting and Drilling Structures All necessary drilling, cutting, and patching of structures required for proper installation of piping or bolts shall be done, but only as indicated on the drawings, specified herein, or with the consent of the Purchaser. Any penetrations provided by others are shown on the drawings. Holes shall not be cut in structural steel. Wherever possible, clamps shall be used for attaching erection rigging. Lugs may be welded to structural steel only with the consent of the Purchaser. Upon completion of the work, the lugs shall be removed and the surfaces ground smooth. Holes cut in grating or floor plate shall be banded and reinforced in accordance with the details indicated on the drawings, if details are provided. If no details are indicated on the drawings, holes cut in floor grating shall be banded with 1/4 inch (6 mm) steel bands or standard weight steel pipe welded to the Source: 15921, 2014, v2.0 Piping Erection Page 130 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 main carrying bars. The bands shall extend the full depth of the grating and shall project 4 inches (100 mm) above the top of the grating. If normal grating support is removed by the cutting of holes, the Contractor shall add miscellaneous angles or other steel as required to properly support the grating. Holes in floor plate shall be machine cut. Aluminum shall be used for banding aluminum plate and steel for steel grating or floor plate. After bands and reinforcements have been installed, all welds shall be ground smooth and weld areas, bands, and reinforcements shall be painted to match adjacent surfaces. Two coats of zinc rich galvanizing repair compound shall be applied to damaged areas of galvanized metals. Holes in concrete floors shall be provided with machine cut steel pipe sleeves in accordance with the details indicated on the drawings, if details are provided. If no details are provided, holes in concrete floors required for installation of piping shall be formed with steel sleeves that extend the full depth of the concrete and extend 4 inches above the floor line. Sleeves shall be fabricated from 1/4 inch thick steel plate or from standard weight steel pipe. Sleeves greater than 12 inchesin diameter shall be made from 3/8 inch thick steel plate. Each sleeve shall be provided with anchors welded to the sleeve as indicated on the drawings. The minimum spacing of anchors shall be 18 inches that a minimum of three anchors shall be provided for each sleeve. All sleeves shall be machine cut and ground smooth. Holes for uninsulated cold pipe may be filled with a suitable expansion material in lieu of installing a sleeve. All openings in concrete shall be made by core drilling, saws, or similar clean cutting equipment. Where boxouts are left in concrete walls for the passage of pipes, the Contractor shall weld 1/4 inch (6 mm) thick steel seal rings on the pipes and fill the space between the pipe and the boxout with concrete. Holes cut in walls and roofs shall be complete with sleeves, collars, panel edge closures, reinforcing, flashing, and other accessories in accordance with the details indicated on the drawings. Field cut holes through walls or roof shall be done with proper cutting equipment, leaving a clean finished edge. Burning or other nonexact methods shall not be used. All field cut holes and sleeves shall have adequate provisions to allow for insulation and expansion of piping as required. 15921.3.9 Equipment Connections When attaching piping to equipment connections, special care shall be taken so that excessive stresses are not transmitted to, and imposed upon, such connections. Piping connections to rotating equipment shall not be finalized until the shaft is aligned and the equipment grouted in. As piping is connected, shaft alignment shall be monitored to determine if piping stress causes any change. An indicator tolerance beyond 0.002” shall typically require correction. The Construction Manager shall make the final determination of tolerance depending on the equipment service. In the case of flanged connections, the piping shall be installed and supported so that accurate matching of bolt holes and uniform contact over the entire flange area are obtained prior to the installation of any flange bolts. Bolts shall be carefully tightened to uniformly compress the gaskets and minimize flange stress. Special precautions shall be taken in allowing for shrinkage during the welding of nozzle connections so that excessive stresses are not imposed on the equipment. Fit-up of the flanges to equipment connections may be checked after the bolting has been installed at the request of the Construction Manager. Such bolting shall be removed and replaced and new gaskets installed if requested by the Purchaser. Source: 15921, 2014, v2.0 Piping Erection Page 131 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Piping erection connections to rotating equipment shall not commence until the rotating equipment has been installed, aligned, and grouted in place. For connections to rotating equipment, piping erection shall start at equipment connections and progressively build away from the equipment connection to the farthest distance practical; this shall mean, as a minimum, that at least the first three dead weight supports going away from the connection shall be installed on the piping being erected. In addition, the piping must have two offsets or changes in direction. Pipe misalignment adjustments shall not be made within this minimum distance from the rotating equipment. Flange connections should be initially fit and held in relative position using machine pins or other loose-fitting devices. Flange bolts shall not be installed until after final flange alignment and rough equipment alignment has been completed. Rough alignment is required to ensure that final alignment is achievable. The equipment shall be securely bolted to the structure and grouted before flanges are tightened. Travel stops on spring supports shall remain in place until piping erection is complete, insulation erection is complete, liquid filled piping (if applicable) is filled with the process fluid, and all temporary supports are removed. Travel stops shall be installed and remain in place during hydrostatic testing. If the flanged connections are to be disconnected, the travel stops shall be installed prior to draining the piping system. Pipe support turnbuckles shall be used to adjust the spring supports, as indicated in the pipe support installation instructions, to unload the travel stops prior to removal. Final alignment checks and manufacturer representative's acceptance of connection alignment shall only be performed with all travel stops in place and all temporary supports removed. Making up of the welded joints on the steam generator, turbine generator, boiler feed pump turbines, boiler feed pumps, and similar equipment shall be done in strict accordance with the equipment manufacturer's requirements and under the supervision of the equipment manufacturer's representative. It shall be the Contractor's responsibility to determine the manufacturer's requirements. When welding to the exterior of coated tanks, all tank connections and the immediate tank area shall be wrapped. The wrappings shall be kept wetted. Care shall be taken to protect the tank coating during the welding operation. After startup, if the connecting piping is found to be exerting excessive strains on the equipment, the piping shall be altered by adjusting the piping supports, cutting and rewelding joints, and removing sections of piping, all as necessary to eliminate the excessive strains. 15921.3.9.1 Equipment Connections Fit Up Tolerances. Fit up tolerances at turbines, compressors, selected pumps and other rotating equipment shall meet the following: For connections near steam turbines and compressors, other than reciprocating types, fit up shall be within 1/64” for each direction including axial and two lateral offsets 90 degrees apart. For connection near centrifugal pumps, reciprocating compressors and other rotating equipment, fit up shall meet the following for welded and flanged connections. Welded Connections. Utilize the following table for alignment tolerances. Description NPS < 12 14 < NPS < 22 NPS > 22 Axial offset 1/8” 1/16” 1/64” Lateral offset in each of two directions 90 degrees apart 1/8” 1/16” 1/64” Flanged Connections. Utilize the following table for flange alignment tolerances. Source: 15921, 2014, v2.0 Piping Erection Page 132 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Description NPS < 12 14 < NPS < 22 NPS > 22 Vertical bolt hole offset 1/8” 1/16” 1/64” Horizontal bolt hole offset 1/8” 1/16” 1/64” Rotational offset 1/8” 1/16” 1/64” Face parallelism (across dia.) 1/64” 1/64” 1/64” Face separation plus gasket +/- 1/8” +/- 1/16” +/- 1/64” Metric equivalents for welded and flanged connections are 1/64”, 1/16” (1.5 mm) and 1/8” 15921.3.10 Valve Installation Excessive piping strains and bending moments on valves, especially Class 150 large steel gate valves and butterfly valves, shall be avoided. Excessive strains and moments will result in distorted valve seats. All steel globe valves shall be installed, wherever possible, in such a manner that closing of the valve will relieve the pressure from the packing and permit repacking of the valve with the plant in normal operation. This shall be accomplished by installing the valves on all branch lines from a pressure source, with the pressure under the seat of the valve. In the case of a bypass line, or a line containing two or more globe valves connecting two pressure sources that cannot be taken out of service after the plant is in normal operation, the valve at each end of the line shall be installed in such a manner that the connecting line between the valves may be taken out of service for repacking of both valves when they are closed. Exceptions to the above requirements are those valves for which the manufacturer indicates the required direction of flow through the valve and those valves for which the direction of flow is indicated on the drawings. Valve disks and plugs shall be off the valve seats when welding valves into the lines. Check valves shall not be installed in vertical runs of piping unless they are specifically designed for vertical operation. 15921.3.11 Not Used 15921.3.12 Relief Valve Piping Relief valve discharge piping that is not indicated on the drawings and is to be routed outside of the plant shall be installed in a manner to safeguard operating personnel. Unless otherwise indicated on the drawings, piping from relief valve drip pan wells, discharge elbows, bellows, and above seat drains shall be routed to a safe location. 15921.3.13 Making Flanged Connections The faces of all flanges and gaskets shall be wiped clean when making up flanged joints. The contact faces of all flanges shall meet squarely, and particular care shall be exercised in pulling up flanged joints to prevent overstressing of flanges or flange bolting. The threads of all bolting shall be painted with a suitable thread lubricant before the joint is made. The lubricant shall be suitable for the operating temperatures involved. Flange torque values shall be determined based on the following criteria” The manufacturer’s suggested torque values shall be followed for bolting to equipment. Source: 15921, 2014, v2.0 Piping Erection Page 133 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Where no information on flange torque values is available, the Contractor shall determine torque values and submit them for review and acceptance. The manufacturer’s suggested torque values shall be followed for non metallic flanges such as FRP. FRP flanges shall have the required torque values stamped on the flange hub. The following defines three types of gaskets as defined in ASME VIII Division 1 Appendix 2 Mandatory Rules for Bolted Flange Connections with Ring Type Gaskets used on the majority of flanged piping systems addressed in this Specification: Self-energized types such as o rings, elastomeric, other self-seating types such as red rubber below 75A Shore Durometer. Low seating stress such as reinforced teflon, graphite and spiral wound with an approximate minimum design seating stress of 3000 psi. Spiral-wound metallic high seating stress with an approximate minimum design seating stress of 10,000 psi. The following may be used as a reference for torque values for flat face and raised face flanges. PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly indicates that the minimum and maximum loading requirements for bolting must be selected by the end user. Per PCC-1, the maximum loading on bolts is typically in the range of 40% to 70% of the ambient bolt yield stress. The minimum loading on bolts is typically in the range of 20% to 40% of the ambient bolt yield stress. The elastomeric gasket on flat face flanges should no protrude (extend) out beyond the flange after tightening. In some cases finger tight plus ¼ to ½ turn with a wrench may control in lieu of torque values. For typical torque values, refer to Article15921.1.8 Technical Attachments. Flanges shall use the following or similar approved criteria for bolting sequence of flanges. Tightening method and load control techniques shall be completed with approved methods that utilize a single tool with one of the following methods; hand wrench, slug/hand wrench, impact wrench torque tools and tension tools. The tightening sequence shall utilize an approved criteria similar to the five step increment rounds shown in Table 2 Torque Increments for Legacy Cross-Pattern Tightening Using a Single Tool and Table 4 Legacy Cross-Pattern Tightening Sequence and Bolt Numbering System When Using a Single Tool and Table 4.1 Alternative to Legacy Cross-Pattern Tightening Sequence and Bold Numbering System When Using a Single Tool found in PCC-1. Flange fit up shall meet the following tolerances: Holes for bolts shall be within 1/8” Source: 15921, 2014, v2.0 Piping Erection Page 134 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 The flange faces shall be parallel with 1/16” inch/per foot (0.5%) measured across any diameter. Gaps shall be within 1/16” plus space for any required gaskets. 15921.3.14 Hot Tap Branch Connections Where "Hot Tap" connections are indicated on the drawings to connect new piping with piping that is pressurized and in operation, those connections shall be made using a tapping saddle assembly and equipment designed for the hot tapping procedure and by personnel experienced in hot tapping requirements. 15921.3.15 Traps Traps shall be installed in accessible locations and as indicated on the drawings. They shall be installed on supports above floor level if possible and shall be readily accessible for repair and removal. 15921.3.16 Miscellaneous Small Connections All openings for vents, drains, instruments, and other similar connections made after erection of the piping systems shall be drilled. No burning of such openings will be permitted. Connections shall be made in accordance with the details indicated on the drawings, if details are provided. Any burrs remaining on the inside wall of the pipe after drilling shall be removed. The low points of all water piping systems and other systems specified to be hydrostatically tested shall be provided with 3/4 inch minimum screwed plugged openings as indicated on the drawings and as required to permit drainage of the systems. Inspection plugs, drain plugs, and temperature instrument wells having threaded connections to lines operating above 1500 psig or 925 F shall be seal welded. Seal welds shall be a structural weld similar to the welds shown on Figure 127.4.4 (C) of ASME B31.1. For dead end steam and water service, the structural weld shall be capable of withstanding the header pressure and corresponding saturated steam temperature or water temperature, whichever applies. For supercritical pressure conditions, the structural weld shall be suitable for the design pressure and temperature of the main fluid line. Indoor equipment drains and baseplate drains shall be piped to the bell-ups provided in the floors. Drains shall be caulked into the bell-ups where required by the Purchaser. The lubricating oil drains on all machinery shall be provided with a brass plug cock of the same size as the equipment connection and a screwed pipe plug before the installation of the oil. 15921.3.17 Damage to Machined Surfaces Special measures shall be taken to avoid damage to machined surfaces such as flange facings or pipe ends that have been prepared for welding. Any damage to welding ends shall be repaired prior to butting up for welding. If a flange facing is marred, scratched, or damaged to such an extent that, in the opinion of the Purchaser, the flange will be a cause for leakage, such flange shall be repaired or replaced. When welding to equipment that is in the assembled condition, separate ground leads shall be attached to the equipment, pipes, or components to prevent stray welding currents from arcing the internals of the equipment. Wherever possible, the ground lead shall be 2/0 cable or larger directly and mechanically connected adjacent to the welding area and returned directly to the welding power source. 15921.3.18 Piping Isolation All necessary flange isolating materials and insulated bushings, unions, and couplings shall be installed as indicated on the drawings and as required to properly isolate the piping. Bolting at insulated flanges shall consist of studs and nuts with sufficient stud length to allow at least one full stud thread protruding through each nut. Sleeves shall extend into the insulating washers. After installation, insulated flanges, bushings, unions, and couplings shall be tested to determine that the piping is properly electrically isolated to the satisfaction of the Purchaser. Source: 15921, 2014, v2.0 Piping Erection Page 135 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction The Contractor shall electrically isolate the designated piping from connecting piping and equipment, reinforcing steel, structural steel, the station grounding system, and other buried piping. 15921.3.19 Rainhoods Pipes passing through sleeves in the roof shall be provided with rainhoods in accordance with the details indicated on the drawings. Rainhoods are not required for pipes on which flexible weatherproofing is installed. 15921.3.20 Flexible Weatherproofing After insulation work is complete, flexible weatherproofing shall be furnished where indicated on the drawings for piping that passes through walls and floors. The flexible weatherproofing shall be installed in accordance with the details indicated on the drawings. Flexible weatherproofing material shall be as indicated in Articles 15921.1.5 and 15921.1.6 and shall have 0.050 inch minimum thickness. Joints in the fabric shall be weatherproof and shall be sealed with a compatible adhesive. The fabric shall be attached to the piping and sleeves using 3/4 inch wide stainless steel worm drive clamps. The joint between the piping and the fabric shall be sealed with flexible rubber based adhesive. Flexible weatherproofing shall be constructed with sufficient slack to accommodate the pipe movements indicated on the drawings without causing the fabric to become excessively taut. 15921.3.21 Penetration Seals Penetration seals shall be furnished and installed on piping that passes through walls and floors where indicated on the drawings. Seals shall be designed for any expected axial and lateral movements. Seals at penetrations in fire rated walls or enclosures shall be fire rated and shall be acceptable to the Purchaser. Seals in nonfire rated applications shall be Contractor's standard. Seals shall be installed and sealed in accordance with the manufacturer's installation instructions. Insulation work shall be complete before installing seals on insulated piping. The Contractor shall measure the outside diameter of the insulated and lagged pipe and the outside diameter of the penetration sleeve at each point where a penetration seal is to be installed and shall purchase penetration seals of the proper size. 15921.3.22 Drainlines When connecting piping of the same size to a bell-up, the connection shall be caulked. When connecting steel pipe to an HDPE stub, the connection shall be made with a sleeve clamp. When one or more smaller pipes drain into a larger pipe, the bell-up shall remain open to allow visible verification of flow. Caulked joints shall be packed and caulked in a manner acceptable to the Purchaser. The ends of all steel lines to be caulked shall be built up with a continuous bead of weld metal. All drain funnels, bell-ups, and floor drains shall be kept unplugged and free flowing. 15921.3.23 Protective Coatings Where indicated in the Pipeline List, protective coatings will be applied to the exterior surfaces of underground piping. Unless otherwise noted in the Pipeline List, the coatings will be shop applied, and Source: 15921, 2014, v2.0 Piping Erection Page 136 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 the Contractor shall repair the coatings and apply field coatings to field installed joints and to areas not covered by shop coatings. 15921.3.23.1 Field Applied Coatings. Field applied coating systems for all field installed underground piping joints and for any underground piping specials such as fittings, valves, brass or copper pipe, and short lengths of carbon or stainless steel pipe, which may be impractical to shop coat and which are approved by the Purchaser to be field coated, shall be in accordance with this article. Except as otherwise specified, all cleaning, coating, testing, handling, and installation of field applied coating systems shall be in accordance with AWWA C209. The coating system for pipe operating temperatures less than 120° F shall be Coating System 3011 with a minimum of 50 percent overlap. The coating system for pipe operating temperatures between 120° F and 230° F shall be Coating System 3012 with a minimum of 50 percent overlap. The primer shall be compatible with the tape system and shall be chloride free if used on stainless steel. Flanged fittings, bell and spigot fittings, and similar irregularly shaped fittings shall have all void spaces and irregular surfaces primed and filled with a suitable sealant prior to the application of the tape coating system. Shrink sleeves may be used on field welded joints in lieu of the tape and primer coating system specified above. Shrink sleeves shall be of the wraparound type for all pipe sizes for which they are available. 15921.3.23.2 Electrical Inspection. After the field coating work is complete, and just prior to backfilling, 100 percent of all shop and field coated areas shall be inspected by the Contractor using an electrical holiday detector. Holiday detector voltages shall be as follows: Coating System Holiday Detector Voltage Range Shop applied coal tar, fibrous glass, felt In accordance with the standard specified for coating Field applied tape In accordance with manufacturer's recommendation Field applied shrink sleeves In accordance with manufacturer's recommendation Any flaws or holidays found in the coated areas shall be repaired. The pipe coating shall be retested after repair. Testing and repair shall continue until no holidays are detected. 15921.3.23.2.1 Lubrication of threaded components. Thread lubricants used for bolting of carbon and alloy steel shall not be copper based. Lubricants shall not contain lead. Lubricants for austenitic stainless steel bolting shall not contain chlorides. Lubricants shall conform to the following compounds or purchaser acceptable equivalent. Carbon steel 32 F to 150 F Graphite and oil Carbon and alloy steel up to 750 F Fel-Pro Moly Paste, Jet Lube 550 Alloy steel up to 1100 F Fel-Pro Heavy Duty Stainless Steel up to 1600 F Bostic Never Seeze Pure Nickle, FelPro Nickel Source: 15921, 2014, v2.0 Piping Erection Page 137 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Notes 1. Bostic Never Seeze Pure Nickel is acceptable for use down to minus 200 F (minus 130 C). 2. Lubricants listed above are not for use on BPV Code ASME III Nuclear Facility Components. 3. Lubricants shall not be used on any threaded components inside the Condenser. 15921.3.23.3 Coating Repair. The method of field repair of damaged shop applied coatings shall be in accordance with the standard specified for the coating. The repair materials shall be the same as the original coating or as recommended by the coating applicator. The method of field repair of damaged field applied coatings shall be in accordance with the specified standard. The repair materials shall be the same as the original coating or as recommended by the coating manufacturer. 15921.3.23.4 Handling of Coated Pipe. Coated pipe shall be handled at all times so as to prevent damage to the coating. Bare cables, chains, hooks, metal bars, or narrow skids shall not be permitted to come in contact with the coating during handling. Coated pipe shall not be handled when the ambient temperature is below freezing. Coated pipe shall be carefully backfilled with proper backfill materials. No organic material such as sacks or wood blocks shall be allowed in the piping trench. No sharp objects such as stones shall be allowed to contact the coated pipe. 15921.3.23.5 Polyethylene Tube Protection. All ductile iron pipe that is installed underground shall be provided with seamless polyethylene tube protection. The tubing and installation of the tubing shall be in accordance with the specified standard. 15921.3.24 Underground Piping Underground piping shall be installed as indicated on the drawings and as specified herein. Excavation, trenching, embedment, and backfilling shall be in accordance with the requirements of Section 02200 - Earthwork. 15921.3.24.1 Blocking. Underground piping shall be provided with suitable concrete thrust blocks at locations indicated on the drawings and as required to prevent any movement of piping by the unbalanced internal liquid pressure. Concrete and reinforcing steel shall be as specified in Section 03311 - Cast-in-Place Concrete. Thrust blocking to be furnished shall include blocking as required to prevent movement of uncovered piping during hydrostatic testing. The Contractor shall be responsible for all blocking, and blocking shall not be accepted as adequate until piping has been successfully hydrostatically tested as specified herein. Thrust blocking shall bear against undisturbed earth and shall be placed so that the pipe joints will be accessible for inspection and repair. 15921.3.24.2 Pipe Encased in Concrete. Concrete encasements shall be installed where and as indicated on the drawings. Concrete and reinforcing steel shall be as specified in Section 03311 - Castin-Place Concrete. Pipe to be encased shall be installed on a base slab and wedges placed to bring the pipe to exact grade, prevent flotation, and hold the pipe in alignment. The wedges shall be completely encased in the concrete to prevent a water path along the wedges to the outside of the encasement. The slabs shall be provided with keys or water stops to ensure completely watertight and pressure sealed Source: 15921, 2014, v2.0 Piping Erection Page 138 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 encasements. All necessary measures shall be taken to ensure that the piping is isolated from other metal. 15921.3.24.3 Grade and Alignment. Piping shall be laid to the lines and grades indicated on the drawings. Laser beam equipment, survey instruments, or other acceptable construction methods shall be used to maintain alignment and grade. All trenches shall be so graded and pipe so installed that the pipe, when laid on the trench bottom as previously prepared and graded, will be in accurate horizontal and vertical position. Concrete pipe shall be aligned in accordance with the requirements specified below under Article 15921.3.25 - Concrete Pipe Installation. All pipe shall be brought to the terminal points specified. For mislocated terminal points, the Construction Manager shall determine the means for correction. Bending will only be permitted if approved by the Engineer. 15921.3.24.4 Laying Pipe. Pipe shall be protected from lateral displacement by pipe embedment material installed as specified for trench backfill. Under no circumstances shall pipe be laid in groundwater in excavated trenches, and no pipe shall be laid when trench conditions are unsuitable. Trench bottoms that become unstable shall be stabilized in accordance with the requirements stated in these specifications. 15921.3.24.5 Closures. When pipe laying is stopped at the end of the day, or for any other reason, the end of the pipe shall be closed with a watertight plug or bulkhead. All branch outlets shall be adequately sealed as soon as the special or fitting is laid. It is essential that mud, sand, or debris be excluded from the lines at all times. 15921.3.25 Concrete Pipe Installation All recommendations and instructions of the pipe manufacturer relative to the installation of concrete pipe shall be followed. 15921.3.25.1 Alignment. The pipe shall be installed in accurate horizontal and vertical position with a maximum permissible deviation of 3/64 inch per linear foot. 15921.3.25.2 Rubber and Steel Joints. After a section of pipe has been lowered into the trench, the bell and spigot joint connectors shall be prepared and joined in accordance with the pipe manufacturer’s recommendations. The deflection between two joints of pipe shall not exceed the recommendations of the manufacturer. The actual joint openings in pipe deflections shall not exceed 3/8 inch (9.5 mm). It is essential that each gasket be in proper position. A leaking joint will be evidence of an improperly made joint. Each defective joint discovered after the pipe has been laid shall be repaired. If determined to be necessary by the Construction Manager, the repair of each defective joint shall be made by cutting a groove entirely around the pipe adjacent to the joint and, after exposing the adjacent joint ring surfaces, completely sealing the joint by means of a continuous weld, followed by filling the previously cut groove with cement mortar around and to the full thickness of the pipe outside of the joint rings. 15921.3.25.3 Grouting. The joint space remaining after installing the pipe shall be grouted in accordance with the manufacturer’s recommendations. Not less than two lengths of pipe shall be in final position in advance of grouting. Pipe embedment operations shall not be resumed until initial set of the grout has occurred. Care shall be taken to prevent damage to the grout. 15921.3.25.4 Welded Joints. Inside and outside joint spaces of welded joints shall be cemented and grouted after welding, as specified above under Grouting. Source: 15921, 2014, v2.0 Piping Erection Page 139 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 15921.3.25.5 Anchored Joints. Harnessed joints shall be installed at the locations indicated on the drawings and where recommended by the manufacturer. All harnessed joints shall be encased in concrete with wire mesh reinforcement in strict accordance with the pipe manufacturer's recommendations. 15921.3.26 Mechanical Joint Pipe Installation Mechanical joint pipe shall be assembled in complete accordance with the manufacturer's instructions and recommendations. If effective sealing is not obtained in the assembly of mechanical joints, the joint shall be disassembled, cleaned, and reassembled. Overtightening bolts to compensate for poor installation practice will not be permitted. Cutting shall be performed in a neat manner, without damage to the pipe. Cuts shall be straight, smooth, and at right angles to the pipe axis. Ends of ductile iron pipe shall be cut with a saw or abrasive wheel. 15921.3.27 Push-on Joint Pipe Installation All instructions and recommendations of the pipe manufacturer relative to gasket installation and other jointing operations shall be followed by the Contractor. All joint surfaces shall be lubricated with heavy vegetable soap solution immediately before the joint is completed. Lubricant shall be suitable for use in potable water, shall be stored in closed containers, and shall be kept clean. Each spigot end shall be suitably beveled to facilitate assembly. Cutting shall be performed in a neat manner, without damage to the pipe. Cuts shall be straight, smooth, and at right angles to the pipe axis. Ends of ductile iron pipe shall be cut with a saw or abrasive wheel. 15921.3.28 Installation of Restrained Push-on Joint Pipe Where restrained push-on joints are provided, the joints shall be assembled in complete accordance with the manufacturer's instructions and recommendations and in accordance with the specified standard. If effective sealing is not obtained in assembly of a joint, the joint shall be disassembled, cleaned, and reassembled with a new gasket. Field grooving of pipe shall be permitted only on closure pieces. Field cut grooves shall be within the dimensional tolerances of the specified standard. 15921.3.29 Nonmetallic Pipe Installation Not Used. 15921.3.30 Underwater Installation of Piping Installation of piping underwater at river crossings or at discharges into a lake or the sea shall be in accordance with procedures established by the Contractor in conjunction with the pipe manufacturer. The proposed installation procedure shall be submitted with the bid and shall include a detailed description of the method and equipment to be used, and verification that the procedure has been reviewed and approved by the pipe manufacturer. 15921.3.31 Testing Where required by Article 15921.1.1, materials and equipment tests shall be made by the Contractor as specified herein, as specified on the Pipeline List, and as required by code requirements and local and state regulations. Nonmetallic pipe shall be pressure tested per Article 15921.3.29. The cycle makeup and storage, condensate, feedwater, and steam piping shall be hydrostatically tested with chemically treated water defined as demineralized water with sufficient ammonia to raise the pH to approximately 10.0. Water used to test other lines shall be clean, filtered, fresh water (service water or better) and shall be chemically treated to inhibit biological organisms. Treatment levels shall not exceed 2 mg/L of residual chlorine. Testing water shall not be left to stagnate in the lines. Source: 15921, 2014, v2.0 Piping Erection Page 140 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 All materials, equipment, tools, instruments, blocking, bracing, bulkheads, blanking plates, and all labor required to complete the tests shall be furnished by the Contractor. Test water and chemicals shall be furnished by the Contractor or the Purchaser as specified in Article 15921.1.1. If any tests reveal unsatisfactory materials of workmanship, such materials or installation shall be repaired or replaced to the satisfaction of the Purchaser. 15921.3.31.1 Pressure Testing of Piping. When a test pressure is specified for a piping system in the Pipeline List, the specified test pressure shall be applied to the system upon completion of erection. Where no test pressure is specified, pressure testing is not required for that system except as specified otherwise herein. Except as otherwise specified herein or in the Pipeline List for "air test," all pressure testing shall be done hydrostatically in accordance with ASME B31.1. Leaks shall be repaired and the system retested until accepted by the Purchaser as satisfactory. All underground piping shall be given a hydrostatic test prior to covering the line. Underground fire protection system piping shall be hydrostatically tested in accordance with the referenced standard in Article 15921.1.4. The maximum allowable leakage for joints and for components other than gaskets or joints shall be as specified in the referenced standard. The test pressure shall not be applied until the components being hydrostatically tested and the pressurizing medium are at approximately the same temperature. All expansion joint control rods and attachments shall be properly adjusted before application of test pressure. Before applying the test pressure, all air shall be expelled from the piping being hydrostatically tested. If required, taps at the high points of the piping systems shall be made and shall be plugged upon completion of the testing. The addition of high point vents on alloy piping shall be approved by the Engineer. Lines to be air tested shall be completed in accordance with a test plan. The test plan shall address internal and external temperature, stored energy in the system, nonflammable and nontoxic media, increasing the pressure in stages, and safe distance zones during testing. The system shall be given an application of a leak detection fluid that shall reveal the presence of leaks by easily visible means, such as bubble formation. Where specified in Article 15921.1.1, piping installed under separate specifications shall be hydrostatically tested under these specifications. If defects are discovered in the piping that has been installed under separate specifications and tested under these specifications, the Contractor shall inform the Purchaser, who will instruct the installing contractor to return to the site and locate and repair all defects. All costs incurred as a result of defects in piping installed under separate specifications, including costs of subsequent retesting, will be borne by the Contractor who installed that section of pipe in which the leak was found. Piping that must be hydrostatically tested, but would be adversely affected by rust as indicated in Article 15921.1.1 or as directed by the Engineer, shall have a rust preventive added to the test water and shall be forced-air dried after testing. The chemicals shall be added while the piping system is being filled. All temporary piping and equipment required for the addition of the chemicals shall be furnished. All end closures shall be left in place to prevent foreign materials from entering the piping during other work. The low points of the piping shall be provided with drain taps and plugs. All plugs in the piping shall be seal welded. Source: 15921, 2014, v2.0 Piping Erection Page 141 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 15921.3.31.2 Instrument and Control Tubing Testing. Instrument and control tubing shall be tested in accordance with Section 17920 – Instrument Piping and Tubing Installation, Article 17920.3.9 15921.3.31.3 Leakage Tests. When a leakage test is specified for an AWWA C301 piping system on the Pipeline List, the specified test pressure shall be applied to the system. The test pressure shall be maintained within a maximum variation of ±5 percent during the entire time that the line leakage measurements are being taken. Leakage measurements shall not be started until a constant test pressure has been established. Compression of air trapped in unvented pipes or fittings will give false leakage readings under changing pressure conditions. After the test pressure to be used has been established and stabilized, the line leakage shall be measured by means of a water meter installed on the line side of the force pump. Line leakage is defined as the total amount of water introduced into the line as measured by the meter during the leakage test. No pipeline, or tested section thereof, will be accepted if and while it has a leakage rate in excess of 50 gallons per inch of pipe diameter per mile of pipe in 24 hours. All joints in piping shall be watertight and free from visible leaks during the prescribed tests. Each leak that is discovered within 1 year after final acceptance of the work by the Purchaser shall be located and repaired by and at the expense of the Contractor. If the leakage test is made after the pipeline has been backfilled and the joints have been covered, and such test shows a leakage rate in excess of the permissible maximum, the Contractor shall make all necessary surveys in connection with the location and repair of leaking joints to the extent required to reduce the total leakage to an acceptable amount. 15921.3.31.4 Underground Water Lines. All hydrostatically tested underground water lines shall be dewatered after the test to the extent necessary to lower the water level below the frost line. Where dewatering is not practical, other suitable methods shall be used to prevent freezing. These methods shall be acceptable to the Purchaser. 15921.3.32 Cleaning of Pipe The inside and outside surfaces of all pipe, tubing, valves, and fittings shall be cleaned of all dirt, sand, loose mill scale, and other foreign materials immediately after removal from storage and before erection. All lines shall be thoroughly flushed or blown before being placed in service. All fuel gas and compressed air lines shall be air blown. The cycle makeup and storage, condensate, feedwater, and steam piping shall be flushed with chemically treated water defined as demineralized water with sufficient ammonia to raise the pH to approximately 10.0. Water used to flush other lines shall be clean, filtered, fresh water (service water or better) and shall be chemically treated to inhibit biological organisms. Treatment levels shall not exceed 2 mg/L of residual chlorine. Flushing water shall not be left to stagnate in the lines. 15921.3.32.1 Blowing Out Steam Piping. Not Used. 15921.3.32.2 Chemical Cleaning. Not Used. 15921.3.33 Flushing of Oil Piping Not Used. Source: 15921, 2014, v2.0 Piping Erection Page 142 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 15921.3.34 Sterilization of Equipment and Piping Not Used. 15921.3.35 Final Adjustment After a period of initial operation, all flange bolting shall be checked for tightness, and all hangers readjusted. 15921.3.36 Freeze Protection If furnishing and installing freeze protection is to be performed under these specifications, the work shall be in accordance with Section 16901 - Electrical Heat Tracing. If freeze protection is required, but will be installed by others, the piping systems shall be marked, and tags attached that will identify piping systems to be freeze protected to assist the freeze protection contractor in the identification of piping and equipment to be freeze protected. Alternate means of communicating and documenting a release to the heat tracing contractor will be considered and shall be approved by the Construction Manager. The Contractor shall coordinate his work with the freeze protection contractor so as to expedite the freeze protection work. Piping and equipment in the listing of items to be freeze protected shall be installed at a time most advantageous for the efficient prosecution of the freeze protection work. The piping supports for freeze protected piping shall be thermally insulated from the piping if noted in the pipe support list or indicated on the pipe support drawing. 15921.3.37 Identification Where indicated in Article 15921.1.1, pipeline identification markers, indicating the pipeline contents, and direction-of-flow arrows shall be furnished and installed on all piping 2-1/2 inches (63 mm) and larger in diameter. The markers shall be located at strategic points along the pipe length as directed by the Purchaser. At least one marker for each pipeline shall be visible at each floor or access platform level, on each side of walls where piping passes through, at each branch takeoff, at each valve, and at each termination. Each horizontal run of piping greater than 25 feet (7.5 m) long shall have at least one sign and, if necessary, additional signs shall be provided so that the distance between signs does not exceed 50 feet (15 m). A list of legends and samples of the markers shall be submitted to the Purchaser for acceptance before the markers are ordered. The composition of the legends shall be as directed by the Purchaser. 15921.3.37.1 Metal Signs. Metal signs shall be constructed from plain finished aluminum sheet, 0.064 inch (1.62 mm) thick for signs for piping 6.625 inches (168 mm) outside diameter (OD) and smaller and 0.080 inch (2 mm) thick for signs for piping larger than 6.625 inches (168 mm) OD. The OD for insulated piping shall be the finished insulation OD. Sign corners and edges shall be rounded to a 3/8 inch (9.5 mm) radius. Sign legends shall be machine engraved or photoengraved. Machine engraved legends shall be filled with black paint after aluminum surfaces have been etched, flushed with clean water, and allowed to dry. Photoengraved legends shall be filled with black enamel by silkscreen or similar process. Legends shall be block type letters and numerals 3/4 inch (19 mm) high for piping 6.625 inches (168 mm) OD and smaller, and 1-1/4 inches (32 mm) high for piping larger than 6.625 inches (168 mm) OD. Direction-of-flow arrows shall be on separate pieces of metal. Flow arrows shall be approximately 4 inches (100 mm) long for piping 6.625 inches (168 mm) OD and smaller and 6 inches (150 mm) long for larger piping. Signs shall be attached to insulated piping aluminum jackets with hexagonal head aluminum sheet metal screws on centers not exceeding 6 inches (150 mm). Signs shall be attached to bare piping with stainless steel rivet type Nelson studs. Nelson studs shall be on centers not exceeding 12 inches (300 mm). A template or jig shall be used to accurately space the studs. Source: 15921, 2014, v2.0 Piping Erection Page 143 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 15921.3.37.2 Stenciling. Heat resistant black enamel shall be used for stenciled pipe markers. Stenciling shall be done after the completion of final painting. 15921.3.37.3 Adhesive Labels. Labels shall be pressure sensitive vinyl cloth. Labels shall have 2 inch (50 mm) high legends for pipes and insulation 3 inches (75 mm) or more in diameter and shall have 3/4 inch (19 mm) high legends for pipes and insulation less than 3 inches (75 mm) in diameter. The specific background colors, legend colors, and the names for the pipe contents shall be as directed by the Purchaser. Source: 15921, 2014, v2.0 Piping Erection Page 144 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 16410 - Junction Boxes 16410.1 General The junction boxes described herein shall be furnished and installed under these specifications. 16410.2 Description The junction boxes shall be provided as identified on the drawings and as listed in the Contract Documents. 16410.2.1 Nameplates Each junction box shall be identified with an engraved nameplate at the top of the front cover. Each nameplate shall be engraved with the junction box identification. Nameplates shall be in accordance with Section 21000 - Technical Supplemental Specifications. 16410.3 Construction Junction boxes shall be manufactured in accordance with requirements of Section 21000. NEMA type, size, identification, and additional devices, if required, shall be as indicated on the drawings. Terminal blocks mounted in junction boxes shall be mounted on a sheet steel mounting backplate. Terminal blocks shall be as identified on the drawings and as specified in Technical Supplemental Specification E520. The mounting plate shall be finished with gloss white enamel or a white epoxy coating. Terminal blocks and other devices, if required, shall be mounted by screws with drilled and tapped mounting holes. Mounting of the backplate within the junction box shall be by nuts on a welded stud. No mounting holes may penetrate the outside surface of the box. Wiring, if required, shall be as specified in Section 16510 - Conductors and Accessories. Wire size shall be 14 AWG minimum, except for indicating light wiring which shall be 16 AWG minimum and current transformer wiring which shall be 10 AWG. Source: 16410, 2014, v2.0 Junction Boxes Page 145 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 16430 - Disconnect Switches 16430.1 General The disconnect switches described herein shall be furnished and installed under these specifications. 16430.2 Codes and Standards All equipment provided under these specifications shall conform to the applicable standards of ANSI, NEMA, UL, and IEEE, and shall be in accordance with the applicable requirements of the Federal "Occupational Safety and Health Standards." The switches shall be designed and fabricated in accordance with the requirements of NEMA KS 1 for heavy-duty (Type HD) enclosed switches. 16430.3 Description Unless otherwise noted in the scope of work and/or the drawings, the following shall apply. The disconnect switches shall be nonfused or of the fused heavy-duty type, single-throw, rated 600 volts ac. The switches shall be safety type with quick-make, quick-break mechanisms. Provisions shall be provided for padlocking the switches in either the open or closed position. Watertight hubs shall be provided for all NEMA 4 and 4X enclosures. Disconnect switches shall be furnished in the quantities, enclosure type, with voltage ratings, ampere ratings, short-circuit interrupting rating, number of poles, and fusible or nonfusible. The fusible disconnect switches shall be furnished with one set of fuses installed in each switch and 100 percent spare fuses. Fuses shall be Bussmann Type FRS-R or acceptable equal, unless otherwise noted on the drawings. Unless specified otherwise, each switch shall be mounted in a sheet steel enclosure. Each switch enclosure shall be finish painted. An engraved nameplate shall be furnished mounted on the front of each switch enclosure in accordance with Section 21000 - Technical Supplemental Specifications. Nameplate inscription shall consist of the "Abbreviated Description" with the "Engineer’s ID Number" inscribed below the abbreviated description. 16430.4 Installation The Contractor shall install the switches complete as indicated on the drawings. 16430.5 Manufacturers Disconnect switches shall be as manufactured by Siemens or Engineer approved equal. Source: 16430, 2014, v2.0 Disconnect Switches Page 146 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 16501 - Lighting 16501.1 General 16501.1.1 Scope of Supply Scope of supply shall include furnishing and installation of the lighting and convenience receptacle system as specified herein. 16501.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this scope of supply include the following: Not Used. 16501.1.3 Performance and Design Requirements Performance and design requirements for the equipment and materials to be furnished under this section of these specifications are indicated herein. For lighting system materials, the following requirements shall also apply in addition to the requirements of this section: Section 16510, Conductors and Accessories. Section 16920, Raceway Components and Installation. 16501.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Luminaires Fluorescent UL 542, 935, 1598 High intensity discharge (HID) UL 496, 1029, 1598 Incandescent UL 496, 1088, 1574, 1598 Light emitting diode (LED) UL 8750 Exit, emergency, and emergency power equipment UL 924 Hazardous area UL 844 Duplex and single receptacles UL 498, 943, 1010, 1449, 1682, 1686 Switches, dimmers, contactors, and photocells UL 20, 508, 773, 894, 1472 Device plates and outlet boxes (unfinished areas) UL 514 Source: 16501, 2014, v2.0 Lighting Page 147 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction 16501.1.5 Materials The following materials shall be used: Component Bid Issue 2Mar2015 Material Switches Housing and operating levers Phenolic compound Device plates Finished areas (metal) Type 430 satin stainless steel Unfinished areas Formed sheet steel coated with zinc of cadmium Weatherproof receptacle and switches Plates and lift cover Cast aluminum All other metal parts Stainless steel or Monel metal 16501.1.6 Approved Manufacturers of Components For the following components, only the listed manufacturers are recognized as maintaining the level of quality of workmanship required by these specifications. If the Supplier wants to propose a non-listed manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Purchaser: Component Manufacturer Convenience Receptacles Duplex (gray for finished areas and brown for unfinished areas) Hubbell (Generic Cat. No. 5362), Pass & Seymour, Cooper Wiring, or Leviton Single (gray for finished areas and brown for unfinished areas) Hubbell (Generic Cat. No. 5361), Pass & Seymour, Cooper Wiring, or Leviton Kitchen range and clock outlet Hubbell, Pass & Seymour, Cooper Wiring, or Leviton Isolated ground Hubbell (Generic Cat. No. IG5362), Pass & Seymour, Cooper Wiring, or Leviton Ground fault interrupting Hubbell (Cat. No. GF20L), Pass & Seymour, Cooper Wiring, or Leviton Hazardous rated (Class I, Group D and Class II, Group F areas) Appleton EFS "U-Line" or Crouse-Hinds ENR Series Switches Single-pole (gray for finished areas and brown for unfinished areas) Hubbell (Generic Cat. No. 1221), Pass & Seymour, Cooper Wiring, or Leviton Three-way (gray for finished areas and brown for unfinished areas) Hubbell (Generic Cat. No. 1223), Pass & Seymour, Cooper Wiring, or Leviton Four-way (gray for finished areas and brown for unfinished areas) Hubbell (Generic Cat. No. 1224), Pass & Seymour, Cooper Wiring, or Leviton Source: 16501, 2014, v2.0 Lighting Page 148 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Manufacturer Momentary contact Pass & Seymour, Cooper Wiring, or Leviton Two-pole Hubbell (Generic Cat. No. 1222), Pass & Seymour, Cooper Wiring, or Leviton Three-way, four-way (Class I, Group D and Class II, Group F areas) Appleton or Crouse-Hinds "EDS" tumbler series Dimmers Lutron "NOVA" series Device plates Device plates (unfinished areas) Crouse-Hinds or Appleton Device plates (finished areas) Hubbell, Pass & Seymour, Cooper Wiring, or Leviton Weatherproof single receptacle device plates Crouse-Hinds WLRS-1 or Appleton Weatherproof duplex receptacle device plates Crouse-Hinds WLRD-1 or Appleton Weatherproof switch device plates Crouse-Hinds DS185 or Appleton Miscellaneous Lamps General Electric, Osram Sylvania, or Phillips Lighting Fluorescent dimming system Lutron Grafik Eye series Photoelectric controllers Fisher Pierce N7790B Lighting contactors ASCO, Cutler-Hammer, General Electric, Siemens, or Square D Area lighting in-line fused connectors Bussmann 16501.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Supplier is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By Operational test Article 16501.1.4 Manufacturer 16501.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 16501.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. Source: 16501, 2014, v2.0 Lighting Page 149 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 16501.2 Products 16501.2.1 Luminaires Luminaires shall be as specified on the drawings or bill of quantity. 16501.2.2 Luminaire Supports All required luminaire supports, hangers, clamps, and fasteners shall be as specified on the drawings or bill of quantity. 16501.2.3 Plugs One matchup hazardous rated plug shall be furnished for each three hazardous rated receptacles. 16501.2.4 Switches Switches shall be totally enclosed tumbler type with single mounting yoke design. Single and double pole switches shall be position indicating. 16501.2.5 Device Plates Device plates shall be furnished for all device boxes. 16501.2.6 Lamps Lamps shall be furnished for all luminaires. Lamps shall be as specified on the drawings or bill of quantity. Fluorescent and high-pressure sodium lamps shall be compliant with Toxicity Characteristic Leaching Procedure (TCLP) standards. High-pressure sodium and pulse start metal halide lamps shall be clear. 16501.2.7 Lighting Contactors Lighting contactors shall be as specified on the drawings or bill of quantity. Contactors shall include an enclosure rated as indicated on the drawings (NEMA 12 minimum), hand-off-auto control switch, control fuse, and contacts rated for the application. 16501.2.8 Not Used 16501.2.9 Lighting and Convenience Receptacle Conductors The following conductor types for use in the lighting and convenience receptacle circuits shall be provided in accordance with Cable Specification Sheets included in Section 16510 of these specifications: Cable Type Circuit Use THHN (Type L2) For 120 volt circuits in heated areas XHHW-2 (Type L1) All 277 volt circuits and all 120 volt circuits in unheated areas SF-2 (Type SF-2) For incandescent luminaire connections 16501.2.10 Lighting and Convenience Receptacle Raceway The following raceway and raceway fittings for use in lighting and convenience receptacle circuits shall be provided: Raceway Type Use Electrical metallic tubing (EMT) Installed in indoor non-hazardous areas Rigid galvanized steel Outdoors above grade and indoor hazardous areas Flexible metallic tubing Luminaire taps in finished areas Source: 16501, 2014, v2.0 Lighting Page 150 of 280 Calaveras Coal Yard 186144.77.1000 Schedule 40 PVC Bid Issue 2Mar2015 Compressed Air Equipment Construction Area lighting routed underground 16501.3 Execution If lighting installation is included in the Scope of Supply (16501.1.1), the installation shall be in accordance with Section 16940, Lighting Installation. Source: 16501, 2014, v2.0 Lighting Page 151 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 16510 - Conductors and Accessories 16510.1 General 16510.1.1 Scope of Supply Scope of supply shall include conductors and accessories as indicated in the attachments listed in Article 16510.1.8 and as specified herein. The scope of supply includes the following: Procurement of materials from Supplier and installation as part of a construction contract. If conductors and accessories to be furnished under this specification are part of the Scope of Work under a larger procurement package to be designed and furnished by the Supplier, the scope of conductor and accessory materials to be furnished will be determined by the Supplier's overall design. 16510.1.1.1 Quantity Spreadsheet. Not Used 16510.1.1.2 Drawings. Drawings, if included, indicate the circuits, locations, and routing for those components that are to be furnished under this Contract. The Supplier shall use the drawings to determine the quantities and types of materials and components to be furnished. 16510.1.1.3 Circuit Lists. Circuit lists, if included, indicate the circuits and circuit lengths for those materials and components that are to be furnished under this Contract. The Supplier shall use the circuit list to determine the quantities and types of materials and components to be furnished. 16510.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this scope of supply include the following: 16510.1.3 Performance and Design Requirements Performance and design requirements for the material and components to be furnished under these specifications are indicated herein and on the Conductors and Accessories Specification Sheets included at the end of this section. 16510.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With ANSI/IEEE/ICEA/UL/NEC Power, control, instrumentation, thermocouple, and specialty cables The codes and standards indicated in the technical attachments, Article 16510.1.8 Flame Testing of Cables for Use in Cable Tray in Industrial and Commercial Occupancies IEEE 1202 Short-Circuit Performance of Metallic Shields and Sheaths on Insulated Cable ICEA P-45-482 Source: 16510, 2014, v2.1 Conductors and Accessories Page 152 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Work In Accordance With Electrical Power and Control Tray Cables with Optional Optical-Fiber Members UL 1277 UL Standard for Safety – Power Limited Circuit Cables UL 13 UL Standard for Safety – Flexible Cord and Fixture Wire UL 62 UL Standard for Safety – Electrical Wires, Cables and Flexible Cords UL 1581 Cable accessories AEIC CS8, IEEE 404, IEEE 48 16510.1.5 Materials The following materials shall be used: Component Material Power, control, instrumentation, thermocouple, and specialty cables Materials as indicated in the technical attachments, Article 16510.1.8 Cable Accessories As indicated in Article 16510.2.3 16510.1.6 Approved Manufacturers of Components For the following components, only the listed manufacturers are recognized as maintaining the level of quality of workmanship required by these specifications. If the Supplier wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Purchaser: Component Manufacturer ICEA/AEIC medium voltage power cable General Cable , Okonite, Prysmian (Pirelli), Southwire, Kerite ICEA/UL low voltage power cable General Cable, Prysmian (Pirelli), Rockbestos Suprenant, Rome, Southwire, Service Wire, Tamaqua (Draka USA), Kerite, Okonite ICEA/UL control cable Belden, Dekoron, General Cable, Prysmian (Pirelli), Rockbestos Suprenant, Southwire, Shawflex, Service Wire, Tamaqua (Draka USA), Okonite ICEA/UL instrumentation and thermocouple cable Belden, Dekoron, General Cable, Shawflex, Rockbestos Surprenant ICEA/UL insulated ground cable General Cable, Essex/Royal, Okonite, Rockbestos Suprenant, Southwire, BIW Tamaqua 16510.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Source: 16510, 2014, v2.1 Conductors and Accessories Page 153 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Supplier is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By Standard Applicable ANSI, IEEE, ICEA, AEIC and UL Standards or Applicable IEC Standards Manufacturer ICEA/AEIC medium voltage power cable qualification tests AEIC CS8 and ICEA S-97682 Manufacturer Cable type tests, production tests, routine tests and flame tests The codes and standards indicated in the technical attachments, Article 16510.1.8 Manufacturer Cable Flame Tests The codes and standards indicated in the technical attachments, Article 16510.1.8 Post-installation testing Purchaser 16510.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 16510.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 16510.1.10 Certification Requirements Certified test reports for each type of power cable furnished under this Contract shall be provided in accordance with the requirements of AEIC CS8 and ICEA S-97-682 (ICEA/AECI MV power cable), and in accordance with the requirements of ICEA S-95-658 (ICEA/UL LV power cable) and other applicable standards as indicated in the technical attachments, Article 16510.108. 16510.2 Products 16510.2.1 Conductors and Accessories - General Requirements The design and construction of insulated conductors shall be in accordance with manufacturer and utility industry standard practices, except as modified in accordance with these specifications. All insulated cable, conductors, and accessories shall meet the operating conditions and requirements as specified herein and on the Conductors and Accessories Specification Sheet. The term "Type" used in the Circuit List, on the drawings, and in these specifications refers to the letter identification indicated in the upper right corner of each Cable Specification Sheet. 16510.2.1.1 Design Life. All equipment, components, and materials shall have a useful design life of 40 years, accounting for corrosion, erosion, and material degradation. Source: 16510, 2014, v2.1 Conductors and Accessories Page 154 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 16510.2.1.2 Engineering Data. The Supplier shall submit his product specification drawings for all specified cable and accessories to the Purchaser in accordance with the Schedule of Contract Submittals. The drawings shall include dimensions and materials of construction for all materials. Material furnished shall be in accordance with the product specification drawings that receive approval by the Purchaser. 16510.2.1.3 Splicing. Splicing is prohibited, except by the installation contractor for use with lighting conductors and instances where the installed conductors must be connected to factory installed pigtails (motors, solenoids, switches, (etc.). 16510.2.1.4 Stripping Requirements. Any material in contact with the conductor shall be free-stripping. Cables which require wire brushing of the conductor or dipping of the conductor into molten solder to facilitate termination are not acceptable. If the material in contact with the conductor is not free-stripping, the entire cable reel may be rejected at the option of the Purchaser, or the Purchaser may back charge the Supplier for additional labor required to strip the material. 16510.2.1.5 Maximum Cable Diameter. The Supplier shall state in his proposal the guaranteed maximum outside diameter for each cable supplied. The actual outside cable diameters shall not exceed the guaranteed maximum outside diameter stated in the Supplier's proposal. Cable diameters may be measured in the field to determine compliance with the maximum outside diameter stated in the Supplier's proposal. If any of the measured diameters of the cable on any reel are in excess of the maximum value stated in the Supplier's proposal, the cable reel may be rejected by the Purchaser. 16510.2.1.6 Cable Component Thicknesses (IEC Cable). For IEC Cables, the Supplier shall furnish the thickness of cable components so that the thickness of the separation sheath, armor, and oversheath may be verified using sample diameter calculations in IEC 502. 16510.2.1.7 Conductor Identification. The means of identifying single insulated conductors of a multiple conductor cable rated above 2000 volts (ICEA/UL) or 1 kV (IEC) shall be by the use of color coded tapes which are applied between the extruded insulation shield and the metallic tape portion of the insulation shield. Conductor identification of cables rated 2000 volts (ICEA/UL) or 1 kV (IEC) and less shall be as specified on the Cable Specification Sheets. 16510.2.1.8 Length. If cable lengths are indicated in the attachments to this specification, the cable lengths represent estimated total lengths of each cable type and size which will be required. The Supplier shall base the bid on the estimated quantities and supply prices per unit length for each type of cable. The price per unit length will be used to adjust the contract price on the basis of actual quantities ordered. The tolerances for shipped cable lengths shall be minus 0 percent to plus 5 percent (per reel). The Purchaser will pay only for the portion of shipped cable that is within these limits. The Purchaser may specify cut lengths for the cables. If cut lengths are not specified, the Supplier shall supply the cable in lengths that approximately match the "Maximum length on reel" as indicated in the Supplier's proposal. Each reel shall contain one continuous length of cable. 16510.2.1.9 Field and Post Installation Tests. Upon receipt at the site, a dc high voltage will be applied to shielded power cable rated greater than 2000 volts (ICEA/UL) or 1 kV (IEC) to determine that the cable was not damaged during shipment. The Supplier shall bear all costs of replacing defective cable including costs for making and delivering new cable, as well as removing and disposing of defective cable. Cable shall be shipped such that it may be tested on the reel. After installation, a dc high voltage will be applied to shielded power cable rated greater than 2000 volts (ICEA/UL) or 1 kV (IEC) to Source: 16510, 2014, v2.1 Conductors and Accessories Page 155 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 demonstrate that the cable was not damaged during installation. The extent of Supplier's liability is subject to the contract terms regarding guarantees. 16510.2.1.10 Packaging. All cable shall be shipped on industry standard nonreturnable reels except where cable size, length, or weight requires the use of returnable reels. The radius of each flange shall be at least 2 inches (50 mm) greater than the distance from the axis of the reel to the outside of the outermost layer of cable on the reel. Cable ends, whether exposed or concealed, shall be sealed with heat shrinkable caps. Cap sizes shall be as recommended by the cap manufacturer for the cable diameter and insulation. Caps shall contain sufficient adhesive so that shrinkage of the cap during application results in the formation of a positive watertight seal capable of withstanding complete immersion or totally exposed storage over a period of several months without permitting the entrance of moisture. Each reel shall be shipped resting on the edges of the reel flanges. The Supplier shall submit proposed size and weights for reels. The size and weights of reels will be decided on during negotiation of the contract. For ICEA/UL cables, the Purchaser prefers reels with a flange diameter no larger than 84 inches (2.1 meters) and a maximum width of not greater than 47 inches (1.2 meters). For IEC cables, the Purchaser prefers reels with a diameter no larger than 120 inches (3 meters), a flange-to-flange width no larger than 60 inches (1.5 meters), and a maximum reel weight of 13,500 pounds (6,000 kg). Each reel shall have a legible waterproof metal or plastic tag marked to include the following identification: Cable type, conductor size, and number of conductors (cores). The individual reel numbers in the total group of reels having cable of the same type, conductor (core) size, and number of conductors (cores); and the total number of reels in the group. Net length of cable on the reel in feet (meters). Gross and net weight of cable on the reel in pounds (kg). Sequential foot (meter) marking at the reel drum end and at the exposed end. Where returnable reels are required, they shall be of industry standard design. The Supplier shall provide the following data to the Purchaser prior to cable delivery in accordance with the Schedule of Contract Submittals: Serial number of each reel. Dimensions and weight of each reel. The amount of deposit required for each reel and the total deposit amount. The return shipping address (reels will be returned at the expense of the Supplier). 16510.2.1.11 Escalation of Prices. Not Used. 16510.2.2 AEIC/ICEA/UL Cable - Technical Requirements 16510.2.2.1 Conductors. Conductor material, construction and stranding shall be as specified on the Cable Specification Sheets. If copper conductors are specified, either coated or uncoated copper conductors shall be supplied. Uncoated copper conductors may be supplied if the Supplier guarantees that the material in contact with the conductor will not corrode the copper. The Supplier may supply either Source: 16510, 2014, v2.1 Conductors and Accessories Page 156 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 round or compressed conductors. Aluminum conductors shall be hard drawn and shall be 8000 series alloy. The conductor diameter and dc resistance shall meet the tolerance requirements of the applicable standards referenced in Article 16510.1.4 and on the Cable Specification Sheets. 16510.2.2.2 Conductor Shield (Screen). When a conductor shield (screen) is specified, it shall be in accordance with applicable AEIC and ICEA (or IEC) requirements. If compact conductors are supplied, the thickness of the conductor shield shall be determined as if round conductors were being used. The conductor shield shall be an extruded thermosetting, semiconducting material. For IEC cables, the thickness of the screen shall be as specified on the Cable Specification Sheets, or the manufacturer's standard if not specified or otherwise governed by the appropriate national standard. 16510.2.2.3 Insulation. The insulation material shall meet the requirements as specified herein and as indicated on the Cable Specification Sheets. Core identification shall be by numbers printed on the insulation or by coloring of insulation as specified on the Cable Specification Sheets. The conductor insulation shall be a high quality, heat and moisture-resisting compound. The insulation shall fit tightly to the conductor or conductor shield (screen). The insulation shall be applied so that it can be cleanly stripped in the field with conventional stripping tools. Cable strand and insulation shall be free of water and water vapor. The Supplier shall fully describe his methods and procedures for drying and testing cables. 16510.2.2.4 Insulation Shield (Screen). When an insulation shield (screen) is specified, it shall consist of an extruded, thermosetting semiconducting material in combination with a metallic tape. The semiconducting material shall be in accordance with the requirements of AEIC and ICEA (or IEC). For IEC cables, the thickness of the semiconducting compound and dimensions of the metallic tape shall be as specified on the Cable Specification Sheets, or the manufacturer's standard if not specified or otherwise governed by the appropriate national standard. Concentric neutral cables are not acceptable. 16510.2.2.5 Metallic Covering. If a metallic covering is required, the type and material shall be as specified on the Cable Specification Sheets. A fibrous bedding (jute) shall be applied under the metallic covering. 16510.2.2.6 Separation Sheath. A separation sheath shall be extruded for all armored cables. The material of the separation sheath shall be as specified on the Cable Specification Sheets. For multicore cables, fillers compatible with the cable operating temperature shall be used to make the assembly round before the separation sheath is extruded. 16510.2.2.7 Armor. If armor is required, armor type and material shall be as specified on the Cable Specification Sheets. The armor shall be capable of carrying the full earth fault current for the specified time as indicated in Article 16510.1.3 Performance and Design Requirements. Single wire armor (IEC cables) shall be applied in a single layer. A joint in any wire shall be not less than 3.3 feet (1 meter) from the nearest joint in any other wire. A separation sheath shall be extruded for all armored cables. The material of the separation sheath shall be as specified on the Cable Specification Sheets. 16510.2.2.8 Jacket (Outer Sheath). When specified, an overall jacket (outer sheath) shall be extruded onto the cable assembly. The material of the jacket shall meet the ICEA (or IEC) requirements indicated on the Cable Specification Sheets. If single conductor shielded cables are supplied, the thickness of the jacket shall be in accordance with the table titled Single-Conductor Metallic Shielded Cables (ICEA cables). Jackets (outer sheaths) shall consist of an abrasion, moisture, oil, heat, weather, sunlight, and flameresistant compound. The cable jacketing interstitial spaces within the jacket (outer sheath) shall be free of water or water vapor. The jacket (outer sheath) shall be smooth, free-stripping, and free from surface damage and irregularities. Severe damage or recurring irregularities may be cause for rejection of the cable by the Purchaser. Source: 16510, 2014, v2.1 Conductors and Accessories Page 157 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 The halogen content of chlorinated polyethylene and chlorosulfonated polyethylene cable assembly jackets (sheaths) shall not exceed 19 percent by weight. 16510.2.2.9 Inspection and Testing. Cables shall be inspected and tested in accordance with the appropriate codes and standards as indicated in Article 16510.1.4 and on the Cable Specification Sheets. The Supplier shall be responsible for all examinations, inspections, and tests including recording of results and maintenance of records. The Purchaser shall be given full factory access, including Subsupplier's shops, during normal working hours while cables are being manufactured and tested, and access to all fabrication and testing documents. Upon request, the Purchaser shall be given engineering samples of the cable types specified herein. The Supplier shall submit an Inspection and Test Procedure to the Purchaser for review and approval in accordance with the Schedule of Contract Submittals. The Purchaser shall be notified in advance prior to the start of fabrication for conducting general inspections. 16510.2.2.9.1 Qualification tests (ICEA/AEIC medium voltage shielded power cable). Qualification tests shall be performed for each cable type furnished. Qualification tests shall be performed in accordance with ICEA S-97-682 and the additional requirements of AEIC CS 8. A certified copy of the Qualification Test report (and evidence of on-going testing) which represents the cable being furnished shall be provided by the Supplier. The following qualification tests shall be included, as a minimum: Qualification Test Requirements Core Material Qualification Tests (Conductor Shield, Insulation, and Insulation Shield) High Voltage Time Tests Hot Impulse Tests Accelerated Water Treeing Tests Resistance Stability Tests Conductor Shield Protrusions, Convolutions and Voids Insulation Voids and Contaminants Jacket Qualification Tests Sunlight Resistance (PVC and CPE) Environmental Stress Cracking (PE) Abrasion Resistance Halogen Content Other Tests Thermomechanical Qualification Test CV Extrusion Qualification Test Insulation Resistance Accelerated Water Absorption Resistance Stability Brittleness Test for Semiconducting Shields Dissipation Factor Characterization Test Other tests as required by the applicable codes and standards 16510.2.2.9.2 Type tests (IEC cables). Not Used. 16510.2.2.9.3 Production tests (ICEA/AEIC cables). Where applicable, the following tests shall be provided for each cable manufactured. Tests shall be made on all cable in accordance with the applicable standards as indicated on the Cable Specification Sheets. A certified copy of the Production Test Report shall be provided by the Supplier when requested by the Purchaser. Production Test Requirements Medium Voltage (MV) Power Cable Source: 16510, 2014, v2.1 All production tests on cable components and the completed cable shall be performed in accordance with ICEA S-97-682 Conductors and Accessories Page 158 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Production Test Requirements and AEIC CS 8 Conductor Tests All cables Thermocouple extension cables Conductor wire prior to stranding, elongation, finish, continuity, stranded conductor elongation tests, dc resistance determination, cross-sectional area determination, and diameter determination Initial calibration tolerance Insulation Tests (all cables) Physical requirements Tensile strength, elongation, and elongation at rupture Aging requirements Tensile strength and elongation at rupture after aging Other tests (all cables) Hot creep tests, insulation resistance constant, ozone resistance, and accelerated water absorption Other tests (MV cable only) Voids, contaminants, and protrusions Nonmetallic Shield Tests (MV cable) Elongation after air oven tests, brittleness temperature, volume resistivity, thickness, wafer boil, voids and contaminants, stripping tests, and diameter tests Metallic Shield Tests Shield isolation, shield continuity, and dimensions Jacket Tests Physical requirements Tensile strength, tensile stress, heat distortion, and elongation at rupture Aging requirements Tensile strength and elongation at rupture after aging Oil immersion requirements Tensile strength and elongation at rupture after oil immersion Other tests Heat shock, heat distortion, and cold blend Electrical Tests All cables Ac voltage withstand, insulation resistance, conductor continuity, and spark tests for non-shielded single-conductor cables MV cables Partial discharge and jacket spark Other tests as required by the applicable codes and standards 16510.2.2.9.4 Routine tests (IEC cables). Not Used. 16510.2.2.9.5 Special tests (IEC cables). Not Used. 16510.2.2.9.6 Flame tests. Certified flame test reports shall be submitted to the Purchaser for all cable types listed in accordance with the codes and standards referenced on the Cable Specification Sheets. 16510.2.3 Accessories 16510.2.3.1 General. This article covers conductor accessories. All conductor accessories shall be provided as indicated in Article 16510.1 and as specified herein. Source: 16510, 2014, v2.1 Conductors and Accessories Page 159 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction 16510.2.3.2 Terminal Connectors. Bid Issue 2Mar2015 2 16510.2.3.2.1 Terminal connectors for conductors 8 AWG (10 mm ) and larger. Terminal 2 connectors for conductors 8 AWG (10 mm ) and larger shall be pressure or bolted clamp type, Burndy Qiklug, Varilug, or acceptable equal; or compression type, Burndy Type YAV or YA (long barrel), Panduit Type LCA or LCC, or acceptable equal. Reducing pin compression connectors (if required and approved for use by Engineer) shall be Burndy Type YE-P, or acceptable equal for cables that are oversized due to voltage drop or derating that will not fit into equipment lugs. 2 16510.2.3.2.2 Terminal connectors for conductors smaller than 8 AWG (10 mm ). Terminal 2 connectors for conductors smaller than 8 AWG (10 mm ) shall be compression type connectors properly sized for the conductor and the terminal. The connectors shall be constructed of fine grade high conductivity copper and shall be tin-plated. The interior surface of the connector wire barrel shall be serrated, and the exterior surface of the connector wire barrel shall be provided with crimp guides. Noninsulated terminal connectors shall be provided on conductors terminated on devices equipped with individual fitted covers, such as General Electric Type SB-1 control switches and General Electric Type HEA lockout relays. Preinsulated ring type terminal connectors shall be used on all current and 2 potential transformer circuits. All other terminal connectors for conductors smaller than 8 AWG (10 mm ) shall be preinsulated ring type or preinsulated spade type. Preinsulated terminal connectors shall include a vinyl insulating sleeve, color coded to indicate conductor size. Preinsulated terminal connectors shall include a metallic support sleeve bonded to the vinyl insulating sleeve and designed to grip the conductor insulation. Ring type connectors shall be manufactured by AMP, 3M, Panduit, or acceptable equal. Spade type connectors shall be AMP slotted spring spade, 3M Scotchlok Series 6l snap spade, Panduit locking fork terminal connectors, or acceptable equal. Ferrules shall be provided on all stranded conductors that are to be terminated to compression type IEC terminal blocks. 16510.2.3.3 Terminal Blocks. Terminal blocks shall meet the requirements of the Technical Supplemental E520, Terminal Blocks and Fuse Holders. 16510.2.3.4 Splicing Connectors. Splices to factory installed pigtails shall be with compression type 2 connectors. Splices in lighting conductors smaller than 8 AWG (10 mm ) shall be with 3M Company "Scotchlok" twist type insulated spring connectors, Panduit JN wire joints, or acceptable equal. Splices in 2 lighting conductors 8 AWG (10 mm ) and larger shall be with compression type connectors, 3M Company 5300 Series (600V), 3M Company 5500 Series (5 and 15 kV), Raychem Type HVS (5 and 15 kV), (or equal . 16510.2.3.5 Crimping Tools. Crimping tools used to secure conductors in compression type connectors or terminal lugs shall be those made for that purpose and for the conductor sizes involved. The crimping tools shall accurately crimp the connector barrel and shall accurately crimp the conductor insulation support sleeve where provided. Crimping tools shall be provided with guides to position connectors in the tool, shall be provided with stops to prevent overcrimping, and shall be of a type which prevents the tools from opening until the crimp action is completed. Crimping tools shall be a product of the connector manufacturer or shall be as recommended by the connector manufacturer and acceptable to the Purchaser for use with the connectors. 16510.2.3.6 Insulating Materials. Insulating materials for splice and termination insulation shall be in accordance with the following. Source: 16510, 2014, v2.1 Conductors and Accessories Page 160 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 16510.2.3.6.1 1000 volt (or less) cable. Insulating materials for terminal connections in motor terminal housings shall be Raychem Type MCK, 1000 volt motor connection kits, 3M Company 5300 Series or acceptable equal. Insulating materials for terminal connections to busbar shall be Raychem Type FCSM heavy wall flame retardant sleeves with Raychem S1052 electrical putty, or equal, applied to obtain an environmental seal where multiple cables enter a single sleeve. Where heat shrink insulating sleeves and boots cannot be used, insulating materials for terminal connectors or compression type splicing connectors shall consist of varnished cambric tape, rubber tape, and vinyl tape. Taping materials shall be as listed below or acceptable equal: Varnished Cambric Tape - 3M Company Irvington 2520. Rubber Tape - 3M Company Scotch 130C. Vinyl Tape - 3M Company Scotch 33+. Copper Braid Tape – 3M Company Scotch 24 16510.2.3.6.2 Shielded cable rated 5 kV and above. Insulating materials for terminal connectors in motor terminal housings with direct cable connection to the motor leads (for cable rated up to 8 kV) shall be Raychem Type MCK-5 high voltage motor connection kits or acceptable equal. After installation of the cable termination kit as specified in 16510.2.3.11, the terminal connectors in motor terminal housings shall be insulated with Raychem Type MCK-5 high voltage motor connection kits or acceptable equal. Connections to insulated switchgear buses shall be insulated with removable boots furnished with the switchgear or acceptable equal. Other indoor terminal connectors, including those located in air insulated terminal chambers (bus type terminations), shall be insulated using Raychem Type HVBC high voltage bus connection kits or shall be insulated by using a taped system. The HVBC or taped system shall be applied after application of the termination kit specified in 16510.2.3.11. Taping materials shall be as listed below or acceptable equal: Copper Braid Tape - 3M Company Scotch 24. Rubber Tape - 3M Company Scotch 130C. Vinyl Tape - 3M Company Scotch 33+. Splicing connectors for 5 kV and 15 kV cable shall be insulated using 3M Company 5500 Series QuickSplice Inline splicing kits, Raychem Type HVS splicing kits, or acceptable equal. Material for insulation of splices for cable rated above 15 kV and for motor terminal connectors for cable rated above 8 kV shall be as specified on the drawings. 16510.2.3.7 Support Grips. Cable support grips shall be either split or closed woven wire type as manufactured by The Kellems Division, Harvey Hubbell Incorporated, Stonington, Connecticut, Daniel Woodhead Co., or equal. 16510.2.3.8 Wire and Cable Markers. Markers for wire and cable circuits shall be of an opaque nylon material arranged to include a marker board, nonreleasing holding device, and cable fastening tail. The marker board shall not be less than 0.75 inch by 2.5 inch and shall be Panduit Corp., Part No. MP250 marker plates or acceptable equal. One side shall be roughened to hold black nylon marking ink from a fine tip pen similar to Thomas & Betts Company "TY-RAP" marking pen, Catalog No. WT163M-1, or Panduit Corp., Part No. PFX-O marking pen or equal. Identification shall be permanent and waterproof. Source: 16510, 2014, v2.1 Conductors and Accessories Page 161 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 The holding device shall be designed to allow the fastening tail to pass around the cable through the holding device and prevent the removal of the tail without cutting it loose from the marker. 16510.2.3.9 Cable Ties. Lacing materials for field installed cable shall be nonreleasing weatherresistant black nylon ties manufactured by Thomas & Betts Company, Elizabeth, New Jersey; Panduit Corp., Tinley Park, Illinois; 3M Company; or acceptable equal. 16510.2.3.10 Arcproofing Material. Material for the arcproofing of nonflame retardant cable shall be an unsupported intumescent self-extinguishing elastomer tape, 3M Company Scotch Brand No. 77 or acceptable equal, and a pressure sensitive silicone adhesive backed glass cloth holding tape, 3M Company Scotch Brand No. 69 or acceptable equal. 16510.2.3.11 Cable Termination Kits for Shielded Cable Rated 5 kV and Above. All cable termination kits for shielded cable rated 5 kV and above shall be in accordance with the requirements of IEEE 48 for Class 1 terminations. Cable termination kits for 5 kV and 15 kV shielded cable in motor terminal housings shall be Raychem HVT-G/SG series (heat shrinkable), Raychem HVT-Z series (heat shrinkable), Raychem TFT-E series (cold-applied), 3M Company QT-III 7620 series (cold-applied), or acceptable equal. Outdoor cable termination kits and indoor cable termination kits for cable of voltage classes above 15 kV shall be as specified on the drawings. 16510.2.3.12 Cable Glands. Cable glands shall be supplied kit form complete with earthtags, locknuts, and shrouds. The Supplier shall coordinate the cable gland with the outside diameter of the proposed cable. One insulated adapter shall be supplied for each circuit designated as single point bonded. The combination of earthtag and cable glands shall be capable of withstanding the available earth fault current for the designated time. 16510.2.3.13 Pulling Lubricant. Pulling lubricant shall be provided as recommended by the cable manufacturer. 16510.2.3.14 Fiber-Optic Cable Accessories. 16510.2.3.14.1 Inner duct. Inner ducts for fiber-optic cable shall be no smaller than 1 inch (25 mm), flame-resistance, corrugated, orange colored, with measuring/pull tape, and shall be Carlon Plenum-Gard or acceptable equal for plenum, riser and general purpose applications in accordance with NEC Articles 770 and 800. The actual size of the inner duct shall be coordinated with the fiber-optic manufacturer's requirements by the Supplier. The pulling tape shall have a recommended maximum working load of at least 1,200 pounds (544 kg). 16510.2.3.14.2 Pulling equipment. Pulling equipment for fiber-optic cable shall include a recording running line dynamometer graph to measure and record the pulling tension, as manufactured by A.B. Chance Co., Evergreen Co., T.A. Pelsue Co., or acceptable equal. The pulling equipment shall have "slip load" capability to allow the winch to maintain a constant pulling force without taking up the winch line. The pulling equipment shall also be equipped with a hydraulic bypass which shall be set so that a maximum tension of 150 pounds (68 kg) is not exceeded. A reliable, nonfreezing swivel shall be provided for insertion between the pulling line and the cable pulling grip to prevent twisting under strain. The swivel shall be equipped with shear or tension pins with a breaking strength of 150 pounds (68 kg). Swivels shall be manufactured by Condux International or approved equal. Woven wire grips shall be provided to pull the cable unless not allowed by the manufacturer of the fiber-optic cable. Woven wire grips shall be Kellums grip or acceptable equal, with a minimum length of 18 inches (450 mm). The grips shall have provisions for tying the Kevlar jacket to the grip. 16510.2.3.14.3 Pulling lubricants. Pulling lubricants shall be provided for pulling both the inner duct and the fiber-optic cable. Pulling lubricants for installation of the inner duct shall be Polywater Type J as Source: 16510, 2014, v2.1 Conductors and Accessories Page 162 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 manufactured by American Polywater Corporation, Stillwater, Minnesota or acceptable equal. Pulling lubricants for installing the cable shall be Polywater Type F or acceptable equal. 16510.2.3.14.4 Fiber-optic cable terminations. Fiber-optic cable terminations and optical connectors shall be approved by the cable manufacturer for use with the type of fiber-optic cable specified. Utilize ceramic ferrule, field installed and polished, anaerobic cure connectors. Quick connect crimp type connectors shall not be used. As an option, pre-terminated pigtail connectors may be used where they are fusion spliced to the fiber-optic cables and heat shrink tubes and suitable splice trays are utilized. Utilize ST type connectors for DCS system fiber-optic cables, and SC type connectors for Facility LAN system fiber-optic cables unless otherwise noted on the drawings. Any special tools and materials required to install the fiber-optic cable connectors shall be provided by the Supplier. 16510.3 Execution If installation is included in the scope of work, installation shall be in accordance with the requirements of Section 16925 - Conductors Installation. Source: 16510, 2014, v2.1 Conductors and Accessories Page 163 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 16910 - Electrical Equipment Installation 16910.1 General 16910.1.1 Scope of Supply Scope of supply shall include the Electrical Equipment Installation as defined herein. For Purchaserfurnished electrical equipment to be installed under these specifications, the scope of supply shall include all necessary labor, materials, hardware, tools, and consumables as defined in Section 01100 - Onsite Operations. Purchaser-furnished electrical equipment is defined in Section 01631. 16910.1.1.1 Scope of Erection/Installation. The scope of erection/installation shall include the the electrical equipment specified in section 01100. 16910.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this scope of supply are identified on the Purchaser-Furnished Electrical Equipment and Materials Data Sheets in Section 01631. 16910.1.3 Performance and Design Requirements Performance and design requirements for the Electrical Equipment Installation are indicated in the vendor information for the equipment. 16910.1.4 Codes and Standards Not Used. 16910.1.5 Materials Not Used. 16910.1.6 Approved Manufacturers of Components Not Used. 16910.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Contractor unless specifically identified as a Bid Option or Contractor-conducted. Tests identified as an option are to be priced separately. If identified as Contractor-conducted, costs for the initial test will be the responsibility of the Contractor. However, the Contractor is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By Functional Tests of electrical equipment. Contractor Standard Contractor 16910.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 16910.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 16910.2 Products Not used. Source: 16910, 2014, v2.0 Electrical Equipment Installation Page 164 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 16910.3 Execution 16910.3.1 Installation Requirements Applicable to All Equipment 16910.3.1.1 General. This article covers installation work for all electrical equipment installed or furnished and installed under these specifications. Installation work shall include receiving, unloading, storage, removal from storage, hauling, cleaning, installation on foundations, and other work necessary to place all equipment into successful operation. In addition, installation work shall include complete assembly of equipment shipped unassembled; dismantling and reassembly of equipment to make adjustments; and provision of personnel, equipment, and assistance in testing and placing the equipment into operation. Installation procedures not specified herein shall be in accordance with the instructions, recommendations, and/or drawings of the equipment manufacturer. Contradictions between these specifications and the manufacturer's instructions, recommendations, and drawings shall be resolved by the manufacturer's recommendations taking precedence. At the request of the Purchaser, the Supplier shall submit detailed installation procedures, detailed manpower allocation, and schedule for approval by the Purchaser prior to starting installation work. Equipment shall be checked prior to its installation to ensure that it is in conformance with the purchase documents and manufacturer's drawings. Any discrepancies shall be reported to the Engineer. When equipment is shipped unassembled, the complete assembly of such equipment shall be a part of the work included under these specifications. All installation work on this equipment shall be performed under these specifications. Work under these specifications shall include the installation of all wiring that is included under the scope of equipment installed under these specifications. 16910.3.1.2 Miscellaneous Material. All miscellaneous materials, except those specified to be furnished by other suppliers, shall be furnished as required for the complete installation, startup testing, and operation of the equipment. These materials shall include, but shall not be limited to, grout, shims, wedges, dowels, anchors, supports, bolting, gaskets, packing, welding rod, and consumable gases. Cast-in-place anchor bolts will not be provided in all cases for the anchorage of the equipment to concrete bases. Anchors as required by the equipment manufacturer shall be furnished and installed by the Contractor. 16910.3.1.3 Location Tolerances. Equipment shall be located within 1/8 inch (3 mm) of the dimensional location indicated on the drawings unless otherwise permitted by the Engineer. Some equipment is indicated schematically without dimensions. The Contractor shall coordinate the location of this equipment with all other equipment or materials to be installed. 16910.3.1.4 Alignment. Rigid components such as bus, bus duct, throat connections, and enclosures shall be aligned and connected with special care to prevent excessive stress in joints, supports, and connections. Equipment with moving parts and safety interlocks, such as switches, circuit breakers, and switch operating mechanisms shall be carefully aligned to assure free mechanical operation. 16910.3.1.5 Bolted Electrical Connections. Where bolted electrical connections are made to aluminum, the aluminum surface shall be thoroughly cleaned with a wire brush, then coated with joint compound and thoroughly brushed again through the compound. Additional compound shall then be added and the joint bolted together. Source: 16910, 2014, v2.0 Electrical Equipment Installation Page 165 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Where bolted connections are made between copper or brass surfaces, the metal surfaces shall be thoroughly cleaned and coated with a suitable antioxidizing compound. It shall be the Contractor's responsibility to certify that the tightness of each bolt in all bolted electrical connections is in accordance with the manufacturer's recommendations. Factory bolt torques shall be verified as part of the equipment checkout and test procedures. Bolted electrical connections shall be tightened with manual torque wrenches. Torque wrenches shall be constructed so that they will visually or audibly indicate when the proper torque is reached. The accuracy of each torque wrench shall be checked by a testing laboratory acceptable to the Site QA Manager immediately prior to its use on equipment installed under these specifications, and every 6 months thereafter, or sooner if the calibration of the wrench becomes suspect. 16910.3.1.6 Torque Values. If the equipment manufacturer's installation instructions do not include recommended torque values for bolt tightening, torque values shall be in accordance with those listed in the table which follows: Torque Values For Dry, Unplated, Nonlubricated Bolts Bolt Size 18-8 Stainless Steel (in.-lb) Brass (in.-lb) Silicon Bronze (in.-lb) Aluminum 24ST-4 (in.-lb) 316 Stainless Steel (in.-lb) 1/4" - 20 75.2 61.5 68.8 45.6 78.8 1/4" - 28 94.0 77.0 87.0 57.0 99.0 5/16" - 18 132 107 123 80 138 5/16" - 24 142 116 131 86 147 3/8" - 16 236 192 219 143 247 3/8" - 24 259 212 240 157 271 7/16" - 14 376 317 349 228 393 7/16" - 20 400 327 371 242 418 1/2" - 13 517 422 480 313 542 1/2" - 20 541 443 502 328 565 9/16" - 12 682 558 632 413 713 9/16" - 18 752 615 697 456 787 5/8" - 11 1,110 907 1,030 715 1,160 5/8" - 18 1,244 1,016 1,154 798 1,301 Source: 16910, 2014, v2.0 Electrical Equipment Installation Page 166 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Torque Values For Dry, Unplated, Nonlubricated Bolts Bolt Size 18-8 Stainless Steel (in.-lb) Brass (in.-lb) Silicon Bronze (in.-lb) Aluminum 24ST-4 (in.-lb) 316 Stainless Steel (in.-lb) 3/4" - 10 1,530 1,249 1,416 980 1,582 3/4" - 16 1,490 1,220 1,382 958 1,558 7/8" - 9 2,328 1,905 2,140 1,495 2,430 7/8" - 14 2,318 1,895 2,130 1,490 2,420 1" - 8 3,440 2,815 3,185 2,205 3,595 1" - 14 3,110 2,545 2,885 1,995 3,250 16910.3.1.7 Connection Bolt Tightness Check. The tightened bolts in electrical connections shall be checked at random. The Contractor shall be responsible for coordinating the checking of bolt tightness so that minimum interference with equipment installation and connection will be experienced. Removal of covers and similar dismantling of equipment to permit the Site QA Manager to witness the checking of bolt tightness of enclosed connections shall be part of the work included under these specifications. The number of bolts checked shall be acceptable to the Site QA Manager, based upon his observance of the quality and completeness of the tightening operations. A minimum of 10 percent of the bolts in each connection, but not less than two bolts in each connection, shall be checked. Checking of tightness of electrical connections in the presence of the Site QA Manager is intended to assist the Contractor in avoiding the expense of repairing costly connection failures. This check shall not relieve the Contractor of complete responsibility for the integrity of the electrical connections. 16910.3.1.8 Welding. All welding shall be in accordance with the welding supplemental specifications in Section 21000. All workmen performing ferrous welding of any kind shall be qualified according to the codes and standards indicated in the applicable supplemental specification. 16910.3.1.9 Equipment Finish. Surfaces of most electrical equipment, such as panels, switchgear, transformers, and circuit breakers, are finished at the factory. Great care shall be exercised to prevent damage to this original finish during equipment installation and during construction work. If the factory finish is damaged during the course of construction, the damaged component shall be touched up or refinished to the satisfaction of the Owner by the Contractor. Refinishing paint, if furnished with the equipment, may be used; otherwise, the paint shall be obtained from the equipment manufacturer. 16910.3.2 Transformer Erection – Not Used 16910.3.4 Batteries and Battery Chargers Installation – Not Used. 16910.3.5 Panelboard Installation – Not Used. 16910.3.6 Isolated Phase Bus Duct Installation – Not Used. Source: 16910, 2014, v2.0 Electrical Equipment Installation Page 167 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 16910.3.7 Nonsegregated or Segregated Phase Bus Duct or Cable Bus Installation – Not Used. 16910.3.8 Electrical Distribution and Control Equipment Installation 16910.3.8.1 General. Extreme care shall be taken in the storage, handling, and installation of all electrical distribution and control equipment containing solid-state devices or electrical contacts to prevent the entrance of dust, dirt, moisture, or other contaminants. Equipment shall be kept covered and doors shall be kept closed until the equipment is placed into operation and turned over to the Owner. All space heaters inside the equipment shall be energized during storage and construction, as required. Any equipment damaged by contamination or condensation after receipt of the equipment shall be repaired or replaced. Within 1 week after removing electrical equipment from its storage location, the equipment shall be set or installed in its permanent location. Equipment shall be protected from rain or dripping water with waterproof coverings until the structure in which the equipment has been set has proven the integrity of its roof and drainage system through substantial rainfall. 16910.3.8.2 Electrical Cabinets and Enclosures. Electrical cabinets shall be set in place, shimmed level, and anchored so that all doors operate freely throughout their entire travel. Cabinets that are split for shipping shall be aligned, shimmed, and fastened together in accordance with the manufacturer's recommendations. Wiring across shipping splits shall be terminated in accordance with the manufacturer's drawings or instructions. 16910.3.8.3 Medium Voltage Switchgear and Controllers. Not Used. 16910.3.8.4 Low Voltage Equipment. This equipment consists of low voltage unit substations (SUSs), low voltage motor control centers (MCCs), separately mounted motor starters and contactors, reliable power supply equipment, and other low voltage ac switchboards and panels. All low voltage equipment and medium voltage to low voltage transformers shall be installed according to the manufacturer's recommendations and instructions and local code requirements. Installation of this equipment shall include accurately aligning each unit on its foundation and securing it in place; making up the transformer throat connections; installing the drawout circuit breakers, starters, and devices in their respective housings; and checking all main and secondary connections and tightening them where found loose. All covers or enclosures which have been removed for shipment or removed during installation shall be securely bolted in place. Each enclosure shall be installed so that it is level and all doors freely swing full travel. Where top mounted junction boxes are provided, they shall be assembled and bolted to the motor control center enclosures. The Contractor shall assemble enclosures that are split for shipping, make bus and control wire shipping split connections, and assure that mechanical and safety interlocks are installed and functional, all stabs and disconnect devices are properly aligned, isolation barriers are in place, and the drawout units move freely in and out of their compartments. Contractor shall install and exercise all breakers, starters, and miscellaneous devices and assure that the equipment is suitable for electrical energization. The Contractor shall remove and reinstall individual motor starter or breaker cubicles as indicated by the construction documents or as directed by the Engineer. Motor starter overload heater elements or overload relays of various sizes may be shipped separately. Motor nameplate data and MCC manufacturer's bulletins shall be used for field selecting and installing the proper size overload relays and heater elements. The Contractor shall set, remove, or install overload devices as directed by the Engineer. Source: 16910, 2014, v2.0 Electrical Equipment Installation Page 168 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 All circuit breakers, fused switches, motor starters, etc., shall be checked for proper mechanical and electrical operation. All space heaters inside equipment shall be energized during storage and construction, as required. 16910.3.8.5 Miscellaneous Equipment. Any miscellaneous electrical distribution equipment not specified above shall be installed in accordance with the manufacturer's instructions and recommendations. Source: 16910, 2014, v2.0 Electrical Equipment Installation Page 169 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 16920 - Raceway Components and Installation 16920.1 General This section covers the furnishing and field installation of all electrical raceway systems and components. The raceway system and installation shall be in accordance with the drawings, and scope of work described in section 01100. The raceway system is defined to include conduit, flexible conduit, cable tray, below grade conduit, duct bank, wireway, junction boxes and pull boxes, and all materials and devices required to install, support, secure, and provide a complete system for support and protection of electrical conductors. 16920.1.1 Scope of Supply Any materials not specified as being furnished by others, but which are required for a complete raceway installation, shall be furnished. 16920.1.2 Items Furnished by Others and Interfaces Not used. 16920.1.3 Performance and Design Requirements Performance and design requirements for the equipment to be furnished under this section of these specifications are indicated herein. 16920.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Engineer's specifications. In case of conflict, the latter shall govern to the extent of such difference. Raceway systems and components furnished with these specifications shall be manufactured in accordance with applicable standards of the American National Standards Institute (ANSI), the National Electrical Manufacturers Association (NEMA), and Underwriters' Laboratories, Inc. (UL). Raceway systems and components shall be installed in accordance with the applicable requirements of the National Electrical Code (NEC) and the Occupational Safety and Health Administration (OSHA) standards. Areas subject to conditions classified in the NEC as hazardous areas are indicated on the drawings. Raceway systems and components furnished and installed in these areas shall meet the requirements of the NEC for the hazardous condition indicated. 16920.1.5 Materials Not used. 16920.1.6 Approved Manufacturers of Components For the following components, only the listed manufacturers are recognized as maintaining the level of quality of workmanship required by these specifications. If the Contractor wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Engineer: Source: 16920, 2014, v2.0 Raceway Components and Installation Page 170 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Component Bid Issue 2Mar2015 Manufacturer Post-installed mechanical anchor bolts Hilti Kwik-Bolt TZ Fire stops Nelson Fire Stops Flame-Safe Fire Stop Systems Fire Stop Systems Conduit - Steel Allied Tube and Conduit Triangle PWC, Inc. Wheatland Company Conduit - Aluminum Allied Tube and Conduit Wheatland Company Indalex Conduit - Plastic Cantex PVC Products Carlon Plastic Conduit Conduit - Flexible Anamet Canada, Inc. Liquatite International Hose Company Conduit bodies and fittings - Metal O-Z/Gedney Crouse-Hinds Appleton Conduit bodies and fittings - Plastic Cantex PVC Products Carlon Plastic Conduit Support channels and fittings Unistrut Metal Framing B-Line Strut Systems Conduit supports O/Z/Gedney Crouse-Hinds Appleton Wireway B-Line Raceway Systems Hoffman Engineering Company Lee Products Company Boxes and enclosures - Metal Hoffman Engineering Company Wiegmann Appleton Hammond Manufacturing Co. Boxes and enclosures - Plastic Hammond Manufacturing Co. Carlon Plastic Products Crouse-Hinds Cable tray and accessories - Metal B-Line Tray Systems T.J. Cope, Inc. P-W Industries, Inc. Cable tray and accessories - Fiberglass Champion Fiberglass Enduro Fiberglass Systems 16920.1.7 Test Requirements Not used. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 171 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction 16920.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. Bid Issue 2Mar2015 16920.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 16920.2 Products Not used. 16920.3 Execution 16920.3.1 General Installation Requirements The installation specifications included in this article apply to all raceway system components. 16920.3.1.1 Routing of Above Grade Raceway. Electrical cable tray and wireway shall be routed as indicated on the drawings. Conduit shall be field routed according to the general routing indicated on the drawings. The location of field routed raceway and all raceway supports shall be coordinated with other equipment and structures. Wherever practical, field routed raceway shall be routed so that, except where it is changing floor elevations or being lowered to enter equipment, the lowest part of the raceway, including its associated supports and appurtenances, is at least 7'-6" (2.3 m) above the closest floor or walking surface beneath it. Field routed raceway and its associated supports and appurtenances, located at least 7'-6" (2.3 m) above the closest walking surface, may be routed a reasonable distance away from the supporting wall, ceiling, or structural member so long as the specified support is provided and interference with other equipment and structures is avoided. Field routed raceway and its associated supports and appurtenances, which must be routed closer than 7'-6" (2.3 m) above the closest walking surface, shall be routed as close as possible to surfaces of walls, columns, and the equipment served. Field routed raceway and all raceway supports shall be located at least 6 inches (150 mm) from the final outside surface of all steam piping, including insulation, and 2 inches (50 mm) from the final outside surface of all other piping, including insulation if provided. Consideration shall be given to the thermally expanded position of piping when field routing raceway. Field routed raceway and all raceway supports shall be located so that they do not interfere with equipment which expands, vibrates, or moves under normal operation such as a steam generator, flue gas ductwork, or overhead crane. 16920.3.1.2 Brackets. Bracket supports as detailed on the drawings shall be used where specifically indicated and may be substituted for other types of hangers where acceptable to the Engineer. 16920.3.1.3 Raceway Attached to Concrete. Where raceways are supported from concrete surfaces or floors, the anchorage shall be Hilti Kwik-Bolt TZs, or Engineer accepted equal meeting Federal Specification A-A-1923A, IBC, and ACI 318, Appendix D. Raceways mounted on concrete or masonry walls shall be mounted so that there is a minimum of 1/4 inch (6 mm) of air space between the raceway and the concrete or masonry wall. Raceway supports attached to concrete floors shall be installed such that they are elevated and grouted above the finished floor a minimum of 1 inch (25 mm) to prevent corrosion caused by exposure to standing water. 16920.3.1.4 Raceway Attached to Building Steel. Except as otherwise specified, indicated on the drawings, or acceptable to the Engineer, raceway or all raceway supports attached to building steel shall be secured by welding, by drilling and tapping, by powder activated devices and fasteners, or by beam clamps. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 172 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Raceway and raceway supports shall not be attached to grating. Raceway and raceway supports shall not be attached to the flanges of the cold-formed support steel in pre-engineered buildings. Instead, raceway and raceway supports shall be attached to the web of the cold-formed support steel by using bolts installed through holes field drilled in the web. 16920.3.1.5 Insulation. Raceway and all supports for raceway connected to equipment, piping, raceways, etc., that have been electrically insulated from contact with other structures shall be properly installed to prevent shunting of the insulation. Particular attention shall be given to bearings on large motors and insulated piping flanges. 16920.3.1.6 Sleeves and Openings. Sleeves and openings for the passage of electrical raceways or conductors will be located beneath major pieces of electrical equipment and in certain locations where raceway or conductors will pass through floors or walls. Openings provided through ferrous metal walls, floors, and/or cover plates for 3 phase circuits shall consist of a single penetration that will allow all three phases along with the ground conductor (where used) to be grouped together in the single opening in accordance with NEC 300.20. The Contractor shall be responsible for all required openings. Required openings not provided during structure fabrication shall be provided by the Contractor. Openings shall be finished and sealed as indicated on the drawings. 16920.3.1.6.1 Openings through steel beams. Conduit may be routed through building steel only when the routing is reviewed for structural integrity by the Engineer and approved. Holes required for conduit passages shall be drilled or sawed, or flame cut with subsequent reaming and/or grinding to prevent ragged edges, notches, cuts, or cracks. 16920.3.1.6.2 Openings through grating. Where openings through grating are required, the openings shall be made at divisions or ends of grating sections, if possible. These openings shall be square and shall be neatly finished by installing a kickplate around the entire opening and welding it to the cut grating bars. All rough spots shall be ground smooth, and welds and cuts shall be regalvanized. Penetrations in grating shall be sawed or flame cut with subsequent grinding to ensure smooth and straight cut appearance. Openings through grating shall be finished as indicated on the drawings. 16920.3.1.6.3 Openings through concrete and masonry. Openings in concrete floors and concrete or masonry walls for single conduits or minimum quantities of conductor shall be cut using a core drill. Larger openings required for multiple conduits, conductors or cable tray shall be cut using multiple core drills chiseled out to the appropriate size, or by saw cutting. The Contractor shall be responsible for providing all necessary materials to protect equipment and personnel from falling debris and water while making the opening. Required field cut openings larger than 12 inches (305 mm) in any direction shall be approved by the Engineer prior to cutting. Openings cut through concrete floors and concrete or masonry walls for the passage of conduit shall be finished by either grouting or by sealing around the conduit. Openings in concrete floors for the passage of electrical conductors shall be sealed. Openings in concrete floors and concrete or masonry walls for the passage of cable tray shall be sealed. Exposed openings between the edge of raceway components and the edge of field cut concrete floor openings exceeding 1-1/2 inches (38 mm) in width shall have kickplate installed around the entire opening. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 173 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Openings through concrete and masonry shall be finished and sealed as indicated on the drawings. 16920.3.1.6.4 Openings through metal wall panel. Single conduit openings in metal wall panel shall be hole punched or drilled the minimum size to allow passage of the conduit through the wall panel. Openings for multiple conduits or cable tray shall be neatly saw cut 2 inches (50 mm) larger than required on all four sides to allow passage of the raceway components. Insulation removed to clear the opening for the passage of raceway components through metal insulated wall panel shall be reinserted around the outside edges of the opening. Openings through metal wall panel shall be finished and sealed as indicated on the drawings. 16920.3.1.6.5 Openings through roof. No roof openings shall be allowed for raceway components. Where raceway components must access equipment located on a roof, the opening shall be made on vertical portions of walls or parapets as specified herein. Openings shall be finished and sealed as indicated on the drawings. 16920.3.1.6.6 Openings into equipment. All openings beneath equipment and all openings into the top or sides of equipment in non air-conditioned areas, including pull boxes, shall be sealed to prevent the entry of dust and liquids. All sealing materials and installations shall be watertight and flame retardant, and shall be installed in accordance with the manufacturer’s recommendations. The sealing installation shall be finished to provide a smooth, neat appearance. Openings shall not be sealed until all the cables passing through the opening have been installed and tested. All sealing materials and installation methods shall be acceptable to the Engineer prior to installation. All openings beneath equipment shall be sealed as indicated on the drawings. The seal shall provide for a minimum fire rating equal to the floor being penetrated. The cut edge of openings through metal decking beneath concrete floors for the passage of cables not enclosed in conduit shall be smooth to prevent damage to the cable. All openings into the top or sides of equipment in non air-conditioned areas allowing for the passage of cable shall be sealed as indicated on the drawings. The seal shall provide a minimum fire rating of 2 hours. Unused openings into the top or sides of equipment planned for the passage of cable shall be sealed by installing a gasketed plate over the unused opening and securing it to the equipment with stainless steel screws. The gasket and plate shall extend beyond the edges of the opening a minimum of 3/4 inch (19 mm) all around the entire opening. Unused openings into the top or sides of equipment planned for conduit shall be sealed by installing a threaded gasketed conduit hub over the conduit opening and inserting a threaded plug into the hub. The conduit hub shall be sized for the opening in the equipment and securely fastened to the equipment. Rubberized knockout plugs and snap-in steel blanks shall not be allowed. 16920.3.1.6.7 Fire stops. Sleeves and openings for the passage of cable and raceway through walls and floors shall be sealed with UL or Factory Mutual approved fire stops having a fire rating not less than that of the wall or floor penetrated. All fire stops shall be installed in accordance with the manufacturer's recommendations, including installation by trained personnel when so recommended by the manufacturer. All seals shall be finished to provide a smooth, neat appearance. 16920.3.1.7 Extensions of Building Steel to Support Raceway. Extensions of building structures to support raceway shall be of the same material as the structure being extended and shall be finished to match the finish of the extended structure. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 174 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 16920.3.1.8 Beam Clamps. Beam clamps for attachment of hanger rods to structural steel beams shall be electrogalvanized steel and shall be provided with safety beam anchor straps. Swivels shall be provided where required to prevent bends in the hanger rods. 16920.3.1.9 Welding. Welds, welding, and related operations for fabrication of carbon and low alloy steel components shall be in conformance with Q100 - General Welding Requirements in Section 21000, and as specified herein. Tack welds shall either be incorporated into, or removed from, the final assembly. Temporary welds used for erection, lifting lugs, etc., shall be removed and the area ground flush. Weld spatter, including tightly adherent spatter, shall be removed from weld areas and the areas shall be prime painted or regalvanized. All temporary supports which have been welded to the building shall be removed as promptly as possible. After removal, the roughened surface of the building steel shall be ground smooth and a protective primer paint applied equal to that which was initially applied. 16920.3.1.10 Use of Unfinished Conduit. Conduit runs including supports and connections shall be completed prior to the pull-in of conductor where the potential for conductor damage exists. 16920.3.1.11 Repair of Galvanized Surfaces. All galvanized surfaces on which the galvanizing is removed or damaged by cutting, drilling, or any other operation shall be regalvanized in accordance with ASTM A780. 16920.3.2 Raceway Installation Records Not Used. 16920.3.3 Conduit Components An electrical conduit system shall be furnished and installed in accordance with the drawings and the following specifications. Conduit components shall include conduit, fittings, supports, and hardware required for a complete system. 16920.3.3.1 Conduit Materials. Electrical conduit and associated component materials shall conform to the requirements of the articles that follow. Specific conduit component materials shall be as indicated on the drawings for their intended application. 16920.3.3.1.1 Rigid galvanized steel conduit. Steel conduit, couplings and elbows shall be a threaded hot-dipped galvanized rigid mild steel manufactured in accordance with ANSI/NEMA C80.1 and UL 6. The conduit interior and exterior surfaces shall have a continuous hot-dipped galvanized coating with a transparent overcoat of enamel, lacquer, or zinc chromate. Each length of conduit shall have a coupling on one end and a thread protector on the other. The thread protector shall have sufficient mechanical strength to protect the threads during normal handling and storage. Rigid galvanized steel conduit shall be similar to Type GRC as manufactured by Allied Tube and Conduit Corporation, or Engineer accepted equal. 16920.3.3.1.2 Rigid aluminum conduit. Aluminum conduit, couplings and elbows shall be a threaded rigid aluminum alloy metal manufactured in accordance with ANSI/NEMA C80.5 and UL 6. Each length of conduit shall have a coupling on one end and a thread protector on the other. The thread protector shall have sufficient mechanical strength to protect the threads during normal handling and storage. Rigid aluminum conduit shall be similar to Type ARC as manufactured by Allied Tube and Conduit Corporation, or Engineer accepted equal. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 175 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 16920.3.3.1.3 Rigid plastic conduit. Plastic conduit and elbows shall be unthreaded Schedule 40 or Schedule 80 polyvinyl chloride manufactured in accordance with NEMA TC-2 and UL 651. Rigid plastic conduit shall be as manufactured by Cantex, Inc. or Engineer accepted equal. 16920.3.3.1.4 Electrical metallic tubing. Electrical metallic tubing and elbows shall be zinc coated mild steel manufactured in accordance with ANSI/NEMA C80.3 and UL 797. The exterior surfaces of the tubing shall have a hot-dipped galvanized coating with a transparent overcoat of enamel, lacquer, or zinc chromate. Electrical metallic tubing shall be similar to Type EMT as manufactured by Allied Tube and Conduit Corporation, or Engineer accepted equal. 16920.3.3.1.5 Liquidtight flexible metallic conduit. Liquidtight flexible metallic conduit shall be a plastic jacketed, heavy-duty, locking, flexible metal core manufactured in accordance with ANSI/UL 360. The plastic jacket shall be UV, oil, and acid resistant and shall be suitable for a temperature rating of 60 C. The metal core shall be a locking galvanized steel core for use with galvanized conduit systems, or a locking aluminum core for use with aluminum conduit systems. Liquidtight flexible metallic conduit used in high temperature areas shall have a thermoplastic PVC jacket suitable for a temperature rating of 105 C. Galvanized liquidtight flexible metallic conduit shall be similar to Sealtite Type UA as manufactured by Anamet Canada, Inc. or Engineer accepted equal. High temperature galvanized liquidtight flexible metallic conduit shall be similar to Sealtite Type HTUA as manufactured by Anamet Canada, Inc. or Engineer accepted equal. Aluminum liquidtight flexible metallic conduit shall be similar to Sealtite Type EFL as manufactured by Anamet Canada, Inc. or Engineer accepted equal. 16920.3.3.1.6 Flexible metallic conduit. Flexible metallic conduit shall be a heavy-duty, locking galvanized steel core manufactured in accordance with ANSI/UL 1. Flexible metallic conduit shall be similar to Type HWS as manufactured by International Metal Hose Company, or Engineer accepted equal. 16920.3.3.1.7 Flexible metallic couplings. Flexible metallic couplings shall be prefabricated lengths of flexible conduit comprised of a bronze braided brass core and insulating wire duct manufactured in accordance with UL 886. The metallic coupling shall have prefabricated male connectors on both ends. Flexible metallic couplings shall be used in Class I, Div. 1 locations where a liquidtight flexible conduit connection is required. Flexible metallic couplings shall be similar to Type ECGJH as manufactured by O-Z/Gedney, or Engineer accepted equal. 16920.3.3.1.8 Rigid metal conduit bodies and fittings. Rigid metal conduit bodies and fittings shall conform to the requirements of ANSI/NEMA FB-1, UL 514B and UL 886 where these standards apply. Conduit bodies and fittings shall be appropriate for the area and equipment with which they are associated. Conduit bodies and fittings used in hazardous areas shall conform to NEC requirements for the area classification. Threaded galvanized malleable iron or galvanized steel bodies and fittings shall be used with galvanized conduit. Threaded copper free aluminum or aluminum alloy bodies and fittings shall be used with aluminum conduit. Unthreaded zinc coated steel fittings shall be used with electrical metallic tubing. Metallic tubing fittings shall be compression type and watertight. Additional requirements for rigid metal conduit bodies and fittings are as follows. 16920.3.3.1.8.1 Conduit outlet bodies. Conduit outlet bodies shall be provided where required for pulling ease and changing conduit direction. Standard conduit outlet bodies shall be threaded to accept threaded cover screws. Standard conduit outlet bodies installed outdoors or in wet locations shall be gasketed to provide a watertight seal. Conduit outlet bodies used in hazardous areas shall be provided with internally threaded gasketed covers. Standard conduit outlet bodies shall be similar to Types LB, X, LL, LR, T, TB or C as manufactured by OZ/Gedney, or Engineer accepted equal. Hazardous area conduit outlet bodies shall be similar to Type GUA as manufactured by O-Z/Gedney, or Engineer accepted equal. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 176 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 16920.3.3.1.8.2 Insulated bushings. Insulated bushings with insulating inserts in metal housings shall be provided for the termination of all threaded conduits not terminated in hubs or couplings. Insulating inserts shall be phenolic or a similar thermoplastic material. Grounding type insulated bushings shall be provided for all conduits containing power circuits and all conduits located in hazardous areas. Insulated bushings shall be similar to Type IBC as manufactured by O-Z/Gedney, or Engineer accepted equal. Grounding type insulated bushings shall be similar to Type IBC-L-BC as manufactured by OZ/Gedney, or Engineer accepted equal. 16920.3.3.1.8.3 Locknuts. Locknuts shall be provided for the termination of all indoor threaded conduits not terminated in hubs or couplings. One interior and one exterior locknut shall be provided. Exterior locknuts shall be gasketed. Locknuts shall be designed to securely bond the conduit to the box when tightened while also preventing loosening by vibration. Interior locknuts shall be similar to Type 1 as manufactured by O-Z/Gedney, or Engineer accepted equal. Exterior locknuts shall be similar to Type SLG as manufactured by O-Z/Gedney, or Engineer accepted equal. 16920.3.3.1.8.4 Unions. Conduit unions shall be provided for the connection of two threaded conduit ends when the conduit cannot be turned. Standard conduit unions shall be similar to three piece Type 4 Series as manufactured by O-Z/Gedney, or an acceptable equal. Hazardous area conduit unions shall be similar to Type UNF as manufactured by O-Z/Gedney, or an acceptable equal. 16920.3.3.1.8.5 Raintight hubs. Raintight hubs shall be provided for the termination of threaded conduits on outdoor equipment where threaded hubs are not provided. Raintight hubs shall be provided with an insulated throat. Standard raintight hubs shall be similar to Type CHM as manufactured by OZ/Gedney, or Engineer accepted equal. Hazardous area raintight hubs shall be similar to Type EYH-SG as manufactured by O-Z/Gedney, or Engineer accepted equal. 16920.3.3.1.8.6 Combination fittings. Combination fittings shall be provided to connect threaded rigid metal conduit to electrical metallic tubing. Combination fittings shall have a threaded throat to receive the rigid metal conduit, and a threadless compression type throat to receive the electrical metallic tubing. Combination fittings shall be similar to Type ETR as manufactured by O-Z/Gedney, or Engineer accepted equal. 16920.3.3.1.8.7 Expansion fittings. Expansion fittings shall be provided in threaded conduit runs to allow for the expansion and contraction of conduit supported across expansion joints. Expansion fittings shall be watertight, and shall be provided with bonding jumpers. Standard expansion fittings shall be similar to Type EX as manufactured by O-Z/Gedney, or Engineer accepted equal. Expansion fittings for hazardous areas shall be similar to Type UNFE as manufactured by O-Z/Gedney, or Engineer accepted equal. 16920.3.3.1.8.8 Drains. Drains shall be provided in the low spots of outdoor conduit runs, and in outdoor conduit runs prior to entering buildings, to remove condensation from the conduit. Conduit drains shall be similar to Type DB as manufactured by O-Z/Gedney, or Engineer accepted equal. 16920.3.3.1.8.9 Reducers. Reducers shall be provided to connect two different conduit sizes together. Reducers shall be external couplings similar to Type REC as manufactured by Crouse-Hinds, or Engineer accepted equal. 16920.3.3.1.8.10 Seal-off fittings. Seal-off fittings shall be provided to isolate conduit runs and prevent the passage of flammable gases, vapors, and dusts from hazardous areas. Seal-off fittings shall be suitable for vertical and horizontal conduit installations. Seal-off fittings shall have a removable plug for the placement of sealing fiber, and an additional removable plug for the placement of sealing compound. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 177 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Seal-off fittings shall be similar to Type EYA as manufactured by O-Z/Gedney, or Engineer accepted equal. Sealing fiber and sealing compounds shall be compatible with the seal-off fittings provided. 16920.3.3.1.9 Liquidtight flexible metallic conduit fittings. Liquidtight flexible metallic fittings shall be provided to connect liquidtight flexible metallic conduit to rigid metal conduit and devices. Liquidtight flexible metallic fittings shall have insulated throats and shall bear the UL label. Liquidtight flexible metallic fittings shall be similar to Type STB and Type STN as manufactured by Appleton, or Engineer accepted equal. Galvanized malleable iron fittings shall be used with galvanized core flexible conduit. Copper free aluminum or aluminum alloy fittings shall be used with aluminum core flexible conduit. 16920.3.3.1.10 Flexible metallic conduit fittings. Flexible metallic fittings shall be provided to connect flexible metallic conduit to light fixtures and wiring devices in finished areas. Flexible metallic fittings shall have “Squeeze” type or friction connectors for fastening the fitting to the flexible conduit. Flexible metallic fittings shall have insulated throats and bear the UL label. Flexible metallic combination fittings shall have a friction type connector on one end for fastening to flexible metallic conduit, and a compression type connector on the other end for fastening to electrical metallic tubing. Flexible metallic fittings shall be similar to Types C, 24 Series, and CB as manufactured by O-Z/Gedney, or Engineer accepted equal. 16920.3.3.1.11 Rigid plastic conduit bodies and fittings. Rigid plastic conduit bodies and fittings shall be polyvinyl chloride and shall conform to the requirements of NEMA TC-3, NEMA TC-9, and UL 514B where these standards apply. Plastic conduit bodies and fittings shall be of the same schedule or type composition as the plastic conduit attaching to. Plastic conduit bodies and fittings shall use unthreaded solvent cement type joints. Plastic conduit couplings shall have center stops to ensure proper seating. Plastic conduit outlet bodies shall have gasketed screw type covers. Spacers for underground rigid plastic conduit shall be plastic interlocking base and intermediate type spacers. The spacers shall have voids or openings to allow for the flow of concrete along the conduit, thus eliminating any hollow area within the concrete. The separation distance between the outer walls of all conduit interlocked together shall be as indicated on the drawings. Plastic conduit bodies and fittings shall be as manufactured by Cantex, Inc., or Engineer accepted equal. 16920.3.3.2 Conduit Supports. Conduit supports shall conform to the requirements of the articles that follow. Specific conduit support materials shall be as indicated on the drawings. 16920.3.3.2.1 Hanger rods. Hanger rods used for the support of formed channel shall be 1/2 inch (13 mm) diameter electrogalvanized continuous threaded steel rods. Hanger rods shall be similar to Type HTHR as manufactured by Unistrut Metal Framing, or Engineer accepted equal. 16920.3.3.2.2 Support channel. Support channel shall be hot-dipped galvanized formed channel made from 12 gauge steel in 1-5/8 inch (41 mm) series sizes. Support channel shall be similar to Type P1000 Series as manufactured by Unistrut Metal Framing, or Engineer accepted equal. 16920.3.3.2.3 Support channel fittings. Support channel fittings shall be flat plate and angular fittings and brackets designed for use with the 1-5/8 inch (41 mm) series formed channel indicated previously. Support channel fittings shall be hot-dipped galvanized steel. Support channel fittings shall be as manufactured by Unistrut Metal Framing, or Engineer accepted equal. 16920.3.3.2.4 Conduit clamps. Conduits in single runs or groups of two shall be supported by one hole cast metal clamps with clamp backs, or with conduit clamps attached to beams. One hole clamps, clamp backs and conduit clamps attached to beams shall be hot-dipped galvanized malleable iron. One hole conduit clamps and clamp backs shall be similar to Type 14-G Series manufactured by O-Z/Gedney, or Engineer accepted equal. Conduit beam clamps shall be similar to Types UBC, UEC, and UPC manufactured by O-Z/Gedney, or Engineer accepted equal. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 178 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Supports for banks of three or more conduits shall be constructed of formed channel with associated two piece galvanized conduit clamps. Two piece conduit clamps shall be designed for use with the 1-5/8 inch (41 mm) series formed channel indicated previously. Two piece conduit clamps shall be similar to Type P1100 Series or Type P1400 Series manufactured by Unistrut Metal Framing, or Engineer accepted equal. Conduits in single runs or groups of two terminated at cable tray shall be supported from the tray side rail using galvanized malleable iron cable tray conduit clamps similar to Type LCC Series clamps manufactured by Crouse-Hinds, or Engineer accepted equal. Banks of three or more conduits shall be terminated at cable tray with the use of two piece conduit clamps and formed channel attached to the tray side rail as indicated on the drawings. 16920.3.3.3 Conduit Installation. Conduit and associated components shall be installed as indicated on the drawings and as described in these specifications. The following installation requirements are in addition to the requirements indicated in Article 16920.3.1. 16920.3.3.3.1 Routing. Field routed conduit and associated supports shall not interfere with the installation or maintenance of any dimensioned equipment, building steel, cable tray, HVAC duct, fans, dampers, or prerouted piping. Conduit shall not be routed under crane or trolley rails, or through areas designated for the maintenance or removal of equipment accessed by overhead removable panels and hatches. Any conduit which interferes with these areas or purpose shall be promptly removed so as not to delay installation or use of any equipment. Except as otherwise specified or indicated on the drawings, all conduit shall be installed in exposed runs parallel or perpendicular to dominant surfaces with right angle turns made of symmetrical bends or fittings. Except where prevented by the location of other work, a single conduit or a conduit group shall be centered on structural members. 16920.3.3.3.2 Conduit drains. Outdoor conduits shall not contain moisture pockets. Drains shall be installed in outdoor conduit to remove moisture at locations where conduits terminate on equipment or devices, and at locations where conduits penetrate an exterior wall. Outdoor conduits shall be installed so that water will not drain into any equipment containing electrical devices or connections. Drains shall be installed at lowest point in conduit above grade. Outdoor conduits terminating on equipment from above shall have a conduit seal fitting with drain installed in the conduit run near the conduit termination where practical. Outdoor conduit terminating on equipment from the side shall have a conduit “tee” body with drain installed in the conduit run near the conduit termination where practical. Outdoor conduit terminating on equipment from below shall have a conduit “tee” body with drain installed in the conduit run at the lowest vertical location directly below the equipment. Equipment serviced from below by underground or embedded conduits shall not require drains. Outdoor conduits penetrating exterior walls shall have a conduit “tee” body with drain installed on the exterior side of the wall at the “low point” of the conduit as close as practical to the wall penetration. 16920.3.3.3.3 Couplings and unions. Rigid metal conduit shall be joined by threaded conduit couplings with the conduit ends butted. The use of running threads will not be permitted. Where rigid metal conduit cannot be turned and joined together by standard threaded couplings, conduit unions or split couplings may be used. Conduit union coupling nuts shall be installed uppermost on vertical or inclined conduit runs to prevent the entrance of water into the union. Split couplings shall not be installed on outdoor conduit. Plastic conduit shall be joined together in accordance with manufacturer recommendations using unthreaded couplings and a medium bodied solvent cement. Joining surfaces shall be wiped clean of Source: 16920, 2014, v2.0 Raceway Components and Installation Page 179 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 dirt, moisture, or other contaminants prior to application of the solvent cement. If joining surfaces are extremely dirty or coated with oil, a cloth saturated with PVC cleaner shall be used to clean the surfaces. Joining surfaces shall be thoroughly dried before applying solvent cement. Electrical metallic tubing shall be joined together by unthreaded compression couplings. The use of setscrew couplings will not be permitted. 16920.3.3.3.4 Bends and offsets. A run of conduit shall not contain more than the equivalent of four 90 degree bends, including those immediately at outlet bodies and fittings. Field bends shall be made without reducing the internal diameter of the conduit. The center line radius of field bends shall not be less than six times the nominal trade size diameter of the conduit. The use of a pipe tee or vise for bending metal conduit will not be permitted. Plastic conduit bends shall be factory fabricated wherever possible. Where field bending of plastic conduit is required, the conduit length shall be heated to approximately 275 F. Conduit heating may be by radiant heat, hot air, or hot liquid immersion. Open flame heating will not be permitted. Special mandrels or forms shall be used to provide a smooth bend without reduction of the conduit diameter. Conduit discolored by prolonged heating will not be acceptable. 16920.3.3.3.5 Fittings. Conduit outlet bodies installed in conduit runs shall be sized and installed in accordance with the NEC. Covers shall be installed on outlet bodies at the time of installation to prevent the entrance of moisture or contaminants into the conduit system prior to cable pulling operations. Conduit outlet bodies shall not be installed in conduit runs containing 5 kV and higher voltage conductors, unless the type and location have been reviewed for excessive cable bending radius constraints as defined by the cable manufacturer. Conduit fittings for metal conduit shall be installed wrenchtight. Hazardous area conduit seal-off fittings shall be installed at locations required by the NEC for the classified area. Seal-off fitting compounds and fiber shall be installed as recommended by the fitting manufacturer. Completed conduit seal-off fitting installations shall not restrain equipment removal or access beyond that which would be encountered if there were no sealing fitting installed on the conduit run. 16920.3.3.3.6 Cutting and threading. The plane of all conduit ends shall be square and perpendicular with the center line. The ends of all conduit and tubing shall be reamed to remove all rough edges and burrs. Where threads are required, they shall be cut and cleaned prior to conduit reaming. A cutting oil shall be used in threading operations. The dies shall be kept sharp and provisions shall be made for chip clearance. All steel conduit ends, after cutting or threading, shall be regalvanized using a cold galvanizing zinc rich coating. 16920.3.3.3.7 Connections to boxes and cabinets. Conduit shall be securely fastened to all boxes and cabinets. Threads on metallic conduit not terminated in threaded hubs shall project through the wall of the box or cabinet to allow the bushing to butt against the end of the conduit. The locknuts both inside and outside shall then be tightened sufficiently to bond the conduit securely to the box or cabinet. Locknuts on EMT box connectors shall be tightened securely to bond the connectors to the box or cabinet. All conduit terminating on boxes or cabinets located outdoors, or terminating on indoor NEMA 12, NEMA 4, or NEMA 4X enclosures, shall terminate with raintight conduit hubs or threaded hubs provided Source: 16920, 2014, v2.0 Raceway Components and Installation Page 180 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 with the enclosure. Gasketed sealing type locknuts may be used in lieu of threaded hubs for connections to indoor NEMA 12 enclosures. If the conduit connected to the equipment exceeds the number or size of threaded hubs supplied with the equipment, additional material shall be furnished and installed as required to connect the conduit to the equipment. 16920.3.3.3.8 Cleaning. Precautions shall be taken to prevent the accumulation of water, dirt, or concrete in the conduit. Conduit in which water or other foreign materials have been permitted to accumulate shall be thoroughly cleaned. 16920.3.3.3.9 Liquidtight flexible conduit. Liquidtight flexible conduit inserts shall be installed at the locations indicated below. Liquidtight flexible conduit lengths shall not be greater than 24 inches (600 mm) in length for 2 inch (50 mm) and under nominal conduit diameter, and 48 inches (1200 mm) in length for nominal conduit diameter greater than 2 inches ( 50 mm) Liquidtight flexible metallic conduit shall be installed in all rigid metal conduit runs which are supported by both building steel and by structures subject to vibration or thermal expansion. This shall include locations where conduit supported by building steel enters or becomes supported by the turbine generator foundation and where conduit supported by building steel or foundation becomes supported by steam generator framing. Liquidtight flexible metallic conduit shall be installed in rigid metal conduit runs which cross expansion joints or which connect to building supported independent structures, such as heat exchangers, storage tanks, or ash hoppers. Liquidtight flexible metallic conduit should be considered in all long rigid metal conduit runs where differential expansion problems may be expected. Liquidtight flexible metallic conduit shall be installed adjacent to all equipment and devices which move in relation to the supply conduit due to vibration, normal operation of the mechanism, or thermal expansion. The supply conduit shall be connected to pressure switches, thermocouples, solenoids, and similar devices with liquidtight flexible metallic conduit. Liquidtight flexible metallic conduit shall be installed adjacent to the motor terminal housing for motors requiring 4 inch and smaller conduit. Provisions for vibration and thermal expansion at motors requiring larger than 4 inch conduit shall be accomplished by use of pendent hangers or other acceptable means. 16920.3.3.3.10 Flexible metallic conduit. Flexible metallic conduit inserts not greater than 6 feet (1.8 m) in length shall be installed for light fixture tap conductors above finished ceilings. 16920.3.3.3.11 Plastic conduit. Plastic conduit shall be installed in accordance with the installation requirements previously specified for rigid metal conduit. Expansion joints shall be provided as recommended by the manufacturer. 16920.3.3.3.12 Below grade conduit. Below grade conduit shall be rigid galvanized steel or rigid plastic conduit as indicated on the drawings. Aluminum conduit shall not be used for below grade conduit. Below grade conduit shall be routed as closely as possible to the general routing and elevations indicated on the drawings. Conduit riser elbows shall use rigid galvanized steel conduit and shall be concrete encased. Conduit riser extensions shall be rigid galvanized steel with rigid steel main conduit runs, and may be rigid galvanized steel or rigid plastic conduit with rigid plastic main conduit runs. Conduit riser extensions shall be concrete encased. Conduit riser extensions shall terminate 6 inches above finished building Source: 16920, 2014, v2.0 Raceway Components and Installation Page 181 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 floors or finished grade elevations in yard areas. Conduit extensions shall be straight and plumb, plugged prior to pouring of concrete, and remain plugged until conduit is extended later or readied for cable pulling operations. Plugs shall be either threaded plastic or threaded metal inserts. Concrete used for encasing below grade conduit shall conform to the requirements of Section 03311 Cast-in-Place Concrete of these specifications. The concrete shall be vibrated to consolidate it around the conduit and shall be slow cured for several days to provide strength and prevent shrinkage. Below grade conduit shall be accurately positioned and supported for encasement by plastic conduit spacers set in the conduit trench, or by steel wire hangers attached to temporary supports laid across the conduit trench. After the concrete encasement has hardened, the temporary supports and the exposed portions of the steel wire hangers not encased in concrete shall be removed. Warning tape shall be placed in a trench directly over direct buried conduit and direct buried cable. The following requirements also apply to below grade conduit. 16920.3.3.3.12.1 Rigid galvanized steel conduit. Rigid galvanized steel conduit shall not be directly buried in the earth. Single runs of below grade rigid galvanized steel conduit shall be encased with 3 inches (75 mm) of concrete between the conduit outer walls and earth. Multiple runs of below grade rigid galvanized steel conduit shall maintain a minimum 2 inch separation between adjacent conduits to allow for concrete placement. Multiple runs of rigid galvanized steel conduit shall also be provided with 3 inches (75 mm) of concrete encasement between the conduit outer walls and earth. 16920.3.3.3.12.2 Rigid plastic conduit. Below grade rigid plastic conduit shall not require concrete encasement, except where roadway crossings or construction traffic warrant its use for strength and physical protection. Where indicated on the drawings, concrete encasement for plastic conduit shall have the same spatial and envelope requirements as rigid galvanized steel conduit. Where rigid plastic conduit is directly buried in the earth, it shall be laid in a graded 3 inch (75 mm) deep bedding of sand or other finely divided job excavated material free from debris, organic material, and stones. After placement on the bedding, the conduit shall be covered with backfill to 6 inches (150 mm) above the conduit. The backfill shall be of the same material as the bedding. Backfill shall be compacted to meet density requirements of the surrounding earth. 16920.3.3.3.13 Conduit support spacing. All conduit runs shall be rigidly supported in accordance with the following requirements. Vertical rigid metal conduit shall be supported in maximum 20 foot (6 m) intervals. Vertical plastic conduit and electrical metallic tubing shall be supported at the maximum intervals indicated for their respective horizontal conduit support spacing shown below. Rigid metal conduit, plastic conduit, and electrical metallic tubing shall be supported within 3 feet of each junction box, pull box, cabinet, conduit body, or other conduit termination. Horizontal rigid metal conduit, plastic conduit, and electrical metallic tubing shall be supported at the indicated maximum intervals. Maximum Support Intervals Nominal Conduit Size, inches Rigid Metal Spacing, feet Rigid Plastic Spacing, feet Electrical Metallic Tubing Spacing, feet 1/2 10 3 5 3/4 10 3 5 Source: 16920, 2014, v2.0 Raceway Components and Installation Page 182 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Maximum Support Intervals Nominal Conduit Size, inches Rigid Metal Spacing, feet Rigid Plastic Spacing, feet Electrical Metallic Tubing Spacing, feet 1 12 3 6 1-1/2 14 5 7 2 16 5 8 2-1/2 16 6 8 3 20 6 10 4 20 7 10 5 20 7 - 6 20 8 - 16920.3.3.3.14 Conduit identification. All conduit shall be clearly identified with its raceway number as indicated on the drawings, except for lighting, receptacle, and communication conduits. Conduit identification shall be with Electromark Co. Type C-1003 markers or Engineer accepted equal, covered with clear wraparound bands. Markers shall be positioned so that they are easily read by personnel standing on the floors and walkways. Markers shall be installed on each end of conduits which are in excess of 10 feet (3 m), and at only one end of conduits which are 10 feet (3 m) or less in length. 16920.3.4 Wireway Components An electrical wireway system shall be furnished and installed in accordance with the drawings and the following specifications. Wireway components shall include wireway, connectors, fittings, covers, supports, and hardware required for a complete system. 16920.3.4.1 Wireway Materials. Wireway and associated component materials shall conform to the requirements of the articles that follow. Specific wireway component materials shall be as indicated on the drawings for their intended application. 16920.3.4.1.1 Metallic wireway. Metallic wireway, fittings, and covers shall be constructed in accordance with UL 870 and NEMA for their intended service. Standard metallic wireway shall be constructed from manufacturer's standard gauge phosphatized sheet steel or galvanized steel. Metallic wireway for corrosive areas shall be constructed from stainless steel. Metallic wireway shall have “lay-in” features. Metallic wireway shall have removable covers and shall not have knockouts. Unless otherwise indicated on the drawings, wireway enclosure types shall be as indicated below: Location Enclosure Type Indoor (non-hazardous) Conditioned rooms NEMA 1 Process areas (dry) NEMA 12 Process areas (wet) NEMA 12 Corrosive areas NEMA 4X Outdoor (non-hazardous) Noncorrosive areas NEMA 3R Corrosive areas NEMA 4X Hazardous areas Source: 16920, 2014, v2.0 Raceway Components and Installation Page 183 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Location Enclosure Type Class I, Division 2 NEMA 12 Class II, Division 2 NEMA 12 Class III areas NEMA 12 Metallic wireways shall not be installed in hazardous areas classified as Class I, Division 1 and Class II, Division 1. 16920.3.4.1.2 Nonmetallic wireway. Nonmetallic wireway, fittings, and covers shall be constructed in accordance with UL 94, UL 870, and NEMA for their intended service. Nonmetallic wireway shall be constructed from a flame retardant, fiberglass resin material that provides chemical resistance and physical strength. Nonmetallic wireway shall have “lay-in” features. Nonmetallic wireway shall have gasketed, removable covers and shall not have knockouts. Nonmetallic wireway may be used in indoor, corrosive area applications in lieu of stainless steel wireway. 16920.3.4.2 Wireway Supports. Wireway support components shall be comparable to support system components for cable tray as indicated in Article 16920.3.6. Specific wireway support materials shall be as indicated on the drawings. 16920.3.4.3 Wireway Installation. Wireway shall be installed in accordance with these specifications, the manufacturer's instructions, and as indicated on the drawings. All field cuts shall be saw cut and square. Sharp edges shall be filed smooth and touchup painted or regalvanized. Wireway shall be rigidly supported as required by the NEC. 16920.3.4.4 Wireway Identification. The identification number of each wireway shall be engraved on a phenolic nameplate and attached to the wireway. Nameplates attached to wireways in finished areas may be fastened using adhesive tape. For all other areas, nameplates shall be fastened using suitable hardware. 16920.3.5 Junction Boxes and Pull Boxes All boxes required throughout the electrical raceway system shall be furnished and installed in accordance with the drawings and the requirements which follow. 16920.3.5.1 Junction Box and Pull Box Materials. Junction boxes and pull boxes shall be constructed in accordance with UL 50 and NEMA for their intended service. Junction boxes and pull boxes shall not have knockouts. Enclosure type, material, and dimensions shall be as indicated on the drawings and as specified in these specifications. Where no type or size is indicated elsewhere for junction boxes and pull boxes, they shall be in accordance with the requirements of the NEC, Article 314. Unless indicated otherwise, enclosure types shall be as follows: Enclosure Type Location Junction Boxes Pull Boxes Conditioned rooms NEMA 1 NEMA 1 Process areas (dry) NEMA 12 NEMA 12 Process areas (wet) NEMA 4 NEMA 12 Corrosive areas NEMA 4X NEMA 4X Indoor (nonhazardous) Source: 16920, 2014, v2.0 Raceway Components and Installation Page 184 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Enclosure Type Location Junction Boxes Pull Boxes Noncorrosive areas NEMA 4 NEMA 3R Corrosive areas NEMA 4X NEMA 4X Class I, Division 1 NEMA 7* NEMA 7* Class I, Division 2 NEMA 7* NEMA 12 (indoor) NEMA 3 (outdoor) Class II, Division 1 NEMA 9* NEMA 12 (indoor) NEMA 3 (outdoor) Class II, Division 2 NEMA 12 (indoor) NEMA 3 (outdoor) NEMA 12 (indoor) NEMA 3 (outdoor) Class III NEMA 12 (indoor) NEMA 4 (outdoor) NEMA 12 (indoor) NEMA 3 (outdoor) Outdoor (nonhazardous) Hazardous areas Note: * indicates an alpha character identified by the Group designation associated with the known suspended hazard in the air as identified in the National Electrical Code. Junction boxes and pull boxes 4 inch (100 mm) trade size or smaller in any dimension shall be galvanized malleable iron or acceptable equal cast ferrous metal for use with threaded, galvanized steel conduit. Copper free aluminum or aluminum alloy boxes shall be used with threaded aluminum conduit. Galvanized steel boxes shall be used with electrical metallic tubing. Junction boxes and pull boxes larger than 4 inch (100 mm) trade size, and having a depth of not over 24 inches (600 mm), shall be constructed from manufacturer's standard gauge phosphatized sheet steel. The surfaces of the steel shall be finish coated inside and out after fabrication, in accordance with manufacturer's standard. Pull boxes having a depth greater than 24 inches (600 mm) shall be constructed from steel plate reinforced as required to provide true surfaces and adequate strength to support a concentrated load of 200 pounds on the top after erection. The pull box surface shall be finish coated inside and out after fabrication, in accordance with the manufacturer's standard. 16920.3.5.2 Outlet Boxes and Switch Boxes. All outlet boxes, switch boxes, and associated fittings shall be constructed in accordance with UL 514. All surface mounted outlet boxes, switch boxes, and associated fittings shall be galvanized malleable iron or Engineer accepted equal cast ferrous metal for use with threaded steel conduit. Copper free aluminum or aluminum alloy boxes shall be used with threaded aluminum conduit. Galvanized steel boxes shall be used with electrical metallic tubing. 16920.3.5.3 Installation. Cabinets and boxes shall be rigidly mounted. Mounting on concrete shall be by post-installed mechanical anchors. Mounting on steel shall be by drilled and tapped screw holes, or by special support channels welded to the steel, or by both. Cabinets shall be leveled and fastened to the mounting surface with not less than 1/4 inch (6 mm) air space between the enclosure and mounting surface. All mounting holes in the enclosure shall be used. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 185 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Except as prevented by the location of other work, all junction boxes, pull boxes, and outlet boxes shall be centered on structures. Conduit openings in boxes shall be made with a hole saw or shall be punched. All unused threaded openings shall be sealed with threaded plugs. 16920.3.5.4 Pull Box and Junction Box Identification. The identification number indicated on the drawings for each junction box and pull box having a depth greater than 24 inches (600 mm) shall be stenciled on the cover of the box or engraved on a Phenolic tag and attached to the box. The lettering shall be block type and shall be not less than 1 inch (25 mm) high. The identification number of each junction box and pull box having a depth of 24 inches (600 mm) and smaller shall be engraved on a phenolic nameplate and attached to the box. Nameplates attached to pull boxes and junction boxes in finished areas may be fastened using adhesive tape. For all other areas, nameplates shall be fastened using suitable hardware. 16920.3.6 Cable Tray Components An electrical cable tray system shall be furnished and installed in accordance with the drawings and the following specifications. Cable tray components shall include cable tray, fittings, supports, accessories, and hardware required for a complete system. 16920.3.6.1 Cable Tray Materials. Electrical cable tray and associated component materials shall conform to the requirements of NEMA VE-1 for metal cable trays, NEMA FG-1 for fiberglass cable trays, and these specifications. In case of conflict between the NEMA standards publications and these specifications, the requirements of these specifications shall govern to the extent of such conflict. Cable tray components for similar cable tray materials shall be manufactured by one manufacturer. Specific cable tray component materials shall be as indicated on the drawings for their intended application. 16920.3.6.1.1 Steel cable tray. Steel cable tray shall be hot-dipped galvanized after fabrication in accordance with ASTM A123. The galvanizing coat shall cover all interior surfaces of hollow members, as well as exterior surfaces. The minimum metal thickness for tray bottoms or rungs shall be 18 gauge. Steel cable tray shall have concentric curved radius fittings. Ladder type steel cable trays shall have rung spacings on 9 inch (225 mm) centers. The rung spacing shall be maintained at the center line of all horizontal and vertical elbows. Individual rungs shall provide a minimum of 1 inch (25 mm) of cable support surface. Solid bottom steel cable tray shall be constructed with either a flat tray bottom within the cable loading area, or a corrugated tray bottom. Corrugated tray bottoms shall be constructed to provide cable support surface over a minimum of 50 percent of the cable length laid anywhere in the tray. Hardware for steel cable tray shall be case hardened galvanized steel suitable for indoor and outdoor use. 16920.3.6.1.2 Aluminum cable tray. Aluminum cable tray shall be fabricated from copper free aluminum or aluminum alloy. The minimum metal thickness for tray bottoms or rungs shall be 0.063 inch (1.6 mm). Aluminum cable tray shall have concentric curved radius fittings. Ladder type aluminum cable trays shall have rung spacings on 9 inch (225 mm) centers. The rung spacing shall be maintained at the center line of all horizontal and vertical elbows. Individual rungs shall provide a minimum of 1 inch (25 mm) of cable support surface. Solid bottom aluminum cable tray shall not be used. Hardware for aluminum cable tray shall be case hardened galvanized steel suitable for indoor and outdoor use. Hardware for aluminum cable tray in corrosive areas shall be Type 316 stainless steel. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 186 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 16920.3.6.1.3 Fiberglass cable tray. Fiberglass cable tray shall be fabricated from a fiberglass composite resin that is flame retardant and resistant to ultraviolet light. Fiberglass cable trays shall have an outer surface coating that provides chemical protection. All fiberglass cable tray edges shall be sealed. Fiberglass cable tray shall have concentric curved radius fittings. Ladder type fiberglass cable trays shall have rung spacings on 9 inch (225 mm) centers. The rung spacing shall be maintained at the center line of all horizontal and vertical elbows. Individual rungs shall provide a minimum of 1 inch (25 mm) of cable support surface. Solid bottom fiberglass cable tray shall not be used. Hardware for fiberglass cable tray shall be Type 316 stainless steel. 16920.3.6.1.4 Splice plates. Splice plates shall be fabricated from the same material as the cable tray systems they connect, and be engineered for the same. Splice plates shall be connected to the tray side rails using bolts designed to prevent rotation during tightening of the associated nuts. Nuts shall be flanged serrated locknuts, locknuts with serrated washers, or locknuts with captive washers. All bolts holes shall be used on the splice plates. Splice plates shall include straight plates, step-down plates, vertical adjustable plates, horizontal adjustable plates, offset reducing plates, tray-to-box plates, and expansion plates. Expansion plates shall be constructed to allow a minimum of 1 inch (25 mm) of movement for metal cable trays, and a minimum of 0.625 inch (15 mm) of movement for fiberglass cable trays. 16920.3.6.1.5 Barrier strips. Barrier strips shall be hot-dipped galvanized steel for steel cable trays, copper free aluminum or aluminum alloy for aluminum cable trays, and flame retardant fiberglass composite resin for fiberglass cable trays. Plastic barrier strip splices shall be used to hold adjoining barrier strips in alignment. 16920.3.6.1.6 Cable tray covers. Cable tray covers shall be hot-dipped galvanized steel for steel cable trays, copper free aluminum or aluminum alloy for aluminum cable trays, and flame retardant fiberglass composite resin for fiberglass cable trays. Cable tray covers shall have flanged edges, turned down to provide rigidity. The minimum metal thickness for tray covers shall be 18 gauge for steel cable trays, and 0.063 inch (1.6 mm) for aluminum cable trays. Plastic joint plates shall be used to hold adjoining cable tray covers in alignment. Cable tray cover clamps shall be galvanized steel for steel cable trays, copper free aluminum or aluminum alloy for aluminum cable trays, and flame retardant fiberglass composite resin for fiberglass cable trays. Cable tray cover clamps used on outdoor cable trays shall be suitable for outdoor use as recommended by the manufacturer. 16920.3.6.1.7 Cable tray hold-down/expansion clamps. Cable tray hold-down clamps shall be galvanized steel for steel cable trays, copper free aluminum or aluminum alloy for aluminum cable trays, and flame retardant fiberglass composite resin for fiberglass cable trays. Cable tray hold-down clamps shall hold the bottom flange of the tray firmly in place on the supporting cross member without requiring drilling of the tray flange. Cable tray expansion clamps shall be fabricated from the same material as the hold-down clamps. The expansion clamps shall allow the expansion and contraction of the cable tray along its longitudinal center line, while also maintaining the same location of the tray center line. The expansion clamps shall be designed to attach to the supporting cross member of the tray support. 16920.3.6.1.8 Structural requirements. Cable tray shall have a safety factor of 1.5 in regard to destructive load testing in accordance with the requirements of the specified standards for load span class designations, without failure or permanent distortion. In addition to the cable loads defined in the Source: 16920, 2014, v2.0 Raceway Components and Installation Page 187 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 load span class designations, the cable tray shall be capable of supporting an additional 200 pound (91 kg) concentrated load. This concentrated load shall be applied at the midspan on the center line of the tray and at the midspan of either side rail, without causing failure or permanent distortion to the cable tray. Cable tray shall have the following minimum load span class designations. The tray sizes indicated reflect the nominal loading area inside the tray, not the overall outside tray dimensions: Tray Size, inches (mm), nominal loading area NEMA Class Designation 3 x 6 (75 x 150) 12A 3 x 12 (75 x 300) 12C 3 x 18 (75 x 450) 16B 3 x 24 (75 x 600) 16C 3 x 30 (75 x 750) 20B 3 x 36 (75 x 900) 20C 4 x 6 (100 x 150) 12A 4 x 12 (100 x 300) 12C 4 x 18 (100 x 450) 16A 4 x 24 (100 x 600) 16B 4 x 30 (100 x 750) 16C 4 x 36 (100 x 900) 16C 5 x 6 (125 x 150) 12A 5 x 12 (125 x 300) 12A 5 x 18 (125 x 450) 16A 5 x 24 (125 x 600) 16C 5 x 30 (125 x 750) 20B 5 x 36 (125 x 900) 20C 6 x 6 (150 x 150) 12A 6 x 12 (150 x 300) 12A 6 x 18 (150 x 450) 12C 6 x 24 (150 x 600) 16A 6 x 30 (150 x 750) 16C 6 x 36 (150 x 900) 20C 16920.3.6.2 Cable Tray Supports. Cable tray supports shall conform to the requirements of the articles that follow. Specific cable tray support materials shall be as indicated on the drawings. Cable tray supports shall have a minimum safety factor of 2.0 for any support element. 16920.3.6.2.1 Hanger rods. Hanger rods used for the support of formed channel shall be 1/2 inch (13 mm) diameter electrogalvanized continuous threaded steel rods for use with metal cable trays. Electrogalvanized hanger rods shall be similar to Type HTHR as manufactured by Unistrut Metal Framing, or Engineer accepted equal. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 188 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Hanger rods used for the support of formed channel for fiberglass cable tray shall be 1/2 inch (13 mm) diameter continuous threaded Type 316 stainless steel. Stainless steel hanger rods shall be similar to Type ATRSS6 as manufactured by B-Line Systems, or Engineer accepted equal. 16920.3.6.2.2 Support channel. Support channel shall be hot-dipped galvanized formed channel made from 12 gauge steel in 1-5/8 inch (41 mm) series sizes for metal cable trays. Support channel shall be similar to Type P1000 Series as manufactured by Unistrut Metal Framing, or Engineer accepted equal. Support channel used for the support of fiberglass cable tray shall be flame retardant fiberglass composite resin formed channel made in 1-5/8 inch (41 mm) series sizes. Fiberglass support channel shall be similar to Type EC-158 as manufactured by Enduro Fiberglass Systems, or Engineer accepted equal. 16920.3.6.2.3 Support channel fittings. Support channel fittings shall be flat plate and angular fittings and brackets designed for use with the 1-5/8 inch (41 mm) series formed channel indicated previously. Support channel fittings shall be hot-dipped galvanized steel for metal cable trays, and Type 316 stainless steel for fiberglass cable trays. Support channel fittings shall be as manufactured by Unistrut Metal Framing, or Engineer accepted equal. 16920.3.6.2.4 Support loading. Cable tray supports shall be capable of supporting the uniform weight of the trays, plus their nominal uniform cable loads, plus a 200 pound (91 kg) concentrated load without exceeding the allowable load limit for any element of the support system when the safety factor is applied. The following cable loads shall be used for calculating the weight of cables in tray: Nominal Cable Load per Linear Foot, pounds (nominal tray loading depth as indicated) Tray Width, inches (mm) (nominal loading area) 3 inch (75 mm) 4 inch (100 mm) 5 inch (125 mm) 6 inch (150 mm) 6 (150) 15 20 25 30 12 (300) 30 40 50 60 18 (450) 45 60 75 90 24 (600) 60 80 100 120 30 (750) 75 100 125 150 36 (900) 90 120 150 180 16920.3.6.3 Cable Tray Installation. Cable trays and supports shall be installed in accordance with the cable tray manufacturer's instructions, the drawings, and these specifications. 16920.3.6.3.1 Tray surfaces. The Contractor shall cut the trays to length as required. The trays shall be cut with saws and all surfaces over which the conductors and cables will be laid shall be ground or filed to remove any sharp edges which could cause damage to the cable jacket or insulation either during installation or in normal service. The plane of all field cut tray ends shall be square and perpendicular with the center line. Areas on which galvanizing is removed or damaged shall be repaired using a cold galvanizing zinc rich coating. Field cut fiberglass tray edges shall be resealed using a manufacturer approved resin sealant. 16920.3.6.3.2 Application and location of supports. Cable trays shall be bracket supported from walls or columns and hanger supported from overhead structural members, at intervals not exceeding 12 feet (3.6 m) when measured along tray center lines between supports. All fittings shall be supported in accordance with NEMA VE-2 for metal trays, and NEMA FG-1 for fiberglass trays. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 189 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Supports on or from concrete or masonry shall be secured with post-installed mechanical anchors. Beam clamps with safety anchor straps shall be used to secure supports to structural steel beams for horizontal tray hangers. Welding, beam clamps, or drilling and tapping shall be used to secure supports to column steel. Hanger rod support shall include two rods, one on either side of the tray. Nuts shall be fully threaded on the rods. The exact location and dimensions of supports and hangers shall be the Contractor's responsibility. The support system shall be designed so that it does not interfere with the present or future installation or expansion of dimensioned equipment, prerouted pipe, pipe insulation, walls, building steel, or HVAC duct. Hanger rods shall not pass between the side rails or rungs of any tray. Except where supported by brackets, cable tray shall be supported by hanger rods, cross members, and hold-down or expansion clamps. Where feasible, supporting anchors, hangers, clamps, and hardware shall be installed as detailed on the drawings. 16920.3.6.3.2.1 Seismic supports. Seismic cable tray supports shall be located and installed as required to provide the necessary restraint against vertical, transverse, and longitudinal seismic forces which may be applied to the completed tray system. Seismic supports shall be appropriate for the published Seismic Zone Rating in accordance with project requirements and applicable building codes. 16920.3.6.3.3 Expansion joints. Cable tray expansion plates and expansion clamps shall be installed as required to allow for the thermal expansion and contraction of the completed tray system in accordance with manufacturer's recommendations. Bonding ground jumpers shall be installed across all expansion joints, attaching to the tray side rail beyond both ends of the expansion plate. Expansion joints shall allow for a maximum of 1 inch (25 mm) movement for metal cable trays, and 5/8 inch (16 mm) movement for fiberglass cable trays. 16920.3.6.3.4 Tray covers. Where required, tray covers shall be installed after cable pulling through the tray is complete. Immediately before installing covers, all debris shall be removed from the tray. Joint plates shall be used at all cover joints and at locations where tray covers stop, to prevent the covers from buckling or bowing into the tray. Tray covers shall be secured to the tray using the manufacturer's recommended tray cover clamps or with self-tapping screws. In addition to the clamps, at least one bolted connection or screwed connection shall be installed on each cover section through each side rail on vertical tray to prevent the covers from sliding down the tray. Where required, tray covers shall be cut or notched to provide clearance around clamps, conduits, and cables as required for proper fit. Covers shall be saw cut. The cut edges shall be filed smooth and regalvanized or resealed. Cover edges which are in contact with cable shall be covered with protective material. Cable tray covers shall be installed at the following locations. Unless otherwise indicated, the following guidelines apply to indoor and outdoor tray: Accessible vertical ladder type trays shall be furnished with ventilated covers, starting 12 inches (300 mm) below the access floor or platform, and extending to a height of 8 feet (2.4 m) above the access floor or platform. Horizontal trays located under grating floors and platforms, or within 24 inches (600 mm) of insulated pipe, shall be furnished with covers which extend at least 2 feet (600 mm) beyond that part of the trays directly exposed beneath the grating floor, platform, or insulated pipe. Horizontal covers for indoor power trays shall be tight-fitting ventilated covers or raised solid covers. Horizontal covers for indoor control and instrument trays shall be tight-fitting Source: 16920, 2014, v2.0 Raceway Components and Installation Page 190 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction or raised solid covers. Horizontal covers for outdoor power trays shall be tight-fitting ventilated covers. Horizontal covers for outdoor control and instrument trays shall be tight-fitting solid covers. Bid Issue 2Mar2015 Covers may be omitted on lower stacked ladder type trays where a covered tray at a higher elevation in the stack provides complete vertical shielding to the lower trays. Raised covers shall not be furnished on outdoor trays. Solid bottom trays shall have tight-fitting solid covers installed throughout the entire tray run, including all straight sections and fittings. 16920.3.6.3.5 Tray identification. Each tray shall be clearly identified with its raceway number as indicated on the drawings. Identification shall be stenciled at all tray junctions and at intervals not to exceed 20 feet (6 m). Individual stenciled numbers shall be a minimum of 2 inches (50 mm) high by 3/4 inch (19 mm) wide. 16920.3.6.3.6 Temporary tray covers. Where horizontal tray is directly under grating, temporary covers shall be installed on top of the grating and securely fastened to the grating. Where horizontal tray is not under grating but the cable is still subject to damage from falling debris, temporary covers shall be connected to building steel or the tray support system. All temporary covers shall extend at least 6 inches (150 mm) horizontally beyond the tray being protected. Temporary covers shall not interfere with the installation of cable in the tray system. Temporary covers shall be constructed of 3/4 inch (19 mm) flame retardant plywood. The location, attachment, and support of temporary covers shall be acceptable to the Site Electrical Liaison. Temporary covers shall be installed before any cable is pulled in the tray, and shall be removed after permanent covers are installed. Temporary covers shall not interfere with the work of any other contractor. 16920.3.6.4 Quality Control. All cable tray and associated components furnished shall be of uniformly high quality. In addition to conforming to the referenced codes and standards, the following shall also apply: Finish shall be uniform. On the galvanized steel tray, a durable, high quality, relatively smooth coating is required. The Seller's attention is directed to the requirements of ASTM A123, ASTM A384, and ASTM A385 in this regard. Grounds for rejection of members because of galvanizing defects shall be as listed in Table II of the "Inspection Manual for Hot-Dip Galvanized Products," published by the American Zinc Institute except that excessive general roughness, pimples, lumpiness, runs, black spots, dull gray coating, rust stains, and bulky white deposits shall be cause for rejection. Straight members shall be free of bends, flat members shall be free from waves and bellies, and curved members shall curve uniformly. Sharp corners and protrusions shall be avoided and dimensional transitions shall be gradual rather than abrupt. Welding fillets shall be uniform in cross section, continuous where applicable, and free from voids, porosity, or inclusions. Metal adjacent to welds shall be free from burnouts or discoloration. Interior of cable tray and cable tray components shall be free of sharp edges or roughness. All cable tray and associated components furnished shall be such that the completed installation will provide a neat and symmetrical appearance. Their construction and assembly shall reflect careful workmanship and rigid quality control in their manufacture. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 191 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction All tray and fittings shall be uniform in appearance and shall be free of all markings except for piece designations, which shall be on the inside of the tray, and cable tray identification markers. Bid Issue 2Mar2015 Components used in trays of different depths and widths shall be similar and uniform in material, shape, appearance, and method of fabrication. It is preferred that trays of different depths and widths shall differ only in dimensions. Differences in construction or appearance which are excessive in the opinion of the Engineer shall be cause for rejection. Method of joining tray sections, fittings, or tray sections and fittings shall provide a smooth, uniform junction of strength and rigidity equal to the tray side rail. 16920.3.7 Duct Bank and Electrical Manhole Components An electrical duct bank and electrical manhole system shall be furnished and installed in accordance with the drawings and the following specifications. Duct bank components shall include conduit, elbows, couplings, spacers, and termination accessories. Electrical manhole components shall include cable pulling eyes and cable racks. 16920.3.7.1 Duct Bank and Electrical Manhole Materials. Duct bank, electrical manhole and associated component materials shall conform to the requirements of the articles that follow. Specific component materials shall be as indicated on the drawings for their intended application. 16920.3.7.1.1 Rigid galvanized steel conduit. Steel conduit, couplings and elbows shall be a threaded hot-dipped galvanized rigid mild steel manufactured in accordance with ANSI/NEMA C80.1 and UL 6. The conduit interior and exterior surfaces shall have a continuous hot-dipped galvanized coating with a transparent overcoat of enamel, lacquer, or zinc chromate. Each length of conduit shall have a coupling on one end and a thread protector on the other. The thread protector shall have sufficient mechanical strength to protect the threads during normal handling and storage. Rigid galvanized steel conduit shall be similar to Type GRC as manufactured by Allied Tube and Conduit Corporation, or Engineer accepted equal. 16920.3.7.1.2 Rigid plastic conduit. Plastic conduit and elbows for duct bank applications shall be unthreaded Schedule 40 or Type DB polyvinyl chloride. Type DB conduit and elbows shall be manufactured in accordance with NEMA TC-8 and shall have modulus strength of 500,000 psi. Rigid plastic conduit shall be as manufactured by Cantex, Inc. or Engineer accepted equal. 16920.3.7.1.3 Duct bank elbows. Horizontal and vertical intermediate duct bank elbows for rigid galvanized steel conduit shall be of the same material as the rigid galvanized steel conduit. Horizontal and vertical intermediate duct bank elbows for rigid plastic conduit shall be of the same material as the rigid plastic conduit. Duct bank elbows shall have a minimum radius of 36 inches (900 mm). 16920.3.7.1.4 Duct bank riser elbows. Duct bank riser elbows shall be rigid galvanized steel elbows, made of the same material as the rigid galvanized steel conduit. Duct bank riser elbows shall have a minimum radius of 36 inches (900 mm). 16920.3.7.1.5 Duct bank end bells. Duct bank end bells shall be plastic for use with the rigid plastic conduit. End bells shall be as manufactured by Cantex, Inc. or Engineer accepted equal. 16920.3.7.1.6 Duct bank plugs. Duct bank plugs for rigid steel conduit shall be threaded, malleable iron, zinc plated plugs, Type PLG, as manufactured by O-Z/Gedney or Engineer accepted equal. Duct bank plugs for rigid plastic conduit shall be plastic, high impact plugs tapered to fit the end bells provided. Plastic duct bank plugs shall have pull tabs. Plastic duct bank plugs shall be as manufactured by Cantex, Inc. or Engineer accepted equal. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 192 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 16920.3.7.1.7 Pulling line. Pulling line installed in duct bank tubes shall be continuous fiber polyline. The pulling line shall be mildew and rot resistant, and shall have a minimum tensile strength of 200 pounds (90 kg). Pulling line shall be as manufactured by Ideal Corp. or Engineer accepted equal. 16920.3.7.1.8 Cable pulling eyes. Cable pulling eyes shall be fabricated from galvanized steel rod and constructed to allow embedment into the walls of electrical manholes. Cable pulling eyes shall be similar to Type DU2T3 as manufactured by Cooper Power Systems, or Engineer accepted equal. 16920.3.7.1.9 Cable racks. Cable racks installed in electrical manholes shall be fabricated from hotdipped galvanized formed channel. Formed channel embedded in the walls of electrical manholes shall be similar to Type P3270 Series support channel as manufactured by Unistrut Metal Framing, or Engineer accepted equal. Formed channel surface mounted to the walls of electrical manholes, and also used as horizontal cable supports, shall be similar to Type P1000 Series support channel as manufactured by Unistrut Metal Framing or Engineer accepted equal. 16920.3.7.1.10 Concrete. Concrete shall conform to Section 03311 – Cast-in-Place Concrete. The top surface of concrete for electrical duct bank shall be red. Red dye applied to the top of the concrete following the final placement of concrete is acceptable. 16920.3.7.1.11 Electrical manholes. Electrical manholes shall be as indicated on the drawings. Electrical manholes may be cast-in-place or prefabricated structures. 16920.3.7.2 Duct Bank Supports. Duct bank conduit supports shall be plastic, high impact, interlocking base and intermediate spacers designed to allow the flow of concrete through and around the spacers. Duct bank spacers shall be as manufactured by Cantex, Inc. or Engineer accepted equal. 16920.3.7.3 Duct Bank Installation. Each duct bank shall be laid to exact grade in the trench and the ends shall enter manholes or buildings as indicated on the drawings. No dips or low points which retain water in any duct will be permitted in ducts between manholes or between buildings and manholes. End bells shall be used on individual plastic ducts, and threaded couplings on individual rigid steel ducts, at the end of duct banks entering manholes or buildings except where another type of termination is specified or detailed on the drawings. All field bends and sweeps shall be a minimum 36 inch (900 mm) radius, unless noted otherwise on the drawings. The ends of the individual plastic ducts shall be cleaned and swabbed with joint sealing compound, and the duct shall then be forced tightly into the coupling to make a watertight connection. The ends of threaded rigid steel conduit shall be installed in couplings with the conduit ends butted. The individual ducts shall be laid in place, held by standard spacers placed at 5 foot (1.5 m) intervals, and secured in place with hemp or sisal twine, or tie wire. The concrete envelope shall be placed after the individual ducts are securely tied in place and adequately anchored and/or weighted to completely counteract the buoyancy of the ducts in the fluid concrete. Care shall be taken in pouring the concrete to prevent the empty ducts from being damaged or displaced, either in grade or alignment. Defective ducts shall not be installed and shall be removed immediately from the site of the work. Particular care shall be taken to keep concrete or other substances from the inside of the individual ducts during construction. All magnetic materials installed in a duct bank shall be parallel to the lengths of the individual ducts. Red dye shall be applied to the top of duct bank concrete after placement. 16920.3.7.4 Testing and Cleaning. After completion of the duct bank and before cable is pulled into duct banks, each duct shall be thoroughly cleaned. All foreign material, earth, sand, and gravel shall be removed from the ducts by an acceptable cleaning method. Ducts which will not be used immediately shall be plugged at each end. A pulling line shall be installed in all unused ducts. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 193 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 16920.3.7.5 Electrical Manhole Installation. Manholes shall be erected and installed at the locations and elevations indicated on the drawings. Manhole sides and tops shall be installed in accordance with the manufacturer's instructions. Joints shall be watertight. Manhole and duct bank interfaces shall be watertight. 16920.3.8 Grout Grout shall be as specified in Section 03611 - Grouting, and modified as follows: Nonshrinking grout shall be used whenever the space to be grouted has a thickness of 2 inches (50 mm) or more and free placement of grout will not be hampered. Fifty pounds (23 kg) of pea gravel may be added to each 100 pounds (45 kg) of grout materials. Grout shall be placed in strict accordance with the directions of the manufacturer to completely fill the openings without voids. Source: 16920, 2014, v2.0 Raceway Components and Installation Page 194 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 16925 - Conductors Installation 16925.1 General This section covers the installation of cable, conductors, and accessories. Insulated cable, conductors, and conductor accessory installation shall be in accordance with the cable manufacturer's recommendations, circuit lists, raceway lists, the drawings, and these specifications. Installation shall be defined to include receiving; unloading; storage; placement; splicing; terminating conductors; coiling and taping of spare conductors; and identification, testing, and verification of each circuit, cable, and conductor. Installation of cable in existing trays shall also include removal and replacement of existing cable tray covers. Terminating a conductor shall include installing cable termination kits for shielded cable, attaching the conductor at its designated location, and insulating the entire connection where specified or required by the application. Phase tape shall be applied to each conductor at the terminations of all power and lighting circuits that are not already properly color coded. Lighting, receptacle, communications, and some 120 volt ac miscellaneous branch circuits and cathodic protection circuits are indicated on the drawings. All other circuits are described in the Circuit List. 16925.1.1 Scope of Supply Unless otherwise specified as being furnished by others, the Contractor, shall furnish all lighting and grounding cable, terminations, fittings, splices, lubricants, equipment, and miscellaneous materials as required for a complete conductor installation. Depending on the division of responsibilities, the Contract or the Engineer may supply the insulated power, control, instrumentation, communication and fiber optic cable. 16925.1.2 Items furnished by Others and Interfaces Not Used. 16925.1.3 Performance and Design Requirements Performance and design requirements for the equipment to be furnished under this article of these specifications are indicated herein. 16925.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. These references shall govern the work except where they conflict with the Purchaser’s specifications. In case of conflict, the latter shall govern to the extent of such difference: Work In Accordance With Cable Installation IEEE 1185, IEEE 336 (Nuclear), IEEE P690 (Nuclear), ANSI/NECA/BICSI 568 Splicing/Terminating IEEE 404, UL 486A, UL 486C, ASTM F1836, ANSI/NECA/BICSI 568 Field Testing IEEE 400, ANSI/TIA/EIA-568B Source: 16925, 2014, v2.0 Conductors Installation Page 195 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 All circuits and cable components shall be installed in accordance with the applicable requirements of NFPA 70 - National Electrical Code. All materials and devices shall be in accordance with the applicable requirements of the Federal "Occupational Safety and Health Standards." 16925.1.5 Materials The following materials shall be used: Component Material Cables Materials as indicated herein or in the technical attachments, Article 16925.1.8 Cable Accessories As indicated in Article 16510.2.3 Cable Pulling Lubricant As recommended by cable manufacturer 16925.1.6 Approved Manufacturers of Components For the following components, only the listed manufacturers are recognized as maintaining the level of quality of workmanship required by these specifications. If the Contractor wants to propose a nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Engineer: Component Manufacturer ICEA/AEIC Medium Voltage Power Cable General Cable, Okonite, Prysmian (Pirelli), Southwire, Kerite ICEA/UL Low Voltage Power Cable General Cable, Prysmian (Pirelli), Rockbestos Suprenant, Rome, Southwire, Service Wire, Tamaqua (Draka USA), Kerite, Okonite ICEA/UL control cable Belden, Dekoron, General Cable, Prysmian (Pirelli), Rockbestos Suprenant, Southwire, Shawflex, Service Wire, Tamaqua (Draka USA), Okonite ICEA/UL Instrumentation and Thermocouple Cable Belden, Dekoron, General Cable, Shawflex ICEA/UL insulated ground cable General Cable, Essex/Royal, Okonite, Rockbestos Suprenant, Southwire, BIW Tamaqua Fiber Optic Corning, Belden, General Cable, or equal Lighting and Specialty Cable As indicated in the technical attachments, Article 16925.1.8 16925.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Contractor unless specifically identified as a Bid Option or Contractor-conducted. Tests identified as an option are to be priced separately. If identified as Contractor-conducted, costs for the initial test will be the responsibility of the Contractor. However, the Contractor is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Source: 16925, 2014, v2.0 Conductors Installation Page 196 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Tests In Accordance With Conducted By Tests after placement Articles 16925.3.5 and 16925.3.7 Contractor Bid Issue 2Mar2015 16925.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 16925.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 16925.1.10 Certification Requirements Certified test reports for each type of power cable furnished under this Contract shall be provided in accordance with the requirements of AEIC CS8 and ICEA S-97-682 (ICEA/AECI MV power cable), and in accordance with the requirements of ICEA S-95-658 (ICEA/UL LV power cable) and other applicable standards as indicated in the technical attachments, Article 16925.1.8. 16925.2 Products Conductors and accessories shall be furnished in accordance with the requirements of 16510 – Conductors and Accessories. 16925.3 Execution 16925.3.1 Handling of Cable Cable reels shall be stored and handled in a manner which will prevent physical damage to the cable. Cable reels shall be stored resting on the edges of the reel flanges on a hard surface to prevent contact between cable insulation and earth due to sinking of the reel. Impact damage between reels shall be prevented by aligning reels flange-to-flange or by using guards across flanges. During storage, the ends of all cable rated 5 kV and above and all aluminum cable shall be protected with end caps. 16925.3.2 Cable Placement Cable shall not be handled when the cable temperature is below the minimum temperature recommended by the manufacturer. If cable heating is required prior to placement, the cable shall be stored in a heated building in accordance with the manufacturer's recommendations for at least 24 hours. Cable shall be placed the same day it is removed from heated storage. If at any time during the progress of the work the Contractor finds raceways which appear inadequate to accommodate the assigned cable, he shall notify the Engineer at once and shall discontinue any further work on the questionable raceway until advised by the Engineer as to how he shall proceed. All cable shall be carefully checked both as to size and length before being pulled into conduits or ducts. Cable pulled into the wrong conduit or duct or cut too short to rack, train, and splice as specified herein shall be removed and replaced. Cable removed from one conduit or duct shall not be pulled into another conduit or duct without prior approval from the Site Electrical Liaison. 16925.3.2.1 Cable in Trays. All cable shall be carefully laid in or pulled through the tray system so that neither the cable nor the trays are damaged. Cable may be laid along the side of the tray system during placement provided it is protected from dirt, water, oil, or other detrimental materials and from mechanical injury. Cable shall be cut sufficiently long to conform to the contour of the trays, with particular attention paid to vertical inside bends. All excessive slack shall be removed from the cable so that it lies parallel to the sides of the trays. Multiple single conductor cable which constitutes a single power circuit shall be grouped together as defined by the NEC to minimize magnetic influence on other cable in the area. Power cables shall be installed in tray in accordance with the NEC and the following additional requirements: Source: 16925, 2014, v2.0 Conductors Installation Page 197 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Low Voltage Power Cables (2000 volts or less) Low voltage power cables (all single-conductor and multi-conductor greater than or equal to 4/0 AWG) shall be installed in cable tray in a single layer. If single-conductor cables are triplexed or bound together in circuit groups, the sum of the diameters of all single conductors shall not exceed the cable tray width. Multiconductor power cables less than 4/0 AWG may be installed in a random manner in accordance with NEC Article 392.22 (A)(1)(b) and (c). Low voltage multi-conductor power cables 4/0 AWG or larger shall be installed in cable tray in the following manner(s): In a single layer with no maintained spacing requirement between cables. The sum of the diameters of all cables shall not exceed the tray width. Low voltage single-conductor power cables shall be installed in cable tray in the following manner(s): In a single layer with no maintained spacing requirement between cables. The sum of the diameters of all cables shall not exceed the tray width. The cable shall be tied to the trays with nylon ties as necessary (but at not greater than 10 foot intervals) to hold it in place. 16925.3.2.2 Cable in Manholes. Cable shall be supported at all times without short bends or excessive sags and shall not be permitted to lie on the manhole floor. Cable ends must not be submerged. Cable racks or trays shall be provided for permanent support. Temporary support required during placement shall be with rope slings, timbers, or alternate methods acceptable to the Site Construction Manager. 16925.3.2.3 Cable Pulling. Fishing and pulling shall be done with flexible metal tape, CO2 propelled polyethylene cord, nylon rope, or manila rope. Unless specified otherwise or acceptable to the Engineer, cable shall not be pulled in a single pull through two sections of raceway connected by a manhole or pull box. Cable shall be pulled out at each manhole and pull box to the length required for termination. Prior to repulling of the pulled out cable, the cable shall be thoroughly inspected, cleaned, and relubricated. Damaged cable shall be removed and replaced. Cable may be pulled in a single pull through two sections of raceway connected by a manhole or pull box only if it can be determined by calculation to the satisfaction of the Engineer that the pulling tension will not exceed the maximum tension allowed by the cable manufacturer. Cable shall not be pulled using trucks, forklifts, cranes, or other devices where the tension of the cable pull cannot be easily controlled. 16925.3.2.4 Cable Grips. Factory installed pulling eyes shall be used for pulling cable where they are 2 available. Woven wire cable grips shall be used to pull all single conductor cable 2/0 AWG (70 mm ) and larger, where pulling eyes are not available, and all multiconductor cable. Pulling loops shall be used to 2 pull single conductor cable smaller than 2/0 AWG (70 mm ). All sharp points and edges on the hardware attaching the pulling rope to the cable shall be taped to prevent snagging or damaging the raceway. Source: 16925, 2014, v2.0 Conductors Installation Page 198 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 When a cable grip or pulling eye is used for pulling, the area of the cable covered by the grip or seal plus 6 inches (150 mm) shall be cut off and discarded when the pull is completed. When pulling loops are used, the entire loop shall be cut off and discarded when the pull is completed. As soon as the cable is pulled into place, the pulling eyes, cable grips, or pulling loops shall be removed and any cable which was sealed shall be resealed. 16925.3.2.5 Swivels. A reliable nonfreezing type of swivel, or swivel connection, shall be inserted between the pulling rope and the cable pulling eye, grip, or loop to prevent twisting under strain. 16925.3.2.6 Pulling Lubricants. Only lubricants recommended by the cable manufacturer and acceptable to the Engineer shall be used. Lubricants shall be applied liberally and continuously during the pull. 16925.3.2.7 Inspection. The outside of each cable reel shall be carefully inspected and protruding nails, fastenings, or other objects which might damage the cable shall be removed. A thorough visual inspection for flaws, breaks, or abrasions in the cable sheath shall be made as the cable leaves the reel, and the pulling speed shall be slow enough to permit this inspection. Damage to the sheath or finish of the cable shall be sufficient cause for rejecting the cable. Cable damaged in any way during installation shall be replaced. 16925.3.2.8 Pulling Tension. The pulling tension of any cable shall not exceed the maximum tension recommended by the cable manufacturer. Pulling mechanisms of both the manual and power types used by the Contractor shall have the rated capacity in tons clearly marked on the mechanism. If any excessive strain develops, the pulling operation shall be stopped at once and the difficulty determined and corrected. 16925.3.2.9 Sidewall Pressure. To avoid insulation damage from excessive sidewall pressure at bends, the pulling tension in pounds shall not exceed the cable manufactures recommendation. 16925.3.2.10 Cable Bends. Tape shielded, flat tape armored, and wire armored cable shall not be bent to a radius of less than 12 times the overall cable diameter. All other cables shall not be bent to a radius of less than 8 times the cable diameter. 16925.3.2.11 Supports. All cable supports and securing devices shall have bearing surfaces located parallel to the surfaces of the cable sheath and shall be installed to provide adequate support without deformation of the cable jackets or insulation. Adequate cable end lengths shall be provided and properly placed in junction boxes and manholes to avoid longitudinal strains and distorting pressures on the cable at conduit bushings and duct end bells. Final inspection shall be made after all cable is in place and, where supports or raceway fittings deform the cable jacket, additional supports shall be provided. Additional cable protection such as a wrapping of light rubber belting, friction tape, or similar material shall be provided where required. Cable in vertical runs shall be supported by woven wire grips in accordance with the NEC requirements, except that the distance between supports shall conform to the following: Vertical Cable Support Spacing Conductor Size Aluminum Conductor Copper Conductor 2 150 feet (45 m) 100 feet (30 m) 2 100 feet (30 m) 50 feet (15 m) 1/0 AWG (50 mm ) and smaller 2/0 AWG (70 mm ) through 2 500 kcmil (240 mm ) Source: 16925, 2014, v2.0 Conductors Installation Page 199 of 280 Calaveras Coal Yard 186144.77.1000 Larger than 500 kcmil 2 (240 mm ) Bid Issue 2Mar2015 Compressed Air Equipment Construction 70 feet (21 m) 30 feet (9 m) 16925.3.2.12 Cable Racks. Where cable trays are not specified in manholes, cable racks shall be furnished and installed according to the drawings and as required to provide the proper cable support. Cable racks shall be installed on spacings of not greater than 36 inches (900 mm) and shall be bolt secured to permanent wall surfaces with self-drilling anchors or continuous slot concrete inserts. 16925.3.2.13 Spare Conductors. All spare conductors of a multiconductor cable shall be left at their maximum lengths for possible replacement of any other conductors in the cable. Each spare conductor shall be neatly dressed for future use. 16925.3.2.14 Lacing. Nylon ties shall be used to neatly lace together conductors entering switchboards and similar locations after the conductors have emerged from their supporting raceway and before they are attached to terminals. 16925.3.2.15 Cable Identification. At terminations, the Contractor shall identify each circuit. Each phase of multiphase power circuits shall be individually identified. The circuit tag shall be so attached that it is readily visible for circuit identification. Phase tape shall be applied to each conductor at the terminations of all power and lighting circuits. The phase taping for power conductors shall be as follows: 208/120 V Circuits Black – Phase A; Red – Phase B; Blue – Phase C; White – Neutral 480/277 V Circuits Brown – Phase A; Orange – Phase B; Yellow – Phase C; Grey – Neutral 4160 (or 6900) V Circuits Black – Phase A; Red – Phase B; Blue – Phase C Green shall be used for ground at every voltage level. Phase taping circuits shall not be required if cable with colored insulation is installed. 16925.3.2.16 Moisture Seals. Each cable rated 5000 volts and above and each cable with an aluminum conductor shall be kept sealed except when termination and splicing work is being performed. The ends of all power cables shall be sealed with heat shrinkable caps for circuits larger than #10 AWG. Circuits #10 AWG and smaller can be sealed with heat shrinkable caps or electrical tape. Cap sizes shall be as recommended by the cap manufacturer for the cable OD and insulation. Caps shall contain sufficient adhesive that shrinkage of the cap during application results in formation of a positive watertight seal capable of withstanding complete immersion or total exposure without permitting the entrance of moisture. Heat shrinkable caps shall be "Thermofit" as manufactured by Raychem Corporation or Engineer acceptable equal. Lead covered cable shall be sealed by a lead cap wiped to the cable sheath. Before and after pulling, the leading end seal of each length of cable shall be examined and repaired if necessary. All cut cable ends shall be promptly sealed after cutting except those to be spliced or terminated immediately. 16925.3.2.17 Direct Buried Cable. Direct burial of cable shall be accomplished in the following manner. Except for risers to above grade terminations, cable rated 600 volts and less shall be buried in a trench at a minimum depth of 2 feet (600 mm) below finished grade, and cable rated above 600 volts through 40 kV shall be buried in a trench at a minimum depth of 3 feet (900 mm) below finished grade. Source: 16925, 2014, v2.0 Conductors Installation Page 200 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Cable trench dimensions shall be such that a minimum of 4 inches (100 mm) of bedding material separates each trench wall from the cable closest to that wall. Before placement of any cable, the bottom 4 inches (100 mm) of the trench shall be backfilled with job excavated material free from debris, organic material, and stones. If more than one cable is laid in a single trench, the cable shall be carefully placed so that no cable crosses or rests upon another. One cable shall not be laid directly upon another. If the cable to be laid in a single trench cannot be laid in a single layer, it shall be laid in multiple layers with 4 inches (100 mm) of clean, job excavated backfill material between layers. Backfill to approximately 8 inches (203 mm) above the upper layer of cable shall be the same as the bedding material. Cable marking tape shall be located 12 inches (305 mm) below finish grade, covering all cable for the entire length of the direct buried cable run. Cable marking tape shall be 6 inch (152 mm) wide yellow plastic strip with the words "CAUTION BURIED ELECTRIC LINE BELOW" printed in black. Marking tape shall be as manufactured by the Allen Systems Inc., or Engineer acceptable equal, and shall be installed flat and directly above the cable with the printed side up. For power cables rated above 600 volts, cable route markers shall be installed flush with the ground above the center line of the cable. The markers shall be installed at each turn in the cable route and at approximately 100 foot (30 m) intervals along the route. Markers shall be A. B. Chance Catalog No. C554-0001. All backfill shall be deposited in layers not to exceed 6 inches (152 mm) in compacted thickness and mechanically compacted to 95 percent of maximum density at optimum moisture content as determined by ASTM D698 when that test is appropriate or to 70 percent relative density as determined by ASTM D4253 and D4254 when those tests are appropriate. 16925.3.2.18 Internal Panel Wiring and Jumpers. Internal panel wiring and jumpers shall be installed in accordance with the drawings, schematic and wiring diagrams, three-line diagrams, one-line diagrams, and as required for a complete functional operation of the system or equipment. Wire markers shall be installed at each end of each jumper, not within the same or immediate adjacent terminal blocks, using slip-on wire markers. The wire markers shall contain the opposite end designation of the jumper. Jumper wire notations shall be acceptable to the Engineer. Jumpers are identified on the drawings and are not included in the Circuit List. 16925.3.3 Splices No splices shall be made in conductors for instrument circuits or control circuits except where required at connections to accessory devices equipped with factory installed pigtails or where high temperature wire is necessary locally to connect to a particular device. Shields may be spliced where necessary to permit connection to the station ground. Power cable circuits may not be spliced unless specifically approved by the Engineer. Where splices are unavoidable, they shall be performed in accordance with the standards listed in this section and at locations acceptable to the Engineer. Splices shall not be made to utilize short lengths of cable nor shall they be made to provide correct lengths on cable initially cut too short for a particular circuit. Source: 16925, 2014, v2.0 Conductors Installation Page 201 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Splices, joints, and connections in cable shall be made only in pull boxes or junction boxes unless otherwise indicated on the drawings and shall be made in accordance with the instructions of the cable manufacturer. Splices in cable shall be prepared and insulated in a manner similar to the cable terminations specified below. 16925.3.4 Terminations Cable shall be terminated in accordance with the following requirements: Train cable in place and cut squarely to required length. Avoid sharp bends. Remove necessary amount of cable jacket and insulation without damage to the conductor. Install terminals or terminal connectors as required, ensuring a firm metal-to-metal contact. Reducing pin terminals (if required and approved for use by Engineer) shall be installed where 600V power cables have been oversized and will not fit into mechanical connections such as on molded case breakers. Install high voltage cable termination kits for shielded cable rated 5 kV and above using the procedures recommended by the manufacturer of the kit being used. Insulate each connection of cable to an insulated conductor (whether cable, bus, or equipment bushing). The insulation shall cover all exposed surfaces of the conductors; the insulation voltage level of the completed termination shall be not less than the insulation voltage level of the connected conductors. Instrument cable shields and drain wires shall remain on the pair as close to the termination point as practical. Shields shall be permanently taped to prevent unraveling and the drain wires shall have insulating sleeves installed up to the point of termination. 16925.3.4.1 Insulation of 600 Volt Cable Connections. Where connections of cable rated 600 volts or less require insulation, all exposed conductor and connector surfaces shall be covered with tape in accordance with the following: A minimum of four half-lapped layers of rubber tape, elongated not more than 20 percent, applied over the silicone rubber tape. A minimum of three half-lapped layers of vinyl tape applied over the rubber tape. The vinyl tape shall extend a minimum of two cable diameters over the cable jacket and a similar distance over the insulation of the conductor to which the cable is connected. 16925.3.4.2 Insulation of Connections on Indoor Shielded Cable Rated 5 kV and Above. Not Used. 16925.3.4.3 Insulation of 5 kV Nonshielded Cable Connections. Not Used. 16925.3.5 Tests After Placement All insulated conductors shall be electrically tested after placement. All circuits, including lighting circuits, shall be tested with the circuit complete except for connections to equipment. All splices, stress cones on shielded cable, and terminal connector attachments shall be complete prior to testing. Source: 16925, 2014, v2.0 Conductors Installation Page 202 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 In addition to the tests performed after cable placement is complete, continuity tests shall be performed on all supervisory and communication cable before and after each splice is made. Any circuit failing to test satisfactorily shall be replaced or repaired and then retested. All equipment and labor required for testing shall be furnished by the Contractor. The Contractor shall provide documentation of the tests on forms provided by the Engineer or acceptable to the Site QA Manager for each test performed. 16925.3.5.1 Continuity and Identification Tests. All insulated conductors shall be tested for continuity and conductor identification. 16925.3.5.1.1 Continuity Tests. Continuity tests shall include all tests necessary to confirm that each conductor is continuous throughout its entire length. 16925.3.5.1.2 Identification Tests. Identification tests shall include all tests necessary to confirm that the conductor being investigated originates and terminates at the locations designated in the Circuit List or indicated on the drawings. 16925.3.5.2 Insulation Tests. Resistance from ground provided by the insulation on all field-installed insulated power conductors shall be measured, excluding 120VAC non-essential power circuits. 16925.3.5.2.1 Cable Rated 5000 Volts and Above. Not Used. 16925.3.5.2.2 Cable Rated Below 5000 Volts. All insulated conductors, except supervisory and communication cable, rated less than 5000 volts shall be tested with a 1000 volt megger or an equivalent testing device. Insulation resistance measurements shall be made between each conductor and ground and between each conductor and all other conductors of the same circuit. Minimum acceptable resistance values shall be approximately 500 megohms. 16925.3.5.2.3 Supervisory and Communication Cable. All insulated conductors of supervisory and communication cable shall be tested for continuity. 16925.3.5.2.4 CAT5e and CAT6 Communications Cable. Not Used. 16925.3.6 Fiber-Optic Conductor Installation and Termination. Not Used. 16925.3.7 Fiber-Optic Test Requirements Not Used. 16925.3.8 Circuit Installation Records Not Used. Source: 16925, 2014, v2.0 Conductors Installation Page 203 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 16930 - Grounding Components and Installation 16930.1 General This section covers the furnishing and field installation of a grounding system and all components. The grounding system and installation shall be in accordance with the drawings and these specifications. 16930.1.1 Scope of Supply Any materials not specified as being furnished by others, but which are required for a complete grounding installation, shall be furnished. Major components of the grounding system include: Joint manhole ground rods and grounding connections. Low profile substation type cable termination structure ground connections. High profile riser pole type cable termination structure ground rods and connections. Ground continuity conductor (GCC). 16930.1.2 Items Furnished by Others and Interfaces Not used. 16930.1.3 Performance and Design Requirements Performance and design requirements for the equipment to be furnished under this section of these specifications are indicated herein. Test Test Criteria Target Value Ground resistance testing 10 ohms or lower 16930.1.4 Codes and Standards Work performed under these specifications shall be done in accordance with the following codes and standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in effect at the date of this document shall apply. Grounding systems and components furnished with these specifications shall be manufactured in accordance with applicable standards of the Institute of Electrical and Electronics Engineers, Inc. (IEEE), the National Electrical Manufacturers Association (NEMA), the American Society for Testing and Materials (ASTM), and Underwriters' Laboratories, Inc. (UL). Grounding systems and components shall be installed in accordance with the applicable requirements of the National Electrical Code (NEC) and the Occupational Safety and Health Administration (OSHA) standards. 16930.1.5 Materials Grounding component materials shall be furnished new and undamaged. 16930.1.6 Approved Manufacturers of Components For the following components, only the listed manufacturers are recognized as maintaining the level of quality of workmanship required by these specifications. If the Contractor wants to propose a non-listed manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the discretion of the Engineer: Source: 16930, 2014, v2.0 Components and Installation Page 204 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Component Manufacturer Ground rods Blackburn Harger Erico, Inc. Conductor Rome Cable Corporation Southwire BICC - General Bus and Bars Erico Harger Thermoweld Exothermal Welds Erico (Cadweld) Harger Thermoweld Burndy (BurndyWeld) Compression Connectors Burndy Electrical Thomas and Betts ILSCO Lugs - Exothermal / Mechanical Erico (Cadweld) Harger Thermoweld Burndy (Burndy/Weld) Lugs - Compression / Mechanical Burndy Electrical Thomas and Betts ILSCO Ground Plates Erico (Cadweld) Burndy 16930.1.7 Test Requirements Not used. 16930.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 16930.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 16930.2 Products Not used. 16930.3 Execution 16930.3.1 Grounding Components An electrical grounding system shall be furnished and installed in accordance with the drawings and the following specifications. Grounding components shall include ground rods, ground conductor, ground bus, above and below grade grounding connections, grounding lugs, and hardware required for a complete system. 16930.3.1.1 Grounding Materials. Grounding component materials shall be furnished new and undamaged, and shall conform to the requirements of the articles that follow. Source: 16930, 2014, v2.0 Components and Installation Page 205 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 16930.3.1.1.1 Ground rods. Ground rods shall be copper clad, cold drawn carbon steel manufactured in accordance with UL 467. The copper cladding shall be electrolytically bonded to the steel rod or bonded by a molten welding process. Cold rolled copper cladding will not be acceptable. Ground rods shall have a conical taper on one end to facilitate soil penetration. Individual ground rods shall be 3/4 inch (19 mm) diameter and 10 feet (3 m) long. Ground rods shall be similar to Type ERITECH as manufactured by Erico, or an Engineer acceptable equal. 16930.3.1.1.2 Conductors. Bare ground conductor shall be soft drawn, stranded copper conforming to the requirements of ASTM B-8. Insulated ground conductor shall be soft drawn, stranded copper conforming to the requirements of UL 83. Insulated ground conductor shall be Type TW or THW having green colored PVC insulation. Ground conductors shall be as manufactured by Rome Cable Corporation, or an Engineer acceptable equal. 16930.3.1.1.3 Bus bar. Ground bus bar shall be soft drawn, uncoated copper conforming to the requirements of ASTM B-187. Bus bar shall be a minimum 1/8 inch (3 mm) thick and 1 inch (25 mm) wide. Where required, bus bar shall be provided with predrilled holes measuring 9/16 inch (14 mm) in diameter with NEMA center line hole spacings. Bus bar shall be as manufactured by Erico, or an Engineer acceptable equal. 16930.3.1.1.4 Exothermal connections. Exothermal connections shall be a standard duty copper molten weld conforming to the requirements of IEEE 837, IEEE 80 Section 11, and UL 467. Molds and powder cartridges used for making exothermal connections shall be furnished by the same manufacturer. Exothermal connections shall be similar to Type CADWELD as manufactured by Erico, or an Engineer acceptable equal. 16930.3.1.1.5 Compression connections. Compression connections shall be irreversible, heavy-duty, copper crimps conforming to the requirements of IEEE 837 and UL 467. Compression fittings and compression tools and dies shall be furnished by the same manufacturer. Compression connections shall be similar to Type HYGROUND as manufactured by Burndy Electrical, or an Engineer acceptable equal. 16930.3.1.1.6 Ground lugs. Ground lugs shall be single hole or two hole, heavy-duty, copper bars conforming to the requirements of IEEE 837 and UL 467. Two hole ground lugs shall have NEMA center line hole spacings. Ground lugs used with the exothermal weld process shall be similar to Type LA as manufactured by Erico, or an Engineer acceptable equal. Ground lugs used with the compression process shall be similar to Type YGHA as manufactured by Burndy Electrical, or an Engineer acceptable equal. 16930.3.1.1.7 Ground plates. Ground plates shall be high strength, four hole copper bodies conforming to the requirements of IEEE 837 and UL 467. Ground plates shall have NEMA center line hole spacings and shall be provided with hole plugs on the mating side of the plate. Ground plates used with the exothermal weld process shall be similar to Type B164 as manufactured by Erico, or an Engineer acceptable equal. Ground plates used with the compression process shall be similar to Type YGF as manufactured by Burndy Electrical, or an Engineer acceptable equal. 16930.3.1.1.8 Hardware. Clamps, connectors, bolts, washers, nuts, and other hardware used with the grounding system shall be of copper, copper alloy, or stainless steel. 16930.3.2 Grounding Installation Grounding system components shall be installed as indicated the drawings and as described in these specifications. 16930.3.2.1 Conductors. Exposed conductors shall be installed inconspicuously in vertical or horizontal positions on supporting structures. When located on irregular supporting surfaces or equipment, the conductors shall run parallel to or normal to dominant surfaces. Source: 16930, 2014, v2.0 Components and Installation Page 206 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 All below grade ground conductors shall be buried a minimum of 18 inches (450 mm) and a maximum of 30 inches (750 mm) below finished grade unless installed under a concrete foundation. Ground grid conductors under foundations shall have 6 inches of earth cover between conductor and bottom of foundation. Conductors routed over concrete, steel, or equipment surfaces shall be kept in close contact with those surfaces by using fasteners located at intervals not to exceed 3 feet. Conductors routed around 90 degree corners shall be kept in close contact with the perpendicular surfaces and shall not be physically damaged due to an insufficient bending radius. Below grade ground conductors shall be placed as indicated on the drawings. Damaged ground system conductors shall be repaired or replaced. 16930.3.2.2 Ground Rods. All ground rods shall be located as indicated on the drawings and installed to the depth indicated. Where the required ground rod length exceeds 10 feet (3 m), ground rod standard sections shall be welded together to provide an extended rod with one true centerline a minimum of joint resistance. During welding, the ground rod sections being welded shall be supported by a guide to ensure proper alignment. 16930.3.2.3 Connections. All connections shall be made by the exothermal welding process except where otherwise indicated on the drawings or in these specifications. All surfaces to be joined by the welds shall be thoroughly cleaned. Powder cartridges and molds shall be kept dry and warm. Worn or damaged molds shall not be used. The manufacturer's instructions on the use of exothermal welding materials shall be followed in all details. All exothermally welded connections shall successfully resist moderate hammer blows. Any connection which fails such test, or which upon inspection indicates a porous or deformed weld, shall be remade. All exothermal welds shall encompass 100 percent of the ends of the materials being welded. Welds that do not meet this requirement shall be remade. All bolted and screwed connections shall be securely tightened. Dies used in the compression tools shall be of the same manufacturer as the compression fittings. The manufacturer's instructions on the use of the compression tools and dies shall be followed in all details. All bolted and screwed connections shall be securely tightened. 16930.3.2.4 Ground Plates. Ground plates embedded in concrete shall be carefully located as indicated on the drawings and firmly secured to the concrete forms. The threaded holes in the mating surface of round plates shall be plugged prior to pouring concrete. The grounding conductor attached to the ground plates shall be inspected prior to the pouring of concrete to ensure a good solid connection in accordance with industry standards. 16930.3.2.5 Column Grounding. Structural steel columns shall be grounded by use of a servit post installed in a pre-drilled hole in the web of the column near the base as indicate on the drawings. The Contractor shall provide a hole in the web of structural steel columns not so equipped for grounding provisions. The hole shall be 9/16 inch (14 mm) in diameter and located approximately 8 inches (200 m(m up from the base. Prior to the installation of the servit post, paint, scale, and other non-conductive substances shall be removed from surfaces of ungalvanized structural steel members by grinding. Galvanized steel surfaces shall be leaned with emery paper. 16930.3.2.6 Conduit Grounding. All conduit grounding bushings within all enclosures, including equipment enclosures, shall be wired together and connected internally to the enclosure grounding lug Source: 16930, 2014, v2.0 Components and Installation Page 207 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 grounding bus with a bare copper conductor. Grounding bushings shall be grounded with conductor sized in accordance with the NEC, but not smaller than 8 AWG. All grounding bushings on conduit runs which are terminated at tray shall be connected to the tray grounding cable or tray side rail with bare copper conductor as indicated on the drawings. Where a conduit run is terminated at tray and the conduit carries a separate insulated grounding conductor, this grounding conductor shall be terminated on the tray grounding cable. If the conduit run is terminated with a grounding bushing and the separate ground conductor it carries is sized in accordance with the requirements of the preceding paragraphs for conduit bushing grounding, the ground conductor in the conduit run may be continued through the conduit bushing ground connection and terminated on the tray grounding cable making unnecessary the installation of a separate conduit bushing grounding cable. Conduit bushing ground conductors shall be connected to the tray ground cable using split bolt connectors or an Engineer acceptable equal mechanical connector. Conduit terminated at equipment and device in threaded hubs shall not require additional grounding provisions. 16930.3.2.7 Tray Grounding. A bare copper grounding conductor shall be installed on all power level cable trays containing single conductor power cables. The tray grounding conductor shall be installed on the outside of the tray side rails, along the entire length of the trays, attaching to each tray fitting and to each straight section of tray at 6 foot (1.8 m) maximum intervals. The tray grounding conductor shall be attached to the trays using bolted ground clamps, and shall be connected to the ground grid at locations indicated on the drawings. Splices for the tray grounding conductor shall be made using compression connectors. Cable trays containing multi-conductor power cables, control, or instrument circuits shall not require a continuous ground conductor installed along the tray. Instead, these tray levels shall be grounded by means of a ground jumper extended from the tray side rail to the continuous ground conductor installed along a power level cable tray, to building steel, or to the ground grid. Grounding intervals shall not exceed 100 feet (30 m). Grounding jumpers shall be required across all expansion splice plates, dropouts and adjustable splice plates where a continuous ground conductor is not installed along the tray level. 16930.3.2.8 Equipment Grounding. Electrical equipment that requires a ground grid extension stinger shall be connected to the ground grid with copper grounding conductor as indicated on the drawings. The term "electrical equipment," as used in this article, shall include all enclosures containing electrical connections or bare conductors except that individual devices such as solenoids, pressure switches, and limit switches shall be exempt from this requirement unless the device requires grounding for proper operation. Large electrical power distribution equipment such as medium or low voltage switchgear or motor control centers will be furnished with a ground bus which the Contractor shall connect to the ground grid at each end of the ground bus. Other equipment will be furnished with grounding pads and/or ground lugs which the Contractor shall connect to the ground grid. All ground connection surfaces shall be cleaned immediately prior to connection. Where ground grid extension stingers are indicated on the drawings to be provided for connection to electrical equipment, the Contractor shall connect the grounding conductor to the equipment ground bus, pad, or lug. In addition to the ground grid extension stingers, a ground conductor shall be provided from the tray ground cable to the incoming line end of the ground bus in each assembly of medium or low voltage switchgear and motor control centers indicated on the drawings. Where a ground conductor is included with the phase conductors of power circuits, the ground conductor shall be connected to the equipment grounding facilities and to the source ground bus. Where a ground Source: 16930, 2014, v2.0 Components and Installation Page 208 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 conductor is not included with the phase conductors, the equipment shall be grounded by connecting a separate ground cable to the equipment grounding facilities and to the tray ground cable or source ground bus. Except where otherwise indicated on the drawings, all equipment ground conductors which are not an integral part of a cable assembly shall be sized in accordance with the requirements of NEC. All ground conductors installed in conduit shall be insulated. Circuits in the circuit List include an insulated ground conductor to all 6,900 volt, 4,160 volt, 480 volt, and 208 volt loads to satisfy the requirements of the preceding paragraph. This ground conductor is either a separate cable, Type GI, or is contained within the multiconductor power cable. Power circuits from 120/208 volt power panels contain one additional conductor which is used for grounding smaller devices which require 120-volt power. Additional grounding cables which would duplicate the ground conductors already in the Circuit List are not required. The Contractor shall design, furnish, and install all equipment grounding cables required in addition to the ground cables contained in the Circuit List. This shall include, but not be limited to, devices which have electrical connections but do not require a power circuit such as junction boxes and control equipment enclosures, any equipment to which the routed ground conductor is not of sufficient size to properly ground the equipment, and any other electrical equipment which is not grounded by means of a conductor in the Circuit List. Suitable grounding facilities shall be furnished on electrical equipment not so equipped. The grounding facilities shall consist of compression type terminal connectors bolted to the equipment frame or enclosure and providing a minimum of joint resistance. Suitable grounding facilities for electrical equipment not so equipped, but requiring multiple grounding connections, shall include the installation of a bare copper ground bus for the connection of several grounding conductors. This ground bus shall be connected to the equipment frame or enclosure, providing a minimum of joint resistance. The conduit system is not considered to be a grounding conductor except for itself and for lighting fixtures. No equipment grounding conductor shall be smaller in size than 12 AWG unless it is a part of an acceptable cable assembly. 16930.3.2.9 Duct Bank and Electrical Manhole Grounding. Two bare copper ground conductors, equal in size to the ground grid conductors, shall be routed with each duct bank routed outside the plant grid or outlying grids as indicated on the drawings. The duct bank ground conductors shall be located at the top of the duct bank and physically separated on each side. The duct bank ground conductors shall be connected to the plant ground grid and outlying grids at locations where the duct bank meets the perimeter of the grids, as indicated on the drawings. A ground conductor, equal in size to the ground grid conductors, shall be installed around the upper interior of each electrical manhole as indicated on the drawings. This ground conductor shall be connected to the duct bank ground conductors or ground grids as indicated on the drawings, The manhole ground conductor shall also be connected to any manhole rebar ground plates, conduit ground bushings, cable racks, and cable tray located in the electrical manhole. 16930.3.3 Ground System Resistance All ground resistance measurements shall be made with the Fall of Potential or slope methods as defined in IEEE 81. Some of the acceptable instruments are as follows: Advanced Geosciences, Inc., Sting R1, Mini Sting, Super Sting R1, or Super Sting R8 Iris Instruments, SYSCAL R1 Plus, SYSCAL R2, or SYSCAL Pro After connection of ground rods to the ground system, the Contractor shall obtain a ground resistance measurement from a selected location on the ground grid, as indicated on the drawings, using methods approved by the Engineer. This data shall be obtained, identified, and recorded. Source: 16930, 2014, v2.0 Components and Installation Page 209 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 The ground resistance measurement data may indicate that additional ground rods are required. The Contractor shall furnish, install, and connect additional ground rods as necessary. Source: 16930, 2014, v2.0 Components and Installation Page 210 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 18031 – Electrical Startup, Testing, and Checkout 18031.1 General 18031.1.1 Scope of Work This section describes and defines general criteria which pertain to the startup, testing, and checkout work covered by these specifications. This work is in addition to testing activities required in other sections of this specification. The Contractor shall be responsible, as part of the base scope, for all labor and materials required to demonstrate that the electrical equipment has been installed correctly and functions properly. Functional testing shall include a demonstration that all major equipment installed can be operated in accordance with the design from local and remote stations, control loops and protective devices perform as designed, and other equipment operates in accordance with their specification. After such demonstration, the systems and components shall be turned over to the Purchaser. Upon acceptance of mechanical completion, the Contractor shall provide standby craft labor to correct discrepancies found during initial operation on a time and material basis when requested by the Engineer. Such standby craft labor shall not be utilized for completion of Contractor punch list items for work later identified as resulting from Contractor's lack of construction completion or Contractor's warranty work. Construction checkout of all electrical systems shall be provided by the Contractor subject to approval by the Engineer. The scope of work extends to all equipment connected and/or installed under these specifications. The Contractor test procedures and plans must meet NETA and IEEE standards for testing on Switchgear, Load Centers, MCCs, Wet and Dry Transformers, Relay Protection, and Circuit Breaker Testing, as well as Circuit Loop Checks and Control Loop Checks. The Contractor shall document all testing and inspections on Construction Execution Guide Manual forms (CEGMF) that will be supplied by the Engineer to document the testing. The Contractor shall supply to the Purchaser's Startup group their proposed Electrical and Instrumentation Testing procedures for review. As an option, the Purchaser may be providing the testing and calibration for the above. The Contractor shall provide an adjustment price to remove testing and calibration of the relays indicated above from the Contract Price. The following activities shall be performed as part of the equipment installation. The Contractor shall perform all mechanical and electrical work required to calibrate, check out, and make the equipment ready for service as required by these specifications. The following activities shall be completed under these specifications: Visual and mechanical inspection of equipment. Mechanical adjustment and testing of all electrical equipment, as required, to assure proper mechanical functioning and operation. All testing and reconnection necessary to obtain correct operation of the electrical equipment. Loop verification of all control and instrumentation circuits, in accordance with the Circuit List, to confirm continuity of conductors and that conductors originate and terminate at the locations designated in the circuit list or on the drawings. All mechanical adjustment necessary or recommended by the manufacturer of all Contractor-supplied or Purchaser-supplied electrical equipment being connected or installed. Complete testing of the lighting and receptacle system, (including any welding receptacles added to the system) as applicable. Source: 18031, 2014, v2.0 Electrical Startup, Testing, and Checkout Page 211 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 All cable and wiring tests in accordance with Section 16510 are complete. All circuit installation records in accordance with Section 16925 are complete. All instruments wired and calibrated, even if installed by others. Assistance shall be provided as required during trial operation and functional testing to correct installation deficiencies. 18031.1.2 Items Furnished by Others and Interfaces Items furnished by others and not in this Scope of Work include the following: 18031.1.3 Electrical Startup, Testing, and Checkout Requirements Electrical startup, testing, and checkout shall be in accordance with the equipment manufacturer's instructions and recommendations, the applicable requirements of the Supplemental Specifications in Section 21000, and the requirements of this section. 18031.1.4 Codes and Standards Not Used. 18031.1.5 Materials Not Used. 18031.1.6 Approved Manufacturers of Components Note Used. 18031.1.7 Test Requirements The following testing shall be conducted in accordance with the specified source. This testing is to be considered part of the defined Scope of Work, and all associated costs are the responsibility of the Contractor unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the initial test will be the responsibility of the Purchaser. However, the Contractor is responsible for all costs associated with correcting deficiencies and retesting in the event of a test failure: Tests In Accordance With Conducted By Acceptance Testing IEEE, NETA Contractor 18031.1.8 Technical Attachments Technical attachments relevant to the work under this section are listed in Section 01100. 18031.1.9 Supplemental Specifications Technical supplemental specifications that are applicable to the work covered under this technical specification section are identified and included in Section 21000. 18031.2 Products Not Used. 18031.3 Execution 18031.3.1 Calibration, Testing, and Checkout Procedures The following procedures shall be performed and followed by the Contractor. The Contractor shall inform the Engineer that specific items, devices, or systems are installed and available for checkout. Documentation of the Inspections and Testing will be done on Construction Execution Guide Manual Forms (CEGMF). These forms will be supplied by the Engineer. Instrument calibration by others. Source: 18031, 2014, v2.0 Electrical Startup, Testing, and Page 212 of 280 Checkout Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 18031.3.1.1 Inspection. The Contractor shall inspect the installed instrument systems and the installed equipment specified herein prior to starting calibration and checkout and shall report in writing to the Engineer all deficiencies that could prevent proper checkout of such equipment and systems. Such deficiencies, if caused by or during installation by the Contractor, shall immediately be corrected. The Engineer will instruct the Contractor if such deficiencies are caused by material furnished and/or installed by others. 18031.3.1.2 Discrepancy Procedure. The Contractor shall endeavor to promptly discover major discrepancies in equipment, materials, and installation so that corrective procedures can be initiated without delay. When the Contractor discovers equipment with an incorrect rating, damage, not being as specified, or is otherwise unsatisfactory, arrangements will be made for replacement of the equipment. The Contractor shall promptly report to the Engineer any improper field installations or material usage which the Contractor believes should be corrected. The Engineer will arrange for corrective action. 18031.3.1.3 Calibration in-Place. All equipment furnished and installed by the Contractor shall be calibrated at the site after installation. The Contractor's technicians performing the calibration shall be experienced in the calibration and adjustment of mechanical equipment and final drive devices. Technicians shall be experienced in working with the necessary diagrams and documents in accordance with the calibration and checkout work assigned to each technician. Devices and equipment shall be adjusted and calibrated with the equipment normally installed in place. Exceptions to this procedure will be permitted with the concurrence of the Purchaser for the specific device categories for which in-place calibration is not practical. 18031.3.1.4 Calibration Range. Analog devices shall be calibrated to be accurate within the manufacturers' specified tolerances over a range of 0 to 100 percent full range, with check readings for accuracy and hysteresis at 0, 25, 50, 75, and 100 percent. Digital or switch contact devices shall be set to actuate or change state at the required process condition, and shall be checked for accuracy and hysteresis (deadband) at this condition. Both accuracy and hysteresis for both analog and digital devices shall be certified to be within the manufacturers' stated tolerances. For instrumentation that interfaces with the DCS all ranges will be confirmed through the DCS for accuracy. Discrepancies between the Contractor calibration range and DCS calibration range will be resolved by the Engineer. 18031.3.1.5 Minor Corrections. Equipment and devices furnished by others may require minor correction to ensure correct operation following calibration and checkout. These minor corrections may include the following: Minor assembly operations within instruments. Removal of factory shunts or jumpers. Minor wiring corrections. The Contractor shall perform minor corrections as part of the work defined by these specifications. In exceptional cases, the Contractor may judge that timely completion of the work requires discrepancies to be repaired by the Contractor. In such cases, the Contractor shall include repair of these discrepancies as part of this work. 18031.3.1.6 Contractor-Caused Defects. The Contractor shall promptly repair at no additional cost to the Purchaser any equipment or devices which are damaged by the Contractor's personnel in the course of performing the work. Such defects shall be promptly reported to the Engineer. 18031.3.1.7 Manufacturers' Procedures. Drawings and installation and operating instructions from manufacturers of the equipment appropriate to the work described in these specifications will be made available to the Contractor as required. The Contractor shall follow the manufacturers' instructions in the Source: 18031, 2014, v2.0 Electrical Startup, Testing, and Checkout Page 213 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 performance of this work and perform all required and recommended tests, calibrations, and settings identified in these instructions. 18031.3.2 Personnel The Contractor shall provide all personnel required to complete the work in accordance with the project schedule. The Contractor shall provide sufficient staff so that the project schedule is met. The Engineer will have the authority to approve and require changes in the Contractor's actual manpower level, including the number of technicians and craft personnel. The number authorized and required may be above or below the Contractor's planned number. Personnel not performing efficiently, in the opinion of the Engineer, shall, upon notification to the Contractor, be immediately removed from the project. Personnel provided by the Contractor shall include the following classifications. 18031.3.2.1 Startup Coordinator. The Contractor's Startup Coordinator shall be experienced in the supervision of power plant calibration and checkout operations, and in the required coordination with the Engineer. The total cost of the Startup Coordinator shall be included in the Base Contract Price. 18031.3.2.2 Electrical and Instrumentation Technicians. The Contractor's technicians shall be experienced in the calibration and adjustment of electrical apparatus, instrumentation, control equipment, and final drive devices. Technicians shall be experienced in working with control electrical schematic and wiring diagrams, electrical one-line diagrams, and electrical three-line diagrams in accordance with the calibration and checkout assignment. The total cost of the technicians shall be included in the base Contract Price. 18031.3.2.3 Craft. Sufficient numbers of craft personnel shall be provided by the Contractor to support completion of the work included under these specifications. The total cost of craft for the level of foreman, journeyman, and apprentice for startup and checkout activities is included in the base Contract Price. The cost of all labor, supervision, materials, equipment, vehicles, supplies, and services necessary to provide field tests and adjustments required to demonstrate that electrical systems are correctly installed, tested, and calibrated shall be included in the base lump sum price. The Contractor shall provide additional support services associated with initial operation of the unit as requested by the Engineer. This service will be by labor rates as included herein. This work would start after Mechanical Completion (as defined in the General Terms and Conditions of the Contract), has been achieved, but shall not include time spent fixing construction errors or omissions caused by the Contractor. All this work shall be as requested by the Engineer and shall be preapproved by the Engineer before being performed by the Contractor. Specific activities shall be tracked by the Contractor in a manner acceptable to the Engineer. Unit pricing based on time and materials shall be provided herein by the Contractor. The Contractor shall include in the bid, 32 manhours for startup services. The contract value will be adjusted based upon the actual hours used. 18031.3.3 Tools and Test Equipment The Contractor shall provide all required tools and test equipment to perform the work in accordance with these specifications and the project schedule. The test equipment shall be periodically certified. Any test equipment found out of tolerance during certification shall be replaced or repaired. The Contractor shall include a list of test equipment provided, including manufacturer and model with the proposal. The Contractor shall provide as many items of each category as are required to perform the work in accordance with the project schedule. The Contractor shall provide the Purchaser with a copy of all certifications for test equipment used on the project including any recertifications or replacement certifications. Source: 18031, 2014, v2.0 Electrical Startup, Testing, and Checkout Page 214 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 18031.3.4 Test Instrument Certification The Contractor shall provide and maintain an onsite facility to perform periodic certification of test instruments and equipment. Test instruments subject to drift or nonobvious miscalibration shall be certified at least weekly. The Contractor's QA program shall be capable of providing verification that the certification is being performed. Certification methods shall follow recommendations of the test instrument manufacturers. The Contractor's personnel performing certification shall be specially trained in the methods and procedures for carrying out these calibration certifications. 18031.3.5 Calibration or Testing Certification Sticker The Contractor shall furnish and affix a self-adhesive label to each device calibrated or adjusted. The label shall indicate the date and the name of the person performing the calibration or adjustment. 18031.3.6 Checkout and Test Report Forms The Contractor shall complete a Checkout and Test Report Form for all instruments, mechanical devices, and electrical devices that are tested or calibrated. The blank forms to be used by the Contractor will be furnished by the Purchaser’s Startup Manager or alternately, the Contractor’s standard forms may be used if accepted in writing by the Purchaser’s Startup Manager. No increase in contract price will be allowed for not using the Contractor’s standard forms. The completed forms shall be submitted to the Purchaser as part of the turnover package as described in Article 18031.3.7. The forms submitted shall include but not be limited to the Checkout and Test Report Forms listed at the end of this section. Forms shall be submitted within 5 calendar days after completion of the activity covered by the Checkout and Test Report Form. 18031.3.7 Startup Startup will be under the jurisdiction of the Purchaser throughout the startup period. Except as stated elsewhere, the Contractor shall render all services and do all work required to place each item of equipment installed by him, including all auxiliaries, in operating condition to the satisfaction of the Purchaser. All equipment shall be prepared for operation as recommended by the equipment manufacturer, as outlined in the Subsystem Turnover Package, and as directed by the Purchaser. It is anticipated that extended hours will be required during the startup phase of the facility. The Contractor shall include in the scheduling of the work and allocation of manpower allowances the additional requirements of startup and extended hours. These allowances shall include all regular and overtime payrolls and all other contingencies in connection with the plant startup and initial operation in the base Contract price excluding standby craft labor as outlined in Article 18031.1. Individual systems and items of equipment shall be completed in a sequence that will permit systematic checkout and trial operation of each such component before it is incorporated in the initial operation. The Owner will furnish operating personnel working under the direction of the Engineer during startup. Unless directed otherwise by the Engineer, the Owner will be the only party authorized to operate permanent plant equipment. The Contractor shall provide all other workers required to make adjustments, couple equipment, and correct deficiencies during the equipment and plant checkout and operation. The Contractor shall provide all temporary instrumentation and gauging devices required during checkout and trial operation of the equipment and systems. 18031.3.7.1 Equipment Checks and Calibration. Preoperational checks and inspections shall be performed on all equipment as specified herein, and in accordance with the equipment manufacturer's recommendations. A representative of the Contractor shall be present during the equipment checks. The sequence of preoperational checks will vary with the system being tested and shall be as directed by the Source: 18031, 2014, v2.0 Electrical Startup, Testing, and Checkout Page 215 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Engineer. Motor coupling will not normally be performed until preoperational electrical and control testing has been completed. The Contractor shall verify in writing that all work and preoperational checkouts have been completed and, when the services of equipment manufacturers' field service representatives are specified, the Contractor shall include verification by such representatives that the equipment is ready for trial operation. 18031.3.8 Electrical and Instrumentation Checkout This article defines the scope of electrical and all instrumentation devices and equipment which shall be calibrated in-place, adjusted, or checked out by the Contractor as part of the work covered by these specifications. The Contractor shall provide all temporary instrumentation and gauging devices required during checkout and trial operation of the equipment and systems. 18031.3.8.1 Equipment Checks. Preoperational checks and inspections shall be performed on all equipment as specified herein and in accordance with the equipment manufacturer's recommendations. A representative of the Contractor shall be present during the equipment checks. All field tests shall be witnessed by the Purchaser at the Purchaser's discretion. Preoperational checks shall include, but not necessarily be limited to, the following: Safety Equipment. All coupling guards, belt guards, and other personnel safety items shall be installed. All bolting shall be securely tightened to the correct torque as recommended by the equipment manufacturer. All fire protection systems and equipment shall be installed and operative. All temporary shipping braces, blocks, or tie rods shall be removed. Motor Insulation. Motor insulation shall be meggered immediately before energization. Instrumentation and Controls. Interlock jumpers shall be removed. Panel instrumentation shall be turned on. Lighting and Receptacle Checkout. The Contractor shall test, check out, and energize the lights and receptacles furnished and installed under this Contract. Lights shall be energized as soon as circuits are complete to increase the lighting level for construction and checkout. Immediately before energizing a lighting or receptacle circuit, the Contractor shall make the following checks: The transformer neutral supplying the source panelboard is solidly connected to ground. The phase and neutral conductors to be energized are free from grounds. All covers are on lighting fixtures, pull boxes, and junction boxes so exposed conductors will not be energized. The ground conductor (if required) is solidly grounded. Source: 18031, 2014, v2.0 Electrical Startup, Testing, and Checkout Page 216 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction After completing the pre-energization checks, the Contractor may energize the circuit under the direction of the Purchaser's startup equipment. Bid Issue 2Mar2015 All metering, including panel meters and transducers, shall be calibrated to within the manufacturer's accuracy. Panel instrumentation indicating lights, switches, and relays shall be adjusted and checked out as part of the checkout of the Contractor-installed electrical equipment. Electric metering for volts, watts, amperes, and other electrical quantity functions shall be checked out as described in this article and the following article. Panel indicators shall initially be calibrated by simulating the electronic signal normally received by the indicator. The final calibration shall be performed using the actual transmitter, signal converter, or system output to be connected to the indicator. The transmitter-receiver combination shall be calibrated to read out accuracy tolerance no greater than twice the average tolerance of the individual devices throughout the range from 0 percent to 100 percent of total scale. In certain instances for specific equipment, the Purchaser will specify a range of interest. In these cases, the Contractor shall calibrate the transmitterreceiver combination to read exactly correct with the calibration standard being utilized, within the range of interest. Electrical panel instrumentation shall be calibrated. Unless specified otherwise, all meters shall be tested and calibrated with equipment of no more than 50 percent of the manufacturer's stated accuracy instrument being tested. All meters shall be visually inspected for damage, and wiring connections shall be verified in accordance with the three-line diagrams. Every instrument utilizing a plastic lens or window shall be given a static effect check. The static check shall consist of wiping the lens or window vigorously with a dry cloth of a type recommended by the manufacturer which will not harm the surface. If the needle or pointer holds up-scale or below zero set for more than 15 seconds, the surface of the lens or window shall be treated with a clear antistatic compound recommended by the manufacturer. The Contractor shall verify that direct grounds do not exist on any dc or 480 volt powered systems. Should a ground be detected, the Contractor shall locate the ground source and inform the Purchaser. Measurement of resistance to ground shall be made of all motors, switchgear, isolated phase bus, cable bus, panelboard bus, nonsegregated phase bus, and motor control center bus immediately prior to placing in service. Measurement of resistance will be with a line operated tester. Voltage of testing device shall be in accordance with the following table or the equipment manufacturer's recommendation, as directed by the Purchaser: Equipment Voltage Voltage, dc Test Current, max, mA 480 volts 1000 volts 3 For each transformer rated 500 kVA or larger, measurement of resistance to ground and polarization index of each winding with all other windings grounded shall be made. Measurements shall be with a winding tester. Measurements for each transformer shall be made immediately prior to placing in service. If a transformer winding has a resistance to ground or polarization index less than recommended by the manufacturer, the transformer will not be placed in service. The voltage of the testing device shall be in accordance with the preceding table. All 5 kV and above power cable shall be hi-pot tested in accordance with IEEE and ICEA standards. Source: 18031, 2014, v2.0 Electrical Startup, Testing, and Checkout Page 217 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Complete check of all field wiring shall be made after installation and connection to verify that field wiring is as indicated on the drawings and schematic wiring diagrams. Equipment jumpers as indicated on the schematics shall be checked. Shielded cable ground check should be made after termination is complete using a volt-ohm meter to determine that each is grounded only at the points indicated on the drawings. All instrument transformers, including bushing current transformers, shall be tested. Ratio and polarity tests shall be performed on all instrument transformers. Current transformer ratio and polarity tests shall be voltage ratio tests using a digital voltmeter or current ratio tests using high current injection test equipment, as directed by the Engineer. The external circuit for each current transformer shall be completely tested before the shorting devices are removed from the current transformer secondary terminals. The tests shall include the following: Continuity check of the circuit external to the current transformer by application of current. Phase check to verify correct phase relationship at each device connected in the current transformer circuit. All protective and alarm devices associated with all power transformers with primary voltage of 4160 volts or higher shall be tested for correct operation and adjusted as required according to the manufacturer's recommendations. This work shall include, but not be limited to, the following: Transformer sudden pressure relays. Transformer pressure relief device. The Contractor shall verify in writing that all work and checkouts have been completed, and when the services of equipment manufacturer's field service representatives are specified, the Contractor shall include verification by such representatives that the equipment is ready for trial operation. 18031.3.8.2 Corrected Drawings. The Engineer will furnish three sets of the following drawing categories to the Contractor for markup purposes: Electrical schematic and wiring diagrams. Electrical one-line and three-line diagrams. Circuit and raceway lists. The Contractor shall neatly and legibly mark each set, in triplicate, including all field corrections performed during calibration and checkout. One copy of each drawing shall be submitted to the Engineer as a part of the completed forms returned with each subsystem startup or turnover package. A second set will be turned over to the Purchaser's Startup Manager for use by Startup and Operations during commissioning. Submittal of these two sets to the Engineer and Purchaser’s Startup Manager shall be concurrent with completion of the startup or turnover package. The third copy shall be retained by the Contractor until the conclusion of the project. The Contractor's copies shall be turned over to the Engineer at the conclusion of the project. Checkout and Test Forms List (refer to Article 18031.3.6) Equipment Equipment Specific Checkout/Testing Requirements Source: 18031, 2014, v2.0 Electrical Startup, Testing, and Checkout Form to be Completed by Contractor Page 218 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Equipment Equipment Specific Checkout/Testing Requirements Form to be Completed by Contractor Lighting Functional Verification QC Cert. Low Voltage Breakers Overcurrent Tripping Device Test CEGMF-802 Low Voltage Breakers Breaker Contact Resistance Testing CEGMF-802 Low Voltage Breakers Bus/Breaker Insulation Resistance (Phase to Ground and Phase to Phase) CEGMF-826 Low Voltage Breakers Ductor (Bolted Joint – Low Resistance Ohm Test) CEGMF-846 Low Voltage Breakers Functional Checks (local/remote operation, indication, protective device trips and interlocks, etc.) Yellow Line Schematic Low Voltage Breakers Initial Energization Checklist SU Checklist Low Voltage Motors 1ph/dc DC Motor Checkout CEGMF800 Low Voltage Motors 1ph/dc Functional Checks CEGMF800 Low Voltage Motors above 50 hp Insulation Resistance CEGMF-826 Low Voltage Motors above 50 hp Functional Checkout (heaters, winding temperature, etc., as applicable) QC Cert. Low Voltage Motors above 50 hp No Load Test – Current, Vibration, and Temperature CEGMF-800 / 833 Low Voltage Motors below 50 hp Insulation Resistance CEGMF-826 Low Voltage Motors below 50 hp Functional Checkout (heaters, winding temperature, etc., as applicable) QC Cert. Low Voltage Motors below 50 hp No Load Test – Current CEGMF-800 MCC’s Bus Insulation Resistance (Phase to Ground and Phase to Phase) CEGMF-810 MCC’s Ductor (Bolted Joint – Low Resistance Ohm Test) CEGMF-846 MCC’s Bucket Inspection/Functional Testing Yellow Line Schematic MCC’s Initial Energization Checklist SU Checklist Instrumentation Instrument Functional Checks QC Cert. Instrumentation Loop Checks Yellow Line Schematics or I/O List Other Valves Other Operated Valve Function Checks (hydraulic, etc.) CEGMF-839 Non-steam Cycle Valves Non-steam Cycle Safety Valve (setting certificates) Supplier Cert. Source: 18031, 2014, v2.0 Electrical Startup, Testing, and Checkout Page 219 of 280 Calaveras Coal Yard 186144.77.1000 Source: 18031, 2014, v2.0 Compressed Air Equipment Construction Electrical Startup, Testing, and Checkout Bid Issue 2Mar2015 Page 220 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 19000 - Quality System Requirements If the Supplier believes that an inconsistency exists between this section and other portions of the contract documents, the Supplier shall immediately notify Purchaser for resolution. 19000.1 General Quality System Requirements 19000.1.1 Quality System The Supplier's quality system shall comply with the following criteria: ISO 9001 Quality Management Systems. American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code(s) as follows: ASME I. ASME VIII, Division 1. ASME VIII, Division 2. ASME X. ASME B31.1. National Board of Boiler and Pressure Vessel Inspectors Code. The Supplier's quality management system shall ensure that all equipment, assemblies, services, and commodities supplied are in conformance with the contract drawings and specifications. The Supplier’s quality management system shall provide assurance that design, procurement, materials, manufacturing processes, inspection and testing, packaging, shipping, storage, and related services comply with the requirements of the contract documents. The Supplier’s quality management system shall have a defined process for reporting, segregation, evaluation, disposition, and closure of nonconforming product. This quality management system shall be available to the Purchaser for review and/or audit at all of Supplier’s locations where work is being performed subject to these contract documents. 19000.1.2 Quality System Manual The quality management system shall be documented in the Supplier's quality system manual. One quality system manual shall be submitted to the Purchaser as defined in the Schedule of Submittals if a current version is not already on file with the Purchaser. If the Supplier's program has been certified by a registered certification agency as satisfying the requirements of ISO 9001, a copy of the Certification Letter or Certification of Authorization shall be submitted along with the quality system manual. 19000.1.2.1 Revisions. Revisions to the Supplier’s quality system manual shall be submitted to the Purchaser throughout the life of these contract documents. If the Supplier has previously submitted a quality system manual to the Purchaser, the Supplier shall submit (in writing) the following information: Title and number designation of the document, e.g., QP 500 Quality Assurance Manual. Applicable Supplier location(s) covered by the document. Revision level and date of the manual that is currently being used. Source: 19000, 2014, v1.1 Quality System Requirements Page 221 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 19000.1.3 Subtier Suppliers The Supplier shall obtain the Purchaser's approval in writing prior to using subtier suppliers for manufacturing or engineering activities. Material/commodity subtier suppliers are exempted from these requirements. All applicable requirements of the contract documents (i.e., technical, quality, and administrative) shall be passed on to the applicable organizations within the Supplier and subtier supplier's companies. The Supplier shall ensure that subtier suppliers have the capabilities to fulfill contract document requirements. Suppliers shall monitor subtier suppliers’ quality of work and shall indicate their strategy on their inspection and test plan. Suppliers shall submit required procedures, drawings, quality manuals, and/or other submittals when required for approval and/or information of subtier supplier's capabilities, processes, or in-process work involving the engineering, fabricating, and manufacturing of equipment and commodities for the Purchaser. Subtier supplier qualification and monitoring are the responsibility of the Supplier. Purchaser has the authority to perform quality audits and inspections, and monitor and/or review subtier supplier processes and facilities, at all locations where work is being performed subject to these contract documents. 19000.1.4 Inspection and Test Plan In accordance with the Schedule of Submittals, a detailed inspection and test plan (i.e., a Quality Assurance/Quality Control Plan) for the work/equipment shall be submitted to the Purchaser as specified in the contract documents prior to starting fabrication. Minimum surveillance activities to be included in the Supplier’s inspection and test plan are specified in Section 20000 – Purchaser’s Shop Quality Surveillance Requirements. The Purchaser will designate any additional test witness points or other inspection points required during review of the Supplier’s submitted detailed inspection and test plan. The inspection and test plan shall identify the inspection and testing points including the acceptance criteria for major components of the work, the facility location for each inspection or test, and inspection target dates for each inspection or test. The inspection and test plan shall be complete when first submitted, and shall be maintained current throughout the life of the contract documents. A monthly update shall be provided to the Purchaser. The plan shall also include the Supplier's strategy for inspecting subtier supplier's work, including inspection by the Supplier at his subtier supplier's facilities. The Supplier shall inspect the work of subtier suppliers to the extent necessary to ensure that proper materials and equipment are furnished and that fabrication, assembly and erection are accomplished in accordance with the contract documents. Commercial off-the-shelf items are exempted from these requirements. The Supplier shall keep the Purchaser informed of the progress of the work. When inspection and test points have been designated by the Purchaser as witness and/or hold points, the Supplier shall notify the Purchaser at least 14 calendar days in advance of the appropriate times for inspections and testing. The work shall not progress past the Purchaser's designated hold point until the Purchaser has verified the work or witnessed the designated test. A witness point is a step in manufacturing where the Supplier is obligated to notify the Purchaser in advance of the performed operation so that it may be witnessed. If the Purchaser is not present at the time and date specified by the Supplier, the Supplier may proceed. A hold point is a designated stopping place during or following a specific activity at which the Purchaser's inspection or witness is required before further work can be performed. The Supplier may not proceed beyond the hold point without inspection or witness by the Purchaser unless prior written authorization is obtained from the Purchaser. The Purchaser may waive the witness of tests; waivers for hold points shall be in writing. Waivers in no way absolve or relieve the Supplier of complying with contractual requirements. Source: 19000, 2014, v1.1 Quality System Requirements Page 222 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 If the Supplier has notified the Purchaser defining the specific test date and time and the Supplier is not ready to conduct the test at the stated date and time, the Supplier shall be accountable for all additional expenses incurred by the Purchaser. 19000.1.5 Inspections by Purchaser The Purchaser may elect to perform assessments, quality audits, or witness testing at any time during the manufacturing process. The Purchaser may designate an authorized agent for assessments, witness testing, or quality audits. Authorized agent may be an employee of the Purchaser or an outside agency. When an outside agency is designated as an authorized agent for the Purchaser, such designation will be in writing with a copy provided to the Supplier. When the term "Purchaser's representative" is used, it may mean the Purchaser or the authorized agent. The following requirements shall apply for Purchaser's inspection at the Supplier's mill, factory, yard, warehouse, or subtier supplier's facilities. 19000.1.5.1 Access. The Purchaser’s representative shall have the right to access the Supplier's and subtier supplier's work and related documents during the manufacturing process without delaying the schedule. The Supplier shall provide, without cost, reasonable facilities including tools, personnel, and instruments for demonstrating acceptability of the work. 19000.1.5.2 Surveillance Activities. In accordance with the contract documents, designated hold points for witnessing, mill and/or factory tests shall be performed in the presence of the Purchaser's representative unless waived in writing by the Purchaser's representative. The Supplier shall bear all costs for such tests, except the compensation and expense of the Purchaser's representative. 19000.1.5.3 Control of Special Processes. It is Supplier's responsibility to ensure that qualified personnel are employed to perform special processes such as welding, nondestructive examination (NDE), coating, painting, etc. If special processes are conducted by unqualified employees, the Purchaser has the right to validate and test the product at Supplier's expense and/or reject the product. The Supplier shall be able to demonstrate the qualifications of personnel in writing. 19000.1.5.4 Corrective Action. Upon identification of a noncompliance with the requirements of the contract documents, the Supplier shall document the noncompliance issue. For noncompliance issues where the nonconforming characteristic can be restored to a condition such that the capability of an item to function reliably and safely is unimpaired, even though that item still does not conform to the original requirement, the Supplier shall submit the noncompliance to the Purchaser for approval. During witness and hold point activities, if the Purchaser's representative identifies a noncompliance issue, the Supplier shall document the noncompliance issue and provide a copy of the documentation to the Purchaser's representative. If the Supplier disagrees and does not document the noncompliance, the Purchaser's representative shall issue a corrective action report to the Supplier for disposition and action. The Supplier shall correct, in a timely manner, all deficiencies identified in the corrective action report. 19000.1.5.5 Rejection. If any items or articles are identified that do not meet the requirements of the contract documents, the lot, or any faulty portion thereof, may be rejected. Before offering specified materials or equipment for shipment, the Supplier shall inspect the material and equipment and eliminate any items that are defective or do not meet the requirements of the contract documents. The fact that equipment or materials have been previously inspected, tested, and accepted does not relieve the Supplier of responsibility in the case of later discovery of flaws or defects. 19000.1.5.6 Receipt Inspection Materials or equipment purchased under these contract documents may be inspected at the specified receiving points and will either be accepted or rejected. Receipt inspection will include testing to determine compliance with the contract documents. Initial receipt inspection acceptance tests will be performed by the Purchaser at the Purchaser's expense. Items found to be defective may be returned to the Supplier for correction at the Supplier's expense, including shipping cost, or the cost to correct and inspect the item will be charged to the Supplier. Source: 19000, 2014, v1.1 Quality System Requirements Page 223 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 21000 - Technical Supplemental Specifications This section contains technical supplemental specifications that provide the requirements of the applicable work. The supplemental specifications appear on the following pages. Source: 21000, 2011 Technical Supplemental Specifications Page 224 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Section 60.0050 – Contractor-Furnished Submittals 1.01 Summary This Section includes definitions, descriptions, transmittal and review of submittals. 1.02 General Requirements for Submittals A. General. This section, in conjunction with the Schedule of Submittals, stipulates the requirements for engineering data that Supplier shall submit for design information and review. Document submittal procedures shall be in accordance with the requirements of this Purchase Order. B. Quality Requirements. Submittals such as drawings and product data shall be of suitable quality for legibility and reproduction purposes. Every line, character and letter shall be clearly legible. Drawings issued by electronic media shall be useable for further reproduction to yield legible hard copy. Documents submitted to Purchaser that do not conform to specified requirements shall be subject to rejection by Purchaser, Supplier shall resubmit conforming documents. If conforming submittals cannot be obtained, such documents shall be retraced, redrawn, or photographically restored as may be necessary to meet such requirements. Supplier’s or its Contractor’s failure to initially satisfy the legibility quality requirements will not relieve Supplier or its Contractors from meeting the required schedule for submittals. Nonconforming submittals are subject to rejection by the Purchaser. C. Language and Dimensions. All words and dimensional units shall be in the English language. All words in foreign languages shall have English translations. English language shall prevail. Metric dimensional unit equivalents may be stated in addition to the English units. However, English units of measurement shall prevail. D. Submittal Completeness. Submittals shall be complete with respect to dimensions, design criteria, materials of construction and other information specified to enable Purchaser to review the information effectively. Where standard drawings are furnished which cover a number of variations of the general class of Equipment, each drawing shall be annotated to indicate exactly which parts of the drawing apply to the Equipment being furnished. Use hatch marks to indicate variations that do not apply to the submittal. The use of “highlighting markers” will not be an acceptable means of annotating submittals. Annotation shall also include proper identification of the submittal permanently attached to the drawing. Reproductions or copies of Contract drawings or portions thereof will not be accepted as complete fabrication or erection drawings. E. Form of Submittals. Electronic technical data submittals shall be made via email using Black & Veatch Project Central, a Web-based file transfer service. (The Uniform Resource Locator [URL] to be used for electronic file submittals will be made available upon Purchase Order award.) Technical data shall be submitted in electronic format to the following email address: 184710CPSCalaverasCoalYard@bv.com Hard copy prints of final, Purchaser-approved electronic files shall also be submitted, as specified below. The hard copy prints shall be submitted to the address indicated in the Supplementary Terms and Conditions of this Purchase Order. The following number of prints shall be submitted unless otherwise indicated in the Schedule of submittals: Submittal Description Source: 21000, 2011 Hard Copies Required Electronic via Email Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 225 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Submittal Description Hard Copies Required Electronic via Email Performance Curves 3 1 Design Data 3 1 Test Reports and Inspection Data 6 1 Samples, Color Charts, etc. 6 NA As Built Documentation 6 paper plus 4 CDs (Microstation format on CD-ROM) 2 in e-native format Written Certificates and Guarantees 6 1 Drawings 3 1 Instructions Manuals See 1.04 Below See 1.04 Below Requirements for electronic submittals: a. Each submittal shall consist of a letter of transmittal (transmittal) and the associated submittal documents. b. Submit a letter of transmittal file with each and every submittal, to include the following items at a minimum: Vendor’s name and address. Sender’s name and e-mail address. Reason for sending the documents. Project name and Purchaser’s project number (XXXXXX). Contract title and number. Unit name and number. Applicable Specification Section and Article number. Supplier’s job code and sub-job code number. Drawing number, title, sheet number (if applicable), revision number (use Rev 0 for initial submittal if document has no revision number established) and electronic filename of each submittal document included in transmittal. Supplier’s transmittal number. c. Drawings shall be submitted electronically in Tagged Image File Format (TIFF) Group 4. Except for final ‘as built’ files, AutoCAD or MicroStation format files are not acceptable. If Supplier does not have the capability to provide TIFF - Group 4 drawings, Supplier shall submit in Adobe *.PDF files (in Adobe’s Latest Version) created directly from native electronic format. d. Submittal documents cannot be resubmitted during Purchaser’s review. For example, if revision 1 of a document has been submitted and is being reviewed by Purchaser, Supplier shall not resubmit Revision 2 until Revision 1 has been returned to Supplier by Purchaser. e. Submittal document filenames shall be identical to a drawing number or item identifier located on the document it refers to. Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 226 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction f. Filenames for each submittal document must be unique. g. For any given submittal, the filename and the format shall be consistent for the initial submission and the subsequent revisions of the same using consistent naming convention throughout. h. If a drawings are submitted using Adobe *.PDF, then each file shall only contain one drawing sheet each. Provide no multiple sheet Adobe *.PDF drawing files. For example, if drawing 3T-670-D1 has three (3) sheets associated with it, submit files named 3T-670D1_01,pdf, 3T-670-D1_02,pdf and 3T-670-D1_03,pdf. i. Product data sheets that contain more than one (1) page can be submitted as one file. j. Submittal files returned to the Supplier by Purchaser will have the same filename as that submitted by Supplier. Returned files will be in *.PDF format. k. Provide “as-constructed” submittals, record documents, Equipment instruction books and operating manuals and other documents on CD-ROM in native format with bookmarks in the file, as appropriate. l. Each submittal document shall have a submittal Information block on it. Electronic files of submittal information blocks will be provided to Supplier for use on electronic submittals. An example of the submittal information block is included at the end of this Section. m. Supplier’s approval shall constitute a representation to Purchaser that Supplier has either determined and verified all design criteria, quantities, dimensions, field construction and installation criteria, materials, catalog numbers, compliance with laws and regulations and similar data, or Supplier assumes full responsibility for doing so and that Supplier has coordinated each submittal with the requirements of the Work and the Contract Documents. n. Make all modifications noted or indicated by Purchaser and return revised submittals until approved. Direct specific attention in writing, on revised submittals, to identify all changes made to the submittals since last submitted. Identification shall include one of the following methods: ballooning all changes, summarizing the changes in the revision block, or summarizing the changes in the transmittal letter. If errors are discovered during manufacture or fabrication, correct the submittal and resubmit for review. o. Following completion of the Work and prior to final payment, furnish record documents and approved samples and drawings necessary to indicate “ As Built” conditions, including field modifications. Submit revisions to Equipment instruction books and operating manuals as required. Submit a final submittal list which shall indicate the final revision status of each drawing on the list. p. Information to Manufacturer’s District Office: Supplier shall arrange for manufacturers and suppliers of Equipment and Materials to furnish copies of all agreements, drawings, specifications, operating instructions, correspondence and other matters associated with this Contract to the manufacturer’s district office servicing the Owner. q. Instruction books, operating manuals and as-constructed drawings shall be sent to Purchaser as indicated in the Schedule of Submittals. Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 227 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 r. Purchaser may copy and use for training, operations and maintenance of the Work any and all document submittals required by this Contract whether or not such documents are copyrighted, at no additional cost to Purchaser. 1.03 Purchaser Review Supplier’s engineering schedule shall allow a minimum of three (3) weeks for mailing, processing and review of drawings and data by Purchaser. Purchaser's review of drawings and other submittals will cover only general conformity of the data to the Specifications and Drawings, external connections, interfaces with equipment and materials furnished under separate specifications and dimensions that affect plant arrangements. Purchaser's review does not include a thorough review of all dimensions, quantities and details of the equipment, material, device, or item indicated or the accuracy of the information submitted. Review and comment by Purchaser of Supplier's Drawings or other submittals shall not relieve Supplier of its sole responsibility to meet the Completion Dates requirement of this Purchase Order and to supply Goods that conform to the requirements of this Purchase Order. Unless this Purchase Order indicates that a drawing or engineering data submittal by Supplier is to be for Purchaser's information only, Purchaser, upon receipt of submittals, shall review and return same to Supplier, marked "No Exceptions Noted," "Exceptions Noted," “Received for Distribution," "Returned for Corrections," “Release for Record,” “Void,” or “Superseded.” The timing of Supplier’s submittals and Purchaser's review shall be in accordance with the Completion Dates for same as set forth in the Purchase Order. The submittal of any drawing or other submittal document by Supplier to Purchaser under this Purchase Order will be certification by Supplier that the information set forth therein is accurate in all material respects. A. No Exceptions Noted (NE) or Received for Distribution (RD). Upon receipt of a submittal marked "No Exceptions Noted" or "Received for Distribution," Supplier may proceed with its Work to the extent of and in accordance with the submittal. No further submittal is required unless the drawing or document is revised. B. Exceptions Noted (EN). Upon receipt of a submittal marked "Exceptions Noted" and if Supplier concurs with Purchaser's comments, Supplier shall incorporate same and may proceed with its Work to the extent of and in accordance with the annotated submittal. Supplier shall submit to Purchaser within fourteen calendar days a revision to the original submittal in which Purchaser’s comments has been incorporated. If Supplier determines that it cannot incorporate Purchaser's comments without prejudice to Supplier’s warranty or other obligations under this Purchase Order, Supplier shall so advise Purchaser in writing within seven calendar days of its receipt of Purchaser's comments, stating the reasons therefore. Supplier may proceed with its Work to the extent of and in accordance with the annotated submittal only upon Purchaser and Supplier resolving Purchaser's comments. C. Returned for Corrections (RC). Upon receipt of a submittal marked "Returned for Corrections," Supplier shall immediately take all necessary action to revise its submittal in accordance with Purchaser's comments, the Specification and the Drawings and shall resubmit to Purchaser for review the corrected original submittal, voiding previous information and adding new documents if required. In no event shall Supplier proceed with the affected Work until its revised submittals have been returned to Supplier marked "No Exceptions Noted" or "Exceptions Noted" by Purchaser. D. Release for Record (RR). Receipt of a submittal marked “Release for Record” indicates that there are no specific objections to the document. Work may proceed. Certain required project information has been added electronically to the drawing and provided to Supplier for the record. Resubmittal by Supplier is not required. Only future revisions of the document shall be submitted. Purchaser's project-specific information shall be added if future revisions and submittals are made. E. Void (VO) or Superseded (SS). Receipt of a submittal marked “Void” or “Superseded” does not require any action by Supplier. “Void” indicates that the submittal is no longer applicable to the project and is not being replaced by other drawings or data. “Superseded” indicates that different drawings or Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 228 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 data have replaced the previously submitted drawings and data; this status does not pertain to revisions of the same drawings and data. F. Hold (HO). A submittal may be given a status of "Hold" by the Purchaser, or the Supplier may have "Holds" on the submitted drawing. For a Hold status designated by the Purchaser, the Supplier shall not proceed with the work that is designated on "Hold" except as specifically directed by the Purchaser. Additional information required for the Supplier to release the "Hold" will be transmitted from the Purchaser later. The Supplier shall provide information to the Purchaser about the cause for any "Holds" designated on the drawing and immediately take all action necessary to resolve the "Holds". The Supplier shall resubmit the drawing for review once the "Holds" are removed from the drawing and should make all efforts to not submit drawings to the Purchaser until drawing review comments have been received back from the Purchaser. G. Re-submittals. If during or subsequent to the completion of the submittal process, Supplier makes further changes to the equipment and materials shown on submittals that have been reviewed by Purchaser, the changes shall be clearly marked on the submittal by Supplier and the submittal process shall be repeated. If changes are made by Supplier after delivery to the Jobsite, as-built drawings indicating the changes shall be prepared by Supplier and submitted to Purchaser for review. Any resubmittal of information shall clearly identify the revisions by footnote or by a form of back-circle, with revision block update, as appropriate. Work related to a submittal requiring an “NE”, “EN” or “RR” designation shall not be commenced or shipped until the submittal has been marked “NE”, “EN” or “RR” by Purchaser. 1.04 Instructions Books and Operating Manuals A. General. Equipment instruction books and operating manuals shall be prepared by the Supplier. Typical or generic leaflets or instructions will not be accepted. Instruction Books and Operating Manuals shall include the following: 1. Table of contents and index tabs. (If multiple volumes are required, a table of contents listing materials included in each volume shall be supplied for each volume.) 2. Specifications, test data and all performance curves specified in the technical specifications. 3. Description of the equipment, including illustrations showing elevations, cross section and all details of the equipment with all parts named, numbered and identified with Purchaser's tag numbers. When multiple model numbers are shown on the drawings, the equipment supplied for the project shall be clearly identified. 4. Concise Data Itemizing: 1 Name of item. 2 Serial number. 3 Design parameters (flow, pressure, temperature, power ratings, etc.). 4 External requirements (cooling water, power supply, etc.). 5 Weight of individual components. 6 Details of bearing, seals and other consumables. 7 Unique ID number assigned to the particular piece of equipment. The ID number Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 229 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction shall be the same as identified in the P&IDs or flow diagrams. Bid Issue 2Mar2015 5. Relevant operating procedures, for the context in which the Equipment and Material is deployed including: 1 Operational parameters, limits, etc. 2 Safety warnings. 3 Operational checks. 4 Protection devices (temp/pressure/flow transmitters, etc.). 5 Performance curves. 6. Detailed maintenance instructions, including: 1 Recommended routine maintenance activities and the frequency at which they should be performed. 2 Recommended lubricants. 3 Overhaul procedures, specific to the furnished Equipment and Material, providing: a All safety warnings. b Step by step dismantling procedures. c List and details of items to be inspected including recommended limits on wear. d List of consumables. e Step by step re-assembly procedure. f A minimum of certified engineering drawings identifying all components referenced above. Ideally, an exploded view of these components. g Recalibration or test requirements following reassembly before placing Equipment or Material back into service. h Name and address of nearest manufacturer-authorized service facility. 7. Parts listing with part numbers, recommended spare parts and reordering details. 8. Bill of material list that lists every component necessary to build the piece of Equipment. 9. Control data to include input/output list, alarm/trip list including any diagnostics and logic diagrams. 10. Items included in the manuals that do not apply to the equipment furnished shall be “marked out” as not applicable. 11. Additional data shown below as applicable to the Work specified:      Instructions for receiving, inspection, storage and handling of equipment prior to installation. Installation instructions. Inspection procedures. All fluid systems schematics and piping diagrams. Electrical wiring diagrams, as applicable. Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 230 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015  Calibration Data Sheet for each adjustable instrument included in the scope of supply.  Motor Information Sheets, as applicable.  Electric Actuator Information Sheets, as applicable.  Control Panel Arrangements, as applicable.  Supplier and Sub-supplier operating and maintenance manuals.  Illustrated parts breakdown.  Assembly drawings.  List of acceptable lubricants.  Nameplate information and shop order numbers for each item of equipment and associated component parts thereof.  List of recommended spare parts.  List of maintenance tools furnished with the equipment. 2. Quantities - Hard copies of the Instructions Books and Operating Manuals shall be submitted to the address indicated in the Supplementary Terms and Conditions of this Purchase Order. The following number of copies shall be submitted unless otherwise indicated in the Schedule of Submittals: Submittal Description Copies Required Proof Copies 3 Final Copies 6 3. Binding - Information listed above shall be bound into hard-back binders of three-post type. Sheet size shall be 8 ½ x 11. Binder color shall be black. Capacity shall be a minimum of 1-1/2-inches, but sufficient to contain and use sheets with ease. a. The following information shall be imprinted, inserted, or affixed by label on the binder front cover: 1 CPS Energy 2 Calaveras Coal Yard 3 Equipment item name 4 Volume number (if applicable) 5 Contract number 6 Manufacturer’s name and address b. The following information shall be imprinted, inserted, or affixed by label on the binder spine: 1 Equipment item name 2 CPS Energy 3 Calaveras Coal Yard 4 Manufacturer’s name 5 Contract number 6 Volume number (if applicable) c. Submit mockup of cover and spine for Purchaser’s review. Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 231 of 280 Calaveras Coal Yard 186144.77.1000 1.05 Submittal of Samples Compressed Air Equipment Construction Bid Issue 2Mar2015 A. Samples shall be of sufficient size and quantity to clearly illustrate the following: 1. Functional characteristics of the product, with integrally related parts and attachment devices. 2. Full range of color, texture and pattern. 3. Material, manufacturer, pertinent catalog number and intended use. 1.06 Submittal Detail Submittals required under this Contract are listed in the Schedule of Submittals. As applicable, the Supplier shall provide submittals with sufficient details which meet the following. A. General Arrangement and Outline Information 1. Location of equipment and material components 2. Outline of assembled equipment and material components drawn to scale, including separate outlines of components as necessary 3. Order and arrangement of assembled sections 4. Dimensions of equipment and materials and weights of assemblies and components to be handled separately 5. Clearance required for operation and maintenance B. Structural Support Design Information 1. Static and dynamic loading requirements for all conditions of testing and operation. These loading conditions shall include, but shall not be limited to, wind, seismic, empty, flooded, full, operating, impact, testing and thermal and all other loading conditions included with Supplier’s design not specifically called for to be submitted. These loads shall be acting at the interface between the Supplier’s equipment and the Purchaser’s concrete or steel support. Loads acting on anchor bolts shall be submitted. 2. Stress and moment data. 3. Structural support design data. 4. Baseplate details including baseplate size & thickness, anchor bolt size & location and anchor bolt material requirements. C. Piping Fabrication Information 1. Dimensions required for fabrication and assembly of piping components including cold spring cut shorts. 2. Location of all field joints. 3. Identification of components to be handled separately with piece mark numbers. 4. Location of hangers and supports including hanger attachments on the piping. 5. Location and details of instrument, vent and drain connections. Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 232 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 6. Welding procedures. 7. Welding qualification test records. 8. Heat treatment records. 9. ASME manufacturer’s data reports when applicable. D. Erection Information 1. Arrangement of components to be erected and installed identified by piece mark numbers, corresponding to fabrication information and bill of material. 2. Tolerances to be maintained in erection, assembly and installation. 3. Location and details of field welds and other field connections and attachments. 4. Storage and maintenance requirements prior to and after erection. E. Internal Arrangement Information 1. Arrangement of internal apparatus and components, when available. 2. Internal piping, tubing, valves, wireways, buses and terminal blocks. 3. Flow diagrams (when applicable), showing fluids handled, flow rates, pressure, temperatures, equipment, devices, valving and instrumentation F. Maintenance Access Information 1. Physical arrangement of all monorail beams and trolleys provided. 2. Rigging diagrams to indicate loads and recommended removal procedures. G. Piping Connection Information 1. Tabulation of all piping connections with each assigned a unique designation, including size and type of each connection. 2. Each connection shall be identified by its unique designation of all views. H. Valve Information 1. Tabulation of all valves furnished, with each assigned a unique designation, including the manufacturer, pressure and temperature rating, body material, trim material and manufacturer’s model or figure number. 2. Cross sections of each different model or figure number valve in details and features of construction, materials of construction and end preparation. I. Pipe Hanger Information 1. Details of engineered hanger assemblies showing plan location, elevations of piping and support steel in the design, cold and hot positions, design loads and a complete bill of material. Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 233 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 2. Hanger load calculations when specifically indicated in the technical specification divisions. J. Insulation Information 1. Tabulation of all insulation materials including manufacturer, manufacturer’s designation and complete specifications including density, thermal conductivity, flexural strength, compressive strength and dimensional stability. 2. Areas of application for each type and thickness of insulation 3. Application details, including jacketing, sealing, weatherproofing, expansion joints and removable sections required for maintenance K. Instrumentation and Control Drive Information 1. Tabulation of all instrument connections furnished in pressure parts, furnace, ductwork and auxiliary equipment. Assign a unique alphanumeric designation to each connection (multiple connections for one function may share a common designation). Indicate type and quantity for each connection. Indicate all locations on the general arrangement drawings, equipment drawings, or special instrumentation drawings. 2. Tabulation of all instruments furnished, with each assigned a unique designation, including type of instrument, manufacturer and manufacturer’s model number. 3. Complete manufacturer’s specifications for each type and model number of instrument. 4. Each instrument shall be identified by its unique designation whenever it appears. 5. Maximum operating torque requirements for all dampers and vanes that require control drives. Provide maximum torque requirements for each such damper at full open, full closed and at least one intermediate position. At least one of these points shall represent the maximum torque requirement of the damper. Also, provide the maximum allowable torque and forces to prevent damage to the damper components. 6. For variable speed drives, provide functional description of drive operation plus all design details required; to define the inputs from control systems such as thrust or torque for control drives, linkage data, type of input control signal, etc. L. Schematic Control Diagrams 1. Complete elementary diagram of all control and alarm functions, both internal and external to the equipment. 2. Identification of all external connection terminals and terminal blocks. 3. Symbols conforming to ANSI standards. 4. External connection wire colors and circuit designations. M. Wiring Diagrams 1. Complete physically oriented diagram of all wiring internal to the equipment. 2. Conventional type wiring diagram with each wire or wire bundle shown by a line, or a point-topoint type wiring diagram with individual wire destinations listed at the location of each termination. Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 234 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 3. Identification of all device and equipment terminals and all internal and external connection terminal blocks. 4. All external wiring connections with wire colors and circuit designations. N. Printed Circuit Board Information 1. Schematic diagram and physical wiring diagram of board or photographs with parts labeled in lieu of physical wiring diagram for each type of board when reasonably available. 2. Parts list containing complete description of all discrete components and integrated circuits when reasonably available. 3. May be included in instruction book in lieu of separate submittal. O. Device List or Bill of Material of All Instrument and Control Devices 1. Tag numbers. 2. Manufacturer. 3. Data or specification sheet numbers. 4. Scheduling information, showing dates for ordering, fabrication, shipment, etc. P. Preliminary Process Analog Control Narratives 1. All major items and their correct functional relationships. 2. Tag numbers. Q. Process Analog Control Narratives 1. All items furnished by this Contract which are part of the control loops. 2. Tag numbers. 3. Correct and complete tubing and wiring required to connect all items in listing above. S. Designations for all tubing and wiring connections and terminals on individual devices, cabinets and control boards. Indicate terminal designations, circuit numbers, wire colors and other designations which will be marked on drawings. T. Data/Specification Sheets. Data or specification sheets for each significant device furnished under this Contract. These shall be the actual sheets, equipment specifications used for ordering and fabrication and shall include the primary manufacturer’s own sheets where applicable in addition to the Contractor’s purchase order forms, including the following. 1. Tag numbers. 2. Manufacturer. 3. Complete catalog or model number. 4. Scale range. Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 235 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 5. Complete electrical information, including current and voltage ratings, contact action (spst, dpdt, etc.). 6. Other pertinent technical data. 7. All accessories required such as capillary tubes, diaphragm seals, etc. U. Outline Drawings - Outline drawings for each type of device furnished. One typical drawing may be used for all devices of the same type, but the drawing shall be marked to list the tag numbers of all devices to which it applies. V. Electric Motor Data. Nameplate data for motors rated 460 volts and above, including the following: 1. Manufacturer’s name and serial number. 2. Horsepower rating. 3. Time rating. 4. Temperature rise and method indicated. 5. Maximum ambient temperature. 6. Insulation class. 7. RPM and rated load. 8. Frequency. 9. Number of phases. 10. Voltage. 11. Rated load amperes. 12. Locked-rotor amperes or code letter. 13. Service factor. 14. Additional data on motors rated 200 horsepower and above. 15. Acceleration time with connected load. 16. Allowable locked-rotor time. 17. Allowable number of starts per hour under connected load conditions. 18. Standard CT excitation curves and ratio correction curves for motors 2,500 horsepower and larger. Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 236 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction SUBMITTAL INFORMATION BLOCK Contractor fill in all blanks without preprinted information For the use of Engineer Art. No. Contractor’s Approval (See Contract Documents) Engineer Record Stamp Project Name Project Number Contract Title Contract No. Spec. Sect. No. Bid Issue 2Mar2015 Engineer’s Action Documents) Contractor Approved By Date (Do not send drawing to Engineer without Contractor’s prior Approval.) Date Received Initials & Date A B C D (See Contract Initials & Date E F G Contractor fill in this block on all submittals 1. Use this decal on all shop drawings, whether prepared by Contractor or Supplier. Place as near as possible to the drawing title in the lower right corner. 2. Affix the gummed edge paper information blocks to all “product data” type submittals immediately inside the front cover. Source: 21000, 2011 Technical Supplemental Specifications 60.0050 – Contractor-Furnished Submittals Page 237 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Section 60.0100 - Supplier Furnished Equipment and Material Requirements 1.0 General These Equipment and Material Requirements apply in general to all equipment and materials and are supplementary to the detailed equipment and material requirements included in the technical sections of the Specification. If requirements stated herein are in conflict with the detailed equipment and material requirements, the detailed requirements shall govern to the extent of such conflict. Equipment and materials furnished by the Supplier shall fully comply with the requirements included herein. It is recognized that the equipment and material manufacturers and suppliers utilized by the Supplier may have standardized on the use of certain components, materials, processes, or procedures different than those included herein. Substitution on the basis of supplying the manufacturer’s or supplier’s standard components, materials, processes or procedures will be considered by the Purchaser. Substitution shall be in accordance with the procedures included herein. 2.0 Referenced Standards Reference to the standards of any technical society, organization, or association, or to the laws, ordinances, or codes of governmental authorities shall mean the latest standard, code, or specification adopted, published and effective at the date of the contract agreement unless specifically stated otherwise herein. The specifications, codes and standards referenced in these Contract Documents (including addenda, amendments and errata) shall govern in all cases where references thereto are made. In case of conflict between the referenced specifications, codes, or standards and these Contract Documents, the latter shall govern to the extent of such difference. 3.0 Materials and Equipment Unless specifically provided otherwise in each case, all materials and equipment furnished for permanent installation in the work shall conform to applicable standard specifications and shall be new, unused and undamaged. Individual parts shall be manufactured to standard sizes and gauges so that repair parts, furnished at any time, can be installed in the field. Like parts of duplicate units shall be interchangeable. All materials and equipment shall be the latest or proven design and the first quality standard product of manufacturers or fabricators regularly engaged in the production of such materials and equipment. When two or more units of the same class of equipment are required, they shall be the products of a single manufacturer. 4.0 Arrangement Orientation of equipment shall be as required to minimize objectionable noise and to provide the most suitable access for maintenance and operations. Arrangement of equipment accessories and appurtenances shall be coordinated with facilities as required to provide an optimum layout and economical space use and shall be subject to approval by the Purchaser. 5.0 Experience of Equipment Suppliers All equipment and materials furnished by the Supplier shall have an acceptable history of satisfactory reliable service in central power station use for a period of at least three (3) years at comparable design conditions. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 238 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 Latest or newly developed equipment with less than three (3) years actual service may be considered from established manufacturers, only if it has been adequately tested, meets the requirements of this contract and is approved by the Purchaser. 6.0 Product Substitution Throughout the Contract Documents equipment and material requirements are defined by the Calaveras coal yard, reference standards, manufacturers, trade names, catalog numbers and other like definitions. Substitution for these products may be made in accordance with the following articles. 6.1 Supplier's Substitution Options The Supplier has the following options regarding substitutions of products for the Calaveras coal yard Work. Substitution may be made following written request to the Purchaser and written approval of the substitution by the Purchaser.    For products which are not identical to those installed in the Calaveras coal yard, or for identical Calaveras coal yard products not used in the same application, substitution shall be made with Purchaser approval. For products defined only by reference standard, any product meeting the reference standard and all other requirements of the Specification, may be substituted with Purchaser approval. Where one or more specific products are named in the Specification and the option of selecting an equivalent product is indicated by stating “or equal,” “or approved equal,” or “acceptable equal,” or “unless otherwise approved”, substitution may be made with Purchaser’s approval. 6.2 Requests for Substitution The contents of Purchaser’s requests for substitution of products and/or materials shall contain the following information.            Complete data substantiating compliance of proposed substitution with Contract Documents. Product identification, including manufacturer’s name and address. Manufacturer’s literature giving: o Detailed description including drawings and pictures. o The specific model, size, catalog number, or type clearly identified. o Reference standards o Performance and test data o Dimensions, weight, finish, material, etc. A description of installation requirements impacting construction procedures or schedules. Samples as required. Delivery schedule Name and address of similar projects on which product was used and date of installation. Performance guarantees and warranty provisions on the product Required changes to Design Drawings caused by the proposed substitution Itemized comparison of proposed substitution to the named product Accurate cost data on proposed substitution compared with the named product, whether or not change in Contract Price is to be a consideration, including cost of operation and maintenance. Substitutions will be rejected if (1) they are indicated or implied on Compliance Submittals without formal request submitted in accordance with Article 6.1 herein, (2) acceptance is not in the best interest of the Purchaser, or (3) they adversely affect unit availability, or other unit or equipment performance guarantees. 7.0 Factory Tests and Reports All manufacturer's standard factory tests plus those tests required by the applicable codes, standards and as required by these Contract Documents shall be performed. The Supplier shall submit reports to the Purchaser certifying the results of all factory tests. The Supplier shall notify the Purchaser 15 working Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 239 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 days prior to factory tests so that the Owner may have a representative witness the tests, if desired. Tests where proper notification has not been issued shall be considered invalid resulting in the Supplier retesting. 8.0 Shipment of Equipment and Materials All equipment and materials shall be shipped to the jobsite in accordance with these requirements. 8.1 Protection The Supplier shall provide protection for equipment and materials in the period between completion of manufacture and placing into service. Protection shall include but not be limited to, the following provisions.                  Special handling instructions visibly displayed on the shipment. Adequate preparation to facilitate rigging and handling, including lifting lugs where appropriate. Adequate crating, blocking and anchoring, as required to prevent damage and loss during transit. Proper loading of plate, tubular products, formed shapes and sheet metal work and other similar equipment and material, so as to prevent permanent deformation or crimps in material during transit or unloading. Affix durable metal, plastic, or wood covers to openings to keep pipe, vessels and machinery closed after final shop inspection. Provide covers, enclosures and other means to prevent corrosion, moisture damage, mechanical injury and accumulation of dirt in equipment and machinery. Protect surfaces subject to damage from oxidation, permanent staining, or other attack caused by atmospheric elements. Provide suitable rust-preventive compound for outdoor storage on exposed machined surfaces and unpainted iron and steel. Provide suitable compound or similar means for protection of cosmetic finishes. Provide grease packing or oil lubrication in all bearings and similar items, where applicable. Provide enclosure and/or moisture absorbing compound to protect equipment subject to internal moisture deterioration in a saturated or high-moisture atmosphere. Provide indoor or covered storage of all equipment and materials to comply with manufacturer’s recommendations. Protect equipment where damage can result from entry of dust or other foreign matter. Block, bolt, or otherwise restrain movement of internal parts where damage could result from normal handling during transit, unloading and erection. Pack separately all spare parts and special tools. Instruction Books shall be issued to the Contractor’s engineer before being submitted to the field. Energize space heaters as necessary. Periodically rotate equipment shafts in accordance with the equipment manufacturer’s recommendations. 8.2 Marking Identification of equipment and materials shall include, but not be limited to the following provisions.     Each item of equipment and material shall be tagged or marked as identified in the delivery schedule or on the Submittal Schedule and complete packing lists and bills of material shall be included with each shipment. Identify containers, crates, etc., containing spare parts, tools, or Instruction Books. Affix adequate labels on equipment shipped with bags of desiccant inside and to indicate existence of dog bolts or other restraints against movement of internal parts. Include packing lists in duplicate in each crate, package or bundle shipped. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 240 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 9.0 Special Tools The Supplier shall furnish all special tools required for installation, maintenance and dismantling of equipment and materials furnished under these Contract Documents. The Supplier shall turn over all purchased special tools to the Owner, upon Owner’s request. A listing shall be submitted to the Purchaser under separate cover which identifies the special tools, stock numbers and identification of equipment for which the tools were used. Submit this listing with the spare parts list. Special tools shall be retagged or marked as required for identification. Identification shall correspond to the list submitted to the Purchaser. The Supplier shall check the special tool inventory prior to turning over to the Owner to verify completeness. 9.1 Use of Special Tools Special tools supplied with the Supplier-furnished equipment and materials may be used by the Supplier during erection and installation. After erection and installation is complete, the Supplier shall turn over all special tools to the Purchaser in good condition, as determined by the Purchaser. The Supplier shall replace any special tools damaged or lost during erection. 10.0 Manufacture and Assembly The manufacturer shall ship equipment as completely assembled as possible, consistent with shipping facilities and construction requirements. The manufacturer shall factory pipe and tube all panel devices to bulkhead fittings ready for external connection. The manufacturer shall factory fabricate and completely assemble electrical control and insert panels at the manufacturing location. The manufacturer shall factory terminate panel wiring and all interconnecting cables with mating plugs where indicated; factory terminate all other wiring with terminal blocks; and factory finish paint panels of a color designated by the Purchaser. For skid-mounted equipment, such as an air compressor and dryer skid, the Supplier shall completely assemble, wire, tube, pipe, paint and test at the factory. 11.0 Correction of Errors Equipment and materials shall be complete in all respects within the limits herein outlined. All errors or omissions required to be corrected in the field shall be done by the manufacturer or his duly authorized representative at the Supplier's expense. 12.0 Numbering System Electrical devices, control and instrumentation equipment, valves and other items of similar nature shall be permanently identified with the identification number supplied by the Purchaser. Prior to the first Supplier document submittal, the Purchaser shall provide the Supplier a block of numbers to be assigned by the Supplier. Except as stated otherwise in these requirements, the identification shall be engraved on stainless steel or laminated phenolic tags or nameplates at the option of the Supplier and permanently affixed to the device. The Supplier's identification numbers shall be included on the manufacturer’s drawings. Identification numbers shall be engraved on stainless steel tags and the tags wired to the appropriate devices. The identification numbers shall be included on the manufacturer’s bill of materials. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 241 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 13.0 Nameplates Nameplates shall be furnished when stipulated in the detailed requirements sections. Nameplates for mounting in the control room shall be made of laminated black phenolic engraving stock with white core. Nameplates to be mounted in locations outside of the control room shall be made of laminated white phenolic engraving stock with black core. The lettering shall be not less than 3/16 inch square, bold engraved through the outside layer so that the letters are the color of the core. Nameplates shall be attached to the equipment with stainless steel pan head screws or rivets. 14.0 Welding All welding of equipment and materials shall be in accordance with the requirements of Section 60.0500 of these Contract Documents. The appropriate welding requirements section for the specific equipment or materials to be furnished shall be furnished to the manufacturer or fabricator by the Supplier prior to commencement of any welding activities. Each manufacturer or fabricator shall submit welding procedures, testing and inspection data to the Purchaser for review and record when requested. If the manufacturer has special requirements relating to welding procedures for welds at the terminals of the equipment the requirements shall be stated on the manufacturer's drawing of the affected part. 15.0 Shop Coating All metallic surfaces subject to corrosion shall be protected by suitable coatings applied in the shop. Surfaces which will be inaccessible after assembly shall be protected for the life of the equipment. The surfaces shall be thoroughly cleaned and prepared in the shop prior to application of coatings. Internal surfaces shall not be blasted with steel shot. Exposed surfaces shall be finished smooth, thoroughly cleaned and filled as necessary to provide a smooth uniform base for painting. Surfaces to be finish painted after installation, or requiring paint for corrosion protection until installation, shall be surface prepared and shop painted with one or more coats of top-coatable paint as hereinafter described. 15.1 Painting Shop coating systems for carbon steel equipment and other ferrous metal surfaces shall be of Owner’s approved manufacture’s standard. All coatings to be applied in the shop shall be top-coatable (I.E., topcoatable such that additional field applied or field applied finish coatings can be applied without excessive effort or removal of the shop coating). Equipment manufacturer to indicate on the compliance submittals the shop applied coating generic type, name brand and number, surface preparation preformed, number of coats and dry film thickness of each coat. All coatings shall be surface prepared, applied, cured, protected and the Work otherwise performed in strict accordance with the paint manufacturer’s printed recommendations. The manufacturer’s standard coating system shall be used. 15.2 Electrical Equipment Electrical equipment; including panels, switchgear, motor control centers, transformers, motors and other similar equipment, shall be cleaned, prepared and coated in shop prior to delivery in accordance with manufacture’s standard and Owner’s approval. Other electrical equipment coatings of the equipment manufacturer’s standard system that are designed and suitable for an industrial indoor or outdoor environment, as applicable based on the location of the equipment, will be acceptable and these include systems of; polyester powder coating over phosphatized surfaces or electrostatically applied and oven baked ANSI 61 polyester powder coatings. Additional field applied coatings to this type equipment will not be required except for field touch up painting. For control panels: Enclosures to be finished with 4 mils of electrostatically applied and oven bakes ANSI 61 polyester powder inside and outside. All inside panels to be gloss white enamel. 15.3 Mechanical Equipment Mechanical equipment (unless otherwise specified within these Contract Documents); including pumps, compressors, valves, valve operators, dampers, damper drives, mills, grinding apparatus, external piping surfaces, conveying machinery and other similar equipment shall be cleaned, prepared and prime coated Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 242 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 in the shop prior to delivery. For equipment that will not be insulated and lagged, the equipment shall be shop coated using the appropriate manufacture’s standard dependent upon the expected service/operating temperature of the equipment. Subject to the Owner’s approval, the equipment manufacturer’s standard industry grade coating must meet the following minimum criteria: 1) suitable for the intended industrial and coal power plant environment, 2) suitable for the expected operating temperatures and conditions, 3) suitable for the intended location of the equipment within the plant, 4) minimum surface preparation of SSPC-SP6 blasted quality, 5) minimum of 6 mils DFT of coating system consisting of primer and epoxy topcoat of the same paint manufacturer. For equipment that will be insulated and lagged the equipment shall receive a minimum coating equal to the 2 mils (prime coat) dry film thickness and be subject to the Owner’s approval. Mechanical equipment surfaces that will not be insulated, lagged, or otherwise covered shall receive additional field applied coatings to be addressed elsewhere within these Contract Documents. 15.4 Structural Steel and Miscellaneous Metals Structural steel and miscellaneous metals; including all items fabricated of structural and miscellaneous steel such as ducts, hangers, supports and similar fabricated steel assemblies that are not covered with insulation and lagging shall be cleaned, prepared and coated in the shop in accordance with the Owner approved manufacture’s standard. Structural steel and miscellaneous metals; including all items fabricated of structural and miscellaneous steel such as ducts, hangers, supports and similar fabricated steel assemblies that are to be covered with insulation and lagging shall be cleaned, prepared and coated in the. Shop prime coated structural and miscellaneous steel work that will not be insulated, lagged, or otherwise covered shall receive additional field applied coatings to be addressed elsewhere within these Contract Documents. Subject to the Owner’s approval, structural and miscellaneous steel may be hot dip galvanized in lieu of shop and field painted. 15.5 Hot Metal Surfaces Hot metal surfaces that are not insulated and lagged shall be cleaned, prepared and coated in the shop in accordance with the manufacture’s standard based upon the operating temperature of the equipment or material. Hot metal surfaces that are to be covered with insulation and lagging shall be cleaned, prepared and coated in the shop based upon the operating temperature of the equipment or material. Hot metal surfaces that will not be insulated, lagged, or otherwise covered shall receive additional field applied coatings to be addressed elsewhere within these Contract Documents. 15.6 Preservative Coatings Ferrous surfaces which should not be coated and are subject to corrosion shall be protected with Mobil Oil Corporation “Rust Veto”. Machined surfaces of weld end preparations shall be coated with a consumable rust preventative coating to prevent surface corrosion prior to welding and shall be “Deoxaluminate” as manufactured by the Special Chemicals Corporation, “Bloxide” as manufactured by Tempil Inc, or Owner approved equal. 15.7 Galvanizing Galvanizing shall be in accordance with the following requirements. Structural steel members and steel assemblies shall be "pickled" after all cutting, punching, reaming, drilling, tapping and other fabrication processes which would damage galvanizing have been completed. The pickling shall be done in accordance with the latest accepted practice and shall continue until all scale, rust, grease and other impurities have been completely removed. The steel shall then be hot-dip galvanized in accordance with ASTM A123. Where either member to be bolted is galvanized and where required by the detailed specifications, erection and structural bolts shall be galvanized in accordance with ASTM A153. 16.0 Alignment and Balance Major equipment rotating parts shall be true and dynamically balanced. Excessive noise or vibration, in the opinion of the Purchaser, will be sufficient cause for rejection of the equipment. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 243 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 All rotating equipment, except electric motors, shall be factory balanced to a level such that vibration displacement in mils peak-to-peak is not more than indicated under “GOOD” on the IRD General Machinery Vibration Severity Chart, or as required for reliability and longevity. Electric motors shall be balanced by the manufacturer in accordance with NEMA standards. 17.0 Noise Level The equivalent “A” weighted sound pressure level for equipment furnished under these Contract Documents shall not exceed 85 dBA free field measured three (3) feet horizontally from the base of the equipment and five (5) feet above the floor. The combined sound pressure level of the motor and driven equipment shall not exceed 90 dBA free field measured 3 feet horizontally from the base of the equipment and five (5) feet above the floor level. The sound pressure levels stated are decibels to a reference of 20 micropascals. 18.0 Lubrication Equipment shall be lubricated by systems designed for continuous operation. Lubrication systems shall not waste lubricants and shall not require attention during startup and shutdown, or routine inspection more frequently than once weekly. Oil lubricant level indicators shall be furnished and marked to indicate proper levels, where applicable, under both standstill and operating conditions. 19.0 Enclosed Gear Drive Units Enclosed gear drive units furnished as a part of the equipment shall be designed for continuous service and shall be in accordance with the latest AGMA standards for the type of gear drive being furnished. Each gear drive unit shall be capable of withstanding the motor torques developed during start, acceleration and deceleration if stalled. 20.0 Shaft Couplings Shaft couplings, where applicable, shall be used between all drives and driven equipment. Couplings shall be attached to driver and driven shafts by press fits and keys. Shaft couplings shall be sized to transmit the maximum brake horsepower requirements of the driven equipment with a service factor of not less than two (2). 21.0 Safety Guards Manufacturer’s standard safety guards shall be used. 22.0 Equipment Bases Manufacturer’s standard equipment bases shall be used. 23.0 Piping All piping, including control and instrument piping, shall be in accordance with all other sections of these Contract Documents. 24.0 Equipment Lockout Devices All mechanical and electrical equipment shall come complete with provisions able to accept a mechanical lockout device in both the open and closed positions. This includes all valves, switches, breakers, dampers, etc. Cutting off the air to a pneumatically operated damper is not an acceptable lockout device. The damper, or other piece of equipment, shall have a means of being physically locked in place. 25.0 Miscellaneous Mechanical Equipment and Materials Miscellaneous mechanical equipment shall be designed in accordance with the following and shall be comparable to Calaveras coal yard equipment. Miscellaneous equipment not described herein shall be comparable to Calaveras coal yard equipment. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 244 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction 25.1 Not Used 25.2 Rubber Expansion Joints Control units where piping cannot be properly anchored. Joints shall be complete with all required hardware to assure maximum axial movements are not exceeded. Expansion shall be equipped with backing plates. Length of space in pipeline shall be equal to the design installation length of expansion joint. The two flanged joints which are connected by the expansion joint shall be aligned with one another prior to installation of the expansion joint. 25.3 Metal Expansion Joints Control units where piping cannot be properly anchored. Joints shall be complete with all required hardware to assure maximum axial movements are not exceeded. Joints shall have 304 stainless steel corrugations with stainless steel liners. Joints shall be single-unit construction for full vacuum to the design pressure listed in the schedule below. Multi-ply joints are not acceptable. Length of space in pipeline shall be equal to the design installation length of expansion joint. The two sections of pipe which are connected by the expansion joint shall be aligned with one another prior to installation of the expansion joint. 25.4 Sight Flow Indicators Body material shall be the same as valves in the respective pipe. Indicator shall have tempered glass windows. The sight flow indicator shall have a rotor for positive flow indication. The rotating wheel type shall be used for pressures up to 150 psig. Flow indicators shall be installed per manufacturer’s instructions and shall be installed so that the indicator is easily visible. 25.5 Site Gauge Glasses Gauge glasses shall be installed with ball check valves. Site glass shall be installed per manufacturer’s recommendations. 25.6 Backflow Preventers Body material shall be the same as the valves installed in the respective pipe. Backflow preventers shall be of the reduced pressure design and shall consist of two spring loaded check valves, a spring-loaded diaphragm-actuated, differential pressure relief valve located in the zone between the check valves and two isolating gate valves. Backflow preventers shall be installed per manufacturer’s recommendations. 25.7 Not Used 25.8 Not Used 25.9 Y-Type Strainers Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 245 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction Strainer body shall be of the same material and rating as valves in the respective piping. Bid Issue 2Mar2015 Strainer baskets shall be constructed of stainless steel. Two baskets shall be provided with each strainer. Provide 1/2” NPT connections on the inlet and outlet of each strainer for dP gauges. Each Y-type strainer shall be equipped with blowdown valve and piping. 25.10 Basket Strainers Strainer body shall be of the same material and rating as valves in the respective piping. Strainer shall be equipped with an easily removable cover. Strainer baskets shall be removable and constructed of stainless steel. Two baskets shall be provided with each strainer. Provide 1/2” NPT connections on the inlet and outlet of each strainer for dP gauges. Each Y-type strainer shall be equipped with blowdown valve and piping. 25.11 Duplex Strainers Duplex strainers shall be the plug type. Strainer body shall be the same material and rating as valves in the respective piping. Bolted covers shall have lifting lugs. Provide one spare gasket for each bolted cover. Quick opening covers shall have O-ring seals. One spare O-ring shall be provided for each cover. Each half of the strainer shall have an open area of six times the inlet pipe area. Clean water pressure drop shall not exceed 1.5 psi. Strainers shall be equipped with 1/2 inch NPT connections on the inlet and outlet nozzles for measuring differential pressure. Provide 1 inch NPT plugged drain connection in the bottom of each half of the strainer. Baskets shall be constructed of stainless steel materials and shall be easily removable. 26.0 Not Used 27.0 Instrumentation Instrumentation components furnished with the equipment shall be in accordance with the following articles and shall be constructed to withstand the temperatures and pressures encountered in the actual service. Explosion proof construction shall be furnished where required by applicable code. All components shall be provided in accordance with the following articles. All instrumentation shall be provided with a stainless steel tag. All instruments requiring electrical wiring shall be provided with threaded connections to either 3/4 inch conduit or gland seal as appropriate. Electrical housings shall be dustproof and moisture-proof in accordance with NEMA 4 (IP65) requirements or, if they are installed in a hazardous area, shall be of a design suitable for the specific area classification. Components of the instrument that contact the process media shall be stainless steel or a material suitable for service. Coatings shall not be considered adequate protection to resist process corrosion. Pressure and differential pressure measuring instruments for corrosive or thick, plugging process fluids shall be equipped with a threaded remote diaphragm seal assembly complete with flushing connection. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 246 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 The seal diaphragm and housing material shall be suitable for the service required. Capillary tubing shall be armored stainless steel at least 30 feet (10 meters) in length. Pressure instruments shall be capable of withstanding sustained over-pressurization to 150% of the maximum service pressure with no subsequent loss of function or change in measurement accuracy. The process connection on each pressure instrument shall be 1/2 inch MNPT for bottom connection static pressure indicators, at least 1/8 inch (3 mm) FNPT for draft differential pressure devices and at least 1/4 inch FNPT for all others. Each local indicator shall have the service legend engraved on the dial or have a tag, engraved with the Purchaser's ID number and the service legend, attached to it. Each tag shall be engraved laminated phenolic or stainless steel. Legend and tag number will be provided by the Purchaser. The scale range of each indicator shall be selected so that the normal operating condition is approximately mid-scale (between one third and two thirds of full scale of the dial). Except for pressure differential gauges, rotary type indicator full scale pointer travel shall be a minimum of 270 degrees. Indicator dial size shall be at least 4-1/2 inches. Accuracy shall be ±1% of full scale range. Differential pressure indicator full scale pointer travel shall be at least 80 degrees. Indicator dial size shall be at least 4 inches (100 mm). Accuracy shall be 2 to 3% of full scale range. 27.1 Not Used 27.2 Pressure/Differential Pressure Switches Pressure switches shall be electro-mechanical type, where switch elements are actuated/deactuated by mechanical link to a diaphragm which is influenced by the monitored pressure. Switch contacts shall be at least of one SPDT element. Where multiple pole switches are furnished for one trip (actuation) point, actuation and reset of all poles shall occur simultaneously. Switch contact shall be of the snap-acting type. Mercury wetted switch contacts shall not be used without Purchaser's approval. Switch set point shall be field adjustable and tamperproof. Range, repeatability, deadband and overpressure capability shall be acceptable to the Purchaser. Install with plugged test connections between the instrument and its shutoff valve(s). Provide differential pressure switches with 3-valve manifolds. Accessories: Provide pulsation dampeners as required and approved by the Owner. Adjustment: Factory adjust each switch to the required setting before shipment to the jobsite. Indicate the factory setting on the device tag. Switch accuracy shall be ±1% of full scale range. Pressure switch sensing elements shall be bellows, diaphragm, or piston. Wetted parts shall be suitable for the application. Pressure Switch Description Energizing Power Switch Contacts Source: 21000, 2011 Material Wetted Parts Manifold? FailSafe? Deadband Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Acceptable Manufacturer/ Model Page 247 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Pressure Switch Energizing Power Switch Contacts Material Wetted Parts Pressure Switch Gauge N/A SPDT, 120 VAC Pressure Switch Differential (Static Pressure < 500 psi) 110 VAC, 60 Hz Pressure Switch Differential (Static Pressure > 500 psi) None Description Acceptable Manufacturer/ Model Manifold? FailSafe? Stainles s Steel No N/A Manufacture r's Standard United Electric Controls Co. Dwyer Instruments, Inc. – (CapsuPhotohelic) S-O-R, Inc. Purchaser Approved Equal DPDT, 120 VAC Stainles s Steel Yes Yes 1% United Electric Controls Co. Dwyer Instruments, Inc. – (CapsuPhotohelic) S-O-R, Inc. Purchaser Approved Equal DPDT, 120 VAC Stainles s Steel Yes N/A 2% United Electric Controls Co. Deadband Dwyer Instruments, Inc. – (CapsuPhotohelic) S-O-R, Inc. Purchaser Approved Equal 27.3 Temperature Switches Electro-mechanical type wherein temperature is detected indirectly as the vapor pressure of a fluid sealed inside a bulb and capillary system. Vapor pressure actuates/de-actuates the switch elements via a sensing diaphragm. Sensing Elements.   Capillary: Provide stainless-steel interlocked spiral armor or stainless steel tubing on capillary. Bulb: Straight unless otherwise noted, sized for capillary length furnished, union-connected to well. Adjustment: Factory adjust each switch to the required setting before shipment to the jobsite. Indicate the factory setting on the device tag. Each temperature switch shall be furnished with a thermowell (as specified under Thermowells, Protecting Tubes and Test Wells Temperature Switch Description Grounding Construction Gas Filled N/A filled thermal system assembly, with thermowell Source: 21000, 2011 Switch Contact Ratings Acceptable Manufacturer/Model 5A at 120 VAC Ashcroft Type 400B United Electric Series 400 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 248 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 27.4 Level Switches Level switches shall have a float and body construction appropriate to the service conditions of the systems to which they are connected. Two switch elements shall be available at each level point monitored. Each switch element shall be reversible for NC or NO operation or shall be double-throw construction. Switch element leads shall be of high temperature construction, where required and terminated on terminal blocks within the switch housing. Switch housings shall be splash proof construction, unless otherwise required. Ultrasonic type level switches shall be used in special applications such as corrosive service, highly viscous service and highly aerated liquid service. Where applicable the amplifier shall be an integral part of the ultrasonic transducer housing assembly. Two switch elements shall be available at each level point monitored. Each switch element shall be reversible for NC or NO operation or shall be double throw construction. Switch housings shall be splash proof construction unless otherwise required. Materials of construction shall be appropriate to the service conditions to which they are connected. Cages of float type level switches shall be ASME B31.1 compliant and of the all-welded construction type. Each instrument shall have a float, body construction and switch element appropriate for the application. The switch element shall be magnetically coupled to the float or displacers. Level Switch Switch Contacts Deadband 2SPDT, 120 VAC Manufacturer's Standard Switch Construction Cage Construction Material Wetted Parts Snap Acting B31.1 Stainless Steel Acceptable Manufacturer/ Model Magnetrol International SOR, Inc 27.5 Solenoid Valves Solenoid valves shall be selected to incorporate body construction, trim materials and internal arrangements suitable to the application and shall be acceptable to the Owner. Solenoid enclosures shall be NEMA 4 unless otherwise required. Solenoid coils shall be Class H high temperature construction or and shall be suitable for continuous duty. Solenoid Valve Coil Type Coil Rating Manual Operator Type H 120 VAC, 60 Hz Yes ASCO – EFHB8320G174xx (Brass ExP) ASCO – EFHB8320G200xx (Stainless Steel ExP) ASCO – JKH8320G172xx (Brass NEMA 4,<100 dp) ASCO – JKH8320G174xx (Brass NEMA 4) Purchaser Approved Equal Type H 240 VAC, 50 Hz Yes ASCO – EFHB8320G174xx (Brass ExP) ASCO – EFHB8320G200xx (Stainless Steel ExP) ASCO – JKH8320G172xx (Brass NEMA 4,<100 dp) ASCO – JKH8320G174xx (Brass NEMA 4) Purchaser Approved Equal Source: 21000, 2011 Acceptable Manufacturer/Model Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 249 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 27.6 Pressure Gauges Pressure gauges shall be 4-1/2 inch dial weatherproof. Gauges for control air supply and signal pressures integral to the instrument shall be in accordance with the control manufacturer's standards. All other gauges shall be as described herein.       1% accuracy at mid-scale. Select scale range so that normal operating pressure is between 1/3 and 2/3 of full scale. Bourdon tube or bourdon coil (helix) element. Materials: 316L SS bourdon tube and socket. Phenolic case with blow out protection. Each static pressure indicator shall be equipped with a blowout disk. Each indicator shall have a stainless steel movement, wetted parts and socket unless the application requires other materials. The housing shall be dust- and moisture-resistant and shall be furnished with laminated safety glass. Each indicator shall be provided with overpressure stops to protect against pressure surges outside the scale range limits. A piston type pulsation damper shall be furnished on each indicator to protect against process fluid oscillations of ±3% or more of the full scale range. The piston shall be adjustable with the pressure indicator installed on the process line. Pressure Indicator Description Material Wetted Parts Acceptable Manufacturer/Model Pressure Gauge 316 SS or better Ashcroft (Dresser) 1279 Ametek US Gauge Dwyer Orange Research 27.7 Temperature Gauges Temperature gauges shall be 4-1/2 inch dial gas actuated or bimetal type. Gauges for panel mounting shall be Ashcroft 4-1/2 inch dial 600A gas actuated with Type 1377 case and stainless steel armored capillary tubing of length required for the installation. The dials shall be engraved with service legends, or separate nameplates of engraved laminated phenolic shall be furnished attached to the dial faces to identify the service. Legends shall be as directed by the Purchaser. Temperature indicators shall be furnished with a compression union so that the stem will bottom out when placed in the thermowell. If required, thermowells with lagging extensions shall be furnished for all indicators and shall be as specified under the article entitled Thermowells, except that extension nipples shall not be furnished for temperature indicators. Temperature Indicator Description Grounding Construction Bimetallic N/A 4-1/2-inch dial, every angle adjustable Source: 21000, 2011 Switch Contact Ratings N/A Acceptable Manufacturer/Model Ashcroft US Gauge Palmer-Wahl Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 250 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 27.8 Thermocouples and Resistance Temperature Detectors (RTDs) Temperature detectors shall be thermocouples or resistance temperature detectors as required by the following paragraphs and the detailed requirements. Thermocouples equipped with thermowells shall be spring-loaded and shall be furnished as complete assemblies, each including a well, nipple and weatherproof connection head. Thermowells shall be as described under the article entitled Thermowells. Thermocouples shall be dual element, stainless steel sheathed, compacted magnesium oxide insulated type, with ungrounded measuring junctions. Thermocouples and extension wire shall meet the standard limits of error specified in ANSI MC96.1. Thermocouples for bearing and metal temperatures and fluid system temperature measurements shall be ISA Type E (chromel-constantan) thermocouples with Type EX extension wire. Resistance temperature detectors for fluid system temperature measurements shall be 100 ohm platinum, metal sheathed, ceramic packed, ungrounded resistance temperature detectors. Each RTD shall meet the standard limits of error. Temperature Element Switch Contact Ratings Acceptable Manufacturer/Model Description Grounding Construction Thermocouple Ungrounded ISA Type E (ChromelConstantan) with EX Extension Wiring N/A JMS Southeast, Inc.Statesville, NC USA Pyco, Inc. Pyromation Rosemoutn Thermometrics Thermo Electric Resistance Temperature Detector N/A Pt 100-ohm (at 0°C), 3-wire type N/A Manufacturer’s Standard JMS Southeast, Inc. – Statesville, NC USA \MTI I Daily Thermetrics Industrial Sensors Pyromation Rosemount Thermo Electric Special Requirements: Thermocouples shall be type E unless not suitable for the temperature range. RTDs will be used only when an equipment supplier feels it is prudent for a performance reason. 27.9 Thermowells Fluid system temperature sensors shall be equipped with thermowells. Thermowells shall be one piece solid bored Type 316 stainless steel. Thermowells shall be welded and constructed to allow seal welding after installation. If threaded, sizes shall be as follows. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 251 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Low Pressure Applications 1 inch NPT Gas and air duct wells 1 inch NPT All others 1 inch NPT Thermowell insertion length shall be as determined by the manufacturer, unless otherwise required. Suitable lagging extension length shall be provided so that thermowell extends at least ¾” beyond insulation and lagging. Thermowell outside diameter at the beginning of the taper shall be approximately the same as the root diameter of the threads. Each thermowell shall be furnished with a stainless steel extension nipple of the length determined by the manufacturer, unless otherwise required. Each thermowell shall be of one-piece, stepless, tapered, solid bore design with threaded process connection and hex wrench flats. Unless otherwise specified on the tables at the end of this section, material shall be 316 stainless steel, F91 or F11. Bore diameters shall be suitable for 1/4 inch sheaths (0.254 to 0.262 inch. Thermowell outside diameter at the large end of the taper shall be approximately the same as the root diameter of the threads. Each thermowell shall be furnished with a 6 inch stainless steel extension nipple or lagging extension of the length required to keep the thermocouple head away from the insulation and lagging. Each duct temperature sensor shall be equipped with a protecting tube. Each protecting tube shall be 1 inch (25 mm) OD standard weight pipe, stainless steel unless otherwise specified, with a bushing provided to make a 2 inch NPT threaded connection to the duct wall, allowing a variable insertion length into the duct. After the protecting tube has been inserted through the bushing, it will be seal welded to the bushing. 27.10 Not Used 27.11 Not Used 27.12 Transmitters Transmitters for the measurement of static pressure, differential pressure, level, or flow shall be microprocessor-based and of the 2 wire design. Transmitter sensing element shall be of the diaphragm or capsule type. All wetted parts shall be stainless steel unless the application requires another material. Tamperproof zero and span adjustment shall be provided. Transmitter accuracy shall be ±0.10% of calibrated span. Transmitter housing shall be dustproof and moisture-proof. Transmitter digital communications shall use the "HART" protocol for configuration and calibration. Pressure Transmitter Description Transmitter Output Manifold? Material Wetted Parts Acceptable Manufacturer/Model Pressure Transmitter 4-20 mA 2-wire Yes Stainless Steel or better Rosemount – 3051 C Level Transmitter 4-20 mA Yes Stainless Steel or better Rosemount – 3051 C Flow Transmitter 4-20 mA Yes Stainless Steel or better Rosemount – 3051 C Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 252 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Flow Transmitter Transmitter Output Energizing Power Material Wetted Parts Acceptable Manufacturer/Model 4-20 mA 24 VDC Stainless Steel Rosemount -3051 C (for DP) Owner approved Manufacturer's standard for special applications Level Transmitter Transmitter Output Energizing Power Material Wetted Parts 4-20 mA N/A Stainless Steel Cage Material Manufacturer's Standard Cage Construction B31.1 Acceptable Manufacturer/ Model Magnetrol International Fisher Controls 27.13 Pneumatic Valve Positioners and Position Transmitters Each valve positioner shall be microprocessor based electronic-to-pneumatic design. Each valve positioner shall be designed for a 4-20 mA input range unless otherwise specified and an output signal from zero to the full supply air pressure required by the actuator. Each positioner shall be equipped with a filter regulator air supply set mounted on the valve yoke. Each positioner shall be capable of split-range sequencing and direct or reverse action. Other features shall include speed and gain adjustment, failure mode choice, non-interactive adjustments, easy pilot access for cleaning, characterization, automatic zero/span calibration and "HART" protocol for configuration and calibration. Position transmitters shall be integral to valve positioners and shall produce 4-20 mA output in direct relationship to the valve position. The output signal shall be 2 wire, isolated and ±1.0% linear. Positioner Manual Operator Input Signal Acceptable Manufacturer/Model No 4-20 mA Fisher Controls – “Fieldvue” DVC 6000 Series or approved equal Special Requirements Positioner shall be smart type with integral position feedback transmitter Local Controllers Type Input Signal Output Signal Acceptable Manufacturer/Model Pneumatic Process 3-15 psig Fisher 2502 for Level Fisher 4160 or 4195 Series for Pressure Fisher 4166 or 4196 Series for Temperature Foxboro 43AP series 27.14 Not Used 27.15 Not Used Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 253 of 280 Calaveras Coal Yard 186144.77.1000 27.16 Signal Converters Bid Issue 2Mar2015 Compressed Air Equipment Construction 27.17 Instrument Installation All instrument primary piping and tubing, instrument valve manifolds, instrument shutoff valves, instrument equalizing valves and instrument blowdown valves shall be supplied, installed and tested in accordance with ASME B31.1 - Power Piping. Instrument primary piping and tubing is defined as the piping or tubing from the process connection root valve to the blowdown and the instrument valves. Changes in tubing direction shall be made only with tube fittings or tube bending. Tubing bends shall be made without reducing the internal diameter of the tubing. All tubing shall be blown clean with dry compressed air after installation, but prior to attachment to devices at either end. Piping and tubing schematic, connection and interconnection diagrams shall be submitted to the Purchaser for acceptance. 27.17.1 Instrument Primary Tubing. Tubing shall be supported to allow thermal expansion, minimize vibration and protect it from damage. Tubing runs shall be supported both horizontally and vertically. Where continuous support is required, support using tubing tray is preferred. Support using connection to structural steel is allowable when it provides equivalent protection from damage and vibration. 27.17.2 Control and Instrument Enclosure/Rack Tubing. Instrument tubing within enclosures or racks shall be arranged to allow any device to be serviced, disconnected, or removed from the enclosure or rack without disconnecting tubing to other devices. Tubing for external connections shall be terminated on a bulkhead plate, utilizing bulkhead fittings for enclosures, or unions for open racks. Each bulkhead termination shall be identified with a nameplate. 27.17.3 Instrument Valves and Valve Manifolds. Each pressure instrument shall be installed downstream of an instrument shutoff valve or instrument valve manifold designed for instrument shutoff service. In addition, each liquid filled instrument primary line shall be provided with a tee upstream of the instrument valve/manifold and blowdown valve(s). Each differential pressure instrument, when not provided with an instrument valve manifold, shall be provided with an instrument equalizing valve, two instrument shutoff valves and two test tees with 1/4 inch tube plugs. Each remotely mounted static pressure instrument shall be provided with a two-valve manifold. Each differential pressure instrument shall be provided with a three-valve manifold. Each instrument valve shall have stainless steel construction and a grafoil packed stem. In addition, each instrument valve manifold shall be provided with test elbows with 1/4 inch tube plugs (instrument side) and dual ferrule grip type tube fittings for process connections. Flange type (direct mounting) manifolds are preferred by the Purchaser. Coplanar style manifolds will be considered only on a case-by-case basis. 27.17.4 Blowdown Valves. A blowdown valve shall be provided for each instrument primary line except oil, draft and vacuum services. Each blowdown valve shall have a globe pattern design, stainless steel construction, a grafoil packed stem and a minimum 0.25 inch orifice. 27.17.5 Instrument Valves, Fittings and Support Tray. Instrument Process Components Acceptable Manufacturer/Model Tubing - Grip Type Fittings Swagelok Purchaser Approved Equal Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 254 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Instrument Process Components Acceptable Manufacturer/Model Tubing - Socket-Weld Fittings Swagelok Purchaser Approved Equal Valve Manifolds Swagelok Purchaser Approved Equal Instrument Shutoff Valve Swagelok Stainless Steel, Series SS-6DBS8 with Grafoil Packing Purchaser Approved Equal Instrument Equalizing Valve Swagelok Stainless Steel, Series SS-6DBS8 with Grafoil Packing Purchaser Approved Equal Instrument Blowdown Valve Swagelok Stainless Steel, Series SS-6DBS8 with Grafoil Packing Purchaser Approved Equal Instrument Tubing Support Tray James C. White Company, Inc., Series “Tubetrack” Purchaser Approved Equal 28.0 Not Used 29.0 Electrical Enclosures Unless indicated otherwise in these specifications, electrical enclosures, except junction boxes and pull boxes 4 inch trade size and smaller, shall be as follows. Location Enclosure Type Outdoor (Non-hazardous) NEMA 4 Hazardous areas In accordance with the requirements of the National Electrical Code for the location The construction of electrical enclosures located in areas subject to conditions classified in the National Electrical Safety Code and the National Electrical Code as hazardous shall be of a type designated by NEMA as suitable for the environment in which they are located. Electrical enclosures, except those of cast metal, shall be constructed from steel plate reinforced as required to provide true surface and adequate support for devices mounted thereon. Thickness of the steel plate shall conform to the requirements of UL. Enclosures shall be of adequate strength to support mounted components during shipment and to support a concentrated load on their top after erection. Fiberglass enclosures shall be provided in corrosive locations. All junction boxes or pull boxes 4-inch trade size or smaller in any dimension shall be galvanized malleable iron or acceptable equal cast ferrous metal. Junction boxes and pull boxes shall be in accordance with the requirements of NEC, Article 370, Paragraphs 18, 19, 20 and 21 and shall be without knockouts. All junction boxes or pullboxes larger than 4 inch trade size shall be Hoffman or equal with polyester powder coating over phosphatized surfaces. Terminal boxes shall be Hoffman or equal with polyester powder coating over phosphatized surfaces. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 255 of 280 Calaveras Coal Yard 186144.77.1000 30.0 Not Used Compressed Air Equipment Construction Bid Issue 2Mar2015 31.0 Not Used 32.0 Not used 33.0 Termination of Power Cable Supplier’s equipment shall be designed to accept/terminate incoming power cables from Purchaser that are fitted with long barrel compression lugs such as Burndy type YAV or YA. 34.0 Terminal Blocks Terminal blocks shall be furnished with white marking strips and, where permitted by the safety codes and standards, shall be without covers. Spare unused terminals shall be furnished on each terminal block for circuit modifications and for termination of all conductors in a multi-conductor control cable. Up to 20% spare unused terminals shall be furnished. Fuses shall not be mounted on terminal blocks. Neither step type terminal blocks nor angle mounting of terminal blocks will be acceptable. All terminal blocks, except internal terminal blocks in factory pre-wired electronic system cabinets and terminal blocks for thermocouple extension wire, shall be rated 300 volts minimum and shall have strap screw terminals. Terminal blocks for 10 AWG and smaller 600 volt insulated conductors shall be Marathon 1500 series terminal block or Purchaser approved equal. This series of terminal blocks shall be used in control and thermocouple wiring applications where continuous currents do not exceed ten (10) amperes and where intermittent currents are no more than 30 (thirty) amperes, for a duration of no longer than twenty (20) cycles. Higher current applications require a Marathon 1600 series terminal block or Purchaser approved equal, for 10 AWG and smaller 600 volt insulated conductors. Terminal blocks shall be appropriately sized for larger wire size or higher voltage insulated incoming conductors as necessary. 35.0 Fuse Blocks Where fuse blocks rated 30 amperes, 250 volts are required, they shall be modular type with bakelite frame and reinforced retaining clips. Blocks shall be Class H, 2-pole, or three pole as required. 30 amp, with screw terminals. Blocks for other current and voltage ratings shall be similar in construction. 36.0 Fuses Where slow blow fuses are required for protection of equipment, they shall be Bussmann Type MDL, or Purchaser approved equal, with ampere ratings of 1/4, 1/2, 1, or 2. Where fast acting fuses are required for protection of equipment they shall be Bussmann Type NON, or acceptable equal, with ampere ratings of 1, 3, 6, 10, 15, 20, or 30. 37.0 Electrical Accessory Devices Electrical accessory devices shall be furnished in accordance with the requirements stated herein unless otherwise stipulated in the detailed requirements sections. 37.1 Electrical Instruments Indicating instruments for electrical quantities shall be of the switchboard type with 1% accuracy classification, shall be designed for flush mounting and shall be approximately 4 inches square. All instrument scales shall consist of black markings on a white background. Any instrument which is checked in the field and found to be inaccurate in excess of 2% will be returned to the Supplier for calibration or replacement without cost to the Purchaser. All ac instruments shall be designed for operation through 5 ampere current transformer secondaries and 120 volt potential transformer secondaries. Instruments shall be General Electric (Yokogawa) Type AB-40, Westinghouse (Weschler) Type 241, or Purchaser approved equal. Individual indicating instruments are not required if meters or relays with digital displays are available to perform the same function. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 256 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 37.2 Control Relays General service externally mounted auxiliary relays shall be Telemecanique Incorporated Type J10A, J11A, J13P, Square D type X or Purchaser approved equal. Where current carrying requirements exceed the capacity of the general service auxiliary relays, auxiliary relays shall be General Electric Type HFA or HGA, ABB Type MG-6, Potter Brumfield Type KR, or Square D Type KP, or acceptable Purchaser approved equal. Timing relays shall be Allen-Bradley Type RT, RTA or Square D Class 9050 Type D or acceptable equal. Timing relays shall be of solid-state construction. Pneumatic timing relays are not acceptable. 37.3 Control Switches Breaker control switches shall be 600 volt, 20 ampere, multistage, rotary type with a minimum of 10 contacts. Switches shall have black, fixed, modern, pistol grip type handles and engraved black plastic escutcheon plates with targets. Switches shall be Electroswitch Type W, General Electric Type SB-1, General Electric Type SB-10, Electro Switch Type 20K, or Purchaser-approved equal. 37.4 Push Buttons and Selector Switches Pushbuttons shall be Culter-Hammer Type 10250T Owner approved. 37.5 Indicating Lights Indicating lights shall be in accordance with 40.3006. 37.6 Alarm Contacts Alarm contacts for remote monitoring will be wired to the Plant DCS. 38.0 Molded Case Circuit Breakers Molded case circuit breakers used in load equipment (not distribution panels or MCCs) furnished under these Contract Documents shall be as listed in the following tables. AC SERVICE Interrupting Capacity (NEMA) AC DC Poles Service Volts ac Frame Rating amperes Trip Range Amperes Symmetrical Amperes Volts Amperes Volts 1 120 100 15 – 100 10,000 120 5,000 125 2 208 100 15 – 100 10,000 208 5,000 250 2 480 100 15 – 100 22,000 480 10,000 250 3 208 100 15 – 100 10,000 208 * * 3 480 100 15 – 100 42,000 480 * * 2 480 225 42,000 480 10,000 250 3 480 225 42,000 480 * * * The construction of all 3-pole circuit breakers furnished under these specifications shall be equivalent to the single-pole and 2-pole circuit breakers specified. This shall include heavy-duty construction and spacing between poles as required for dc rated circuit breakers. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 257 of 280 Calaveras Coal Yard 186144.77.1000 39.0 Not Used Compressed Air Equipment Construction Bid Issue 2Mar2015 40.0 Not Used 41.0 Not Used 42.0 Control Power Electrical power for control and instrumentation will be a nominal 120 volt, single-phase, 60 hertz, alternating current, or a nominal 125 volt direct current. The Supplier shall provide any devices required for proper operation and protection of the equipment during electrical power supply fluctuations described in the following paragraphs. All ac electrical control devices shall, unless otherwise specified, be designed for operation on a nominal 120 volt, 60 hertz, single-phase, alternating current system. The Supplier shall guarantee satisfactory operation when the equipment is continuously energized at any voltage from 102 to 132 volts alternating current. Equipment required for operation at other nominal voltages shall be guaranteed to operate satisfactorily over proportional voltage variations. The dropout voltage shall be less than 75 volts for relays and 90 volts for contactors and starters. All alternating current devices shall be guaranteed to operate satisfactorily under voltage conditions specified in the above paragraphs and at a range of ambient temperatures from 40°C to -20°C outdoors and from 40°C to -10°C indoors. DC voltage equipment is not allowed in the Calaveras coal yard. Source: 21000, 2011 Technical Supplemental Specifications 60.0100 - Supplier Furnished Equipment and Material Requirements Page 258 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Section 60.0110 - Site Design Conditions The Calaveras Plant conditions to be used as design and performance criteria shall be as described herein. These Site design conditions shall be used for the design and selection of all equipment and materials furnished unless otherwise stated. A. Meteorology. The climate in the vicinity of the Calaveras Lake Site is characteristic of the plains of South Texas. The Site ambient conditions are summarized as follows: Elevation 503 ft msl Design ambient temperature 110°F maximum 55°F minimum Dry- and wet-bulb temperature and duration Recorded dry-bulb (December – February) 99% of time above 25°F Recorded dry-bulb and mean coincident wet-bulb (June – September) 1% of time above 99°F/73°F Mean daily range (summer) 19°F Design wet-bulb 1% of time above 77°F 97.5% of time above 30°F 2.5% of time above 97°F/73°F 5% of time above 96°F/73°F 2.5% of time above 76°F 5% of time above 76°F Mean annual precipitation 29 inches B. Natural Phenomena Design Criteria. The design criteria based on natural phenomena shall be as follows. 1. Rainfall. The rainfall design basis may vary for the different systems and system components. a. Precipitation amounts to be used with each design basis are listed in Table 00.00001B-1 included herein for various durations and return periods. The data were obtained from the Rainfall Frequency Atlas of the United States, May 1961. 2. Wind Design Criteria. Wind loads for all structures and equipment shall be per the requirements of International Building Code (IBC), latest edition. The wind design criteria applicable to the project site location, is specified in IBC and shall be applicable to all works herein. Basic wind speed (3-second gust) shall be 90 miles per hour. A step function of pressure with height under Exposure C conditions shall be used. The building classification shall be Category III and accordingly the wind importance factor, Iw, shall be 1.15. a. The design wind pressures shall be determined by applying the above velocity pressures to the appropriate design equations in IBC for building, structure, equipment main wind-force resisting systems, other buildings, components and cladding and other variable design coefficients and factors. Source: 21000, 2011 Technical Supplemental Specifications 60.0110 - Site Design Conditions Page 259 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 3. Temperature. Systems and system component design criteria which require ambient temperature extremes shall use the range from -10°F to 110°F for dry-bulb temperatures. Equipment such as oil-filled power transformers shall be designed for a maximum daily average temperature of 100°F. 4. Relative Humidity. The average annual relative humidity is 67%. 5. Barometric Pressure. The average annual barometric pressure is 29.38 inches Hg abs based on a Site elevation of 503 feet above mean sea level. 6. Frost Depth. All foundations shall bear a minimum depth of 18-inches below finish grade unless a deeper minimum depth is determined to be applicable resulting from the Geotechnical Investigation. a. Frost protection for footings, pipes and other frost susceptible structures shall be designed according to the above criteria; however, unless special localized conditions exist, 18-inches shall be used for frost penetration design. b. Yard fire water and other yard fluid underground piping shall be installed with the depth of bury of the top of pipe relative to finish grade to be not less than the greater of the following (as based upon NFPA 24): (1) One (1) foot below the design frost penetration depth (2) 2.5 feet for normal applications (gravel surfaced grade) (3) 3.5 feet at driveways, roadways and other paved areas (4) 4.5 feet at railroad tracks 7. Seismic Design Criteria. The seismic design criteria applicable to the project site location, is specified in International Building Code (IBC), latest edition and shall be applicable to all herein. Seismic loads for all structures and equipment shall be per the requirements of IBC and the following: a. Mapped spectral acceleration for 0.2-second short period (SS) = 15.0% b. Mapped spectral acceleration for 1-second period (S1) = 4.0% c. Seismic Importance Factor (IE) = 1.25 d. Building Classification = Category III e. Seismic Use Group II Source: 21000, 2011 Technical Supplemental Specifications 60.0110 - Site Design Conditions Page 260 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Section 60.0200 - Electric Motor General Requirements 1.0 General Except for valve, gate and damper motor operators (Section 60.0300), HVAC compressor units, vent fans below 1.0 horsepower, sootblower motors, door operators, crane hoist motors, unit heater fan motors and elevator motors, the requirements of this section are applicable to all electric motors furnished under this Contract. Motor Data Sheets have been included in this section as required. Any motors for which Motor Data Sheets have not been included, but which are required for operation of the equipment, shall be furnished for review and approval by the Owner. In case of conflict between the requirements of the various parts of these Contract Documents relative to electric motors, the requirements of the different parts shall govern to the extent of such conflict in the following sequence: mandatory governmental regulations, codes and standards; Motor Data Sheets (when included); equipment requirements sections; this motor section; and the referenced industry codes and standards. 2.0 Codes and Standards All motors shall conform to applicable standards of ANSI, IEEE, NEMA and AFBMA, except where modified or supplemented by these requirements. In case of conflict between any of the industry standards relative to manufacturing covered in these requirements only by reference to the standards, the requirements of NEMA shall govern. All equipment and materials shall be in accordance with the applicable requirements of the “Federal Occupational Safety and Health Standards.” 3.0 Rating Alternating current motor voltage ratings with relation to horsepower shall be in accordance with the following. Horsepower Volts Phase Below 3/4 (Note 2) 115 1 3/4 thru 200 (Note 1) 460 3 201 and above 4,000 (or 6600 for ID Fan Motors) 3 Note 1 - Motors larger than 200 HP may be used with Purchaser approval. Motors shall be designed for full voltage starting and frequent starting where required and shall be suitable for continuous duty in the ambient temperature in which they are installed. Intermittent duty motors may be furnished where recognized and defined as standard by the equipment codes and standards and acceptable to the Owner. Motors shall be sized for the altitude at which the equipment will be installed. Motor winding insulation shall be Class F design, with Class B temperature rise at rated horsepower. Non-Variable Frequency Drive motor locked rotor current shall not exceed 6.29 x rated current for 460 V motors, 5.77 for motors rated through 500 horsepower and 5.59 for motors rated above 500 horsepower, except the 4000 V coal conveyor drive motors and 4000 V coal crusher drive motors which shall not exceed 6.32 locked rotor KVA/hp. Motors fed from variable frequency drives shall be designed for inverter duty as defined in NEMA MG-1. 4.0 Torque Characteristics Except as stated otherwise in the individual sections, technical sections, or Motor Data Sheets, the torque characteristics of all induction motors at any voltage from 80% rated voltage to 110% rated voltage shall be as required to ac enuous e the inertia loads of the motor and driven equipment to full speed without damage to the motor or the equipment. The starting time of the motor plus one (1) second shall not exceed the safe time while starting at voltages greater than or equal to 80% rated voltage. Source: 21000, 2011 Technical Supplemental Specifications 60.0200 - Electric Motor General Requirements Page 261 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 5.0 Guarantees All motors shall be guaranteed to perform in accordance with these requirements and the applicable standards. The following characteristics shall be guaranteed at rated voltage and 40°C ambient for all motors rated 100 horsepower and larger.     No load current and speed at rated voltage. Locked-rotor current at rated and 80% voltage. Power factor at full, three-fourths, one-half load and no load. Efficiency at full, three-fourths, one-half load and no load. The motor current shall change linearly (i.e. no saturation of the core steel) within the normal 90 to 110% voltage range. The no load current and speed guarantees for the boiler circulating pump motors is not required. (For a wet stator pump/motor, where the impeller is attached to the motor during all operating conditions, no load conditions will exist.) Source: 21000, 2011 Technical Supplemental Specifications 60.0200 - Electric Motor General Requirements Page 262 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Section 60.0220 - 460 Volt Integral Horsepower Motor Requirements 1.0 Design and Construction Design and construction of each 460 volt integral horsepower motor shall be coordinated with the driven equipment requirements and shall be as stated herein. 1.1 Nameplates. The following nameplate data shall be included.    Starting limitations, if any, AFBMA bearing identification number for motors furnished with rolling element bearings, For motors designed for service in hazardous areas: o Location class and group designation. o Maximum operating temperature value or operating temperature code number. All motor nameplates and attachment pins shall be corrosion-resistant metal. 1.2 Enclosures All motors shall be self-ventilated. Enclosure parts for all motors (e.g., frames, bearing brackets, external fan covers) shall be made of cast iron, cast steel, sheet steel, or steel plates. Aluminum enclosure parts are not acceptable and open enclosures are not allowed in the Calaveras coal yard. Fan direction shall be clearly identified on the nameplate. 1.2.1 Totally Enclosed Motors. Totally enclosed motors shall be furnished with rotating shaft seals where available. Drain holes shall be provided for all totally enclosed motors. Totally enclosed motors shall have all exposed metal surfaces protected with a polyester paint or coating and shall have enclosure interior surfaces and the stator and rotor air gap surfaces protected with an alkyd enamel or with polyester or epoxy paint or coating. Bolts, nuts, screws and other hardware items shall be heavy cadmium plated metal. 1.2.2 Motors for Hazardous Locations. Motors located in Class II, Group F locations shall be UL approved and labeled. Construction of motors for Class II, Group F locations shall be dust ignition proof in accordance with UL 674 requirements except the surface temperature for dust ignition proof motor enclosures shall not exceed 120°C under maximum load conditions of nameplate rated current times service factor in accordance with NEC 502- 8(b). A temperature sensing device with one single-pole single-throw contact which operates on high temperature shall be provided within motors located in hazardous areas. The device shall monitor the motor enclosure external surface temperature and respond to excessive temperature from any cause. The device contact shall operate when the maximum motor enclosure surface temperature reaches 165°C for motors in Class II, Group F locations. The device shall be rated for 600 volt ac service and shall have a field convertible contact with a rated interrupting capacity of 5 amperes at 120 volts ac and 0.4 ampere at 125 volts dc. 1.3 Maximum and Minimum Horsepower. The maximum horsepower for 460V, 3-phase motors shall be 200HP except for fire pumps. The minimum horsepower for 460V, 3-phase motors shall be 3/4 HP. Source: 21000, 2011 Technical Supplemental Specifications 60.0220 - 460 Volt Integral Horsepower Motor Requirements Page 263 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 1.4 Sizing and Margin The motor nameplate horsepower multiplied by the motor nameplate service factor shall be 15% greater than the driven equipment operating brake horsepower without exceeding the total limiting temperature rise stated in these requirements. The motor shall provide sufficient torque required to match the driven load speed-torque curves for maximum load and worst case accelerating conditions. 1.5 Voltage The motor shall be capable of starting for a voltage range of 80% rated voltage to 110% rated voltage. The motor shall be capable of running at rated load for a voltage range of 90% rated voltage to 110% rated voltage while maintaining a linear voltage and current relationship. During voltage transients, the running motor shall continue to operate at 75% of rated voltage for 60 seconds. 1.6 Starting Current The locked rotor KVA/hp for motors rated below 200Hp shall not exceed 6.29 at rated voltage. All motors shall be capable of the number of hot and cold starts specified by NEMA. 1.7 Insulation and Windings All insulated windings shall have Class F non-hygroscopic insulation systems. All insulated winding conductors shall be copper. The insulation system shall be the manufacturer’s standard sealed insulation system. The insulation resistance corrected to 40°C shall be not less than motor rated kV+l meg ohms for all windings. 1.8 Temperature Rise The winding temperature rise for all motors, when operating at the nameplate horsepower multiplied by the service factor, shall not exceed the NEMA MG 1 requirements for a Class B insulation system. Service factor shall only be used for run out conditions. Where motors must be designed for ambient temperatures greater than 40°C, the observable temperature rise shall be reduced in accordance with NEMA MG 1 standards. Motors fed from variable frequency drives shall be designed for inverter duty. The increased eddy and stray losses due to harmonic currents shall be included with the temperature rise calculations. 1.9 Space Heaters All motors furnished in NEMA 180 Frame Series or larger shall have space heaters. Space heaters shall be rated 240 volts, single-phase, 60 hertz and operated at 120 volts. Space heaters shall be easily accessible and the leads shall be clearly labeled in the terminal housing as those of a spare set. Space heater leads shall be stranded copper cable with high temperature insulation and shall include terminal connectors. 1.10 Terminal Housings A single terminal housing for motor power leads and accessory leads shall be furnished on each motor. Terminal housings shall be cast iron, pressed steel, or fabricated steel. Gaskets shall be furnished between the housing and the motor frame. Source: 21000, 2011 Technical Supplemental Specifications 60.0220 - 460 Volt Integral Horsepower Motor Requirements Page 264 of 280 Calaveras Coal Yard Compressed Air Equipment 186144.77.1000 Construction 1.11 Leads All leads shall be wired into the motor terminal housing. All leads and their terminals shall be permanently marked in accordance with the requirements of NEMA MG 1, Part 2. Bid Issue 2Mar2015 Leads for dual voltage rated or for multi-speed motors shall be easily connected or reconnected in the terminal housing for the operating voltage or for the designed speeds. Permanent instructions for making these connections shall be furnished inside the terminal housing or on the motor frame or nameplate. 1.12 Terminals Cable type leads shall be provided with compression type terminal connectors. Terminal connectors shall be as follows or acceptable equal. Power Supply Cable Size Burndy Terminal Connector Copper 8 AWG and smaller YAV 6 AWG thru 4/0 AWG YA 250 Mcm and larger YA-2N 1.13 Ground Connectors Each motor shall be furnished with provisions for attaching a grounding connector to the motor frame inside the motor terminal housing. Motors larger than 100 HP shall have an additional frame ground outside the motor terminal box. 1.14 Bearings The type of bearing furnished shall be as stated in Article 4. 1.14.1 Sliding Type Bearings. For motors with sleeve bearings, the bearings, end bells and bearing housings shall be split type. 1.14.2 Antifriction Bearings. Antifriction radial and thrust bearings shall be designed and fabricated in accordance with AFBMA standards to have a minimum L-10 rating life of not less than 130,000 hours for direct coupled service, 100,000 hours for BFP Seal Water Injection pump motors and not less than 42,500 hours for belt or chain connected service. Grease lubricated radial bearings shall be doubleshielded where practical. Motors furnished with spherical roller thrust bearings shall also be furnished with deep groove radial guide bearings. One guide bearing shall be locked to the shaft so that the guide bearing will take upward thrust and to assure that the thrust bearing is always loaded. If spring-loading is furnished, the guide bearing shall not be preloaded during normal operation. Stacked antifriction bearings will not be acceptable, except as vertical thrust bearings in frame sizes up through NEMA 360 Series open type enclosures and up through NEMA 680 Series totally enclosed type enclosures. Where stacked bearings are furnished, matched pair precision tolerance bearings with flush ground sides shall be provided. Bearing seats on the shaft and in the bearing housing shall have accuracy equal to that of the bearing. 1.14.3 Bearing Lubrication Systems. Lubrication for oil lubricated bearings shall be furnished by an internal lubricant recirculation system. Grease lubricated bearings shall be self-lubricating and externally regreaseable. Bearings will be allowed to be furnished without provisions for re-lubrication when approved by the Purchaser. The Supplier shall provide a listing of 460 V integral and fractional HP motors which do not have provisions for re-lubrication. Source: 21000, 2011 Technical Supplemental Specifications 60.0220 - 460 Volt Integral Horsepower Motor Requirements Page 265 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 1.14.4 Miscellaneous Bearing Requirements. All bearing mountings shall be designed to prevent the entrance of lubricant into the motor enclosure or dirt into the bearings and shall be provided with pipes and drain plugs. Fittings for grease lubricated bearings and filler caps for oil lubricated bearings shall be arranged for safe, easy re-lubrication from the outside of the motor while the motor is in service. All oil lubricated bearings shall be provided with oil level sight glasses marked for required oil level at motor running and standstill. Sight windows or bottles shall be of a material not adversely affected by con enuous exposure to sunlight or cleansers. Sight glasses shall be Gits Style FG or BW-20, Tedeco P/NS, or acceptable equal. Bearing housings shall be designed to permit disassembly in the field for inspection of the bearings or removal of the rotor. Bearing lubricants shall contain a corrosion inhibitor. The Supplier shall furnish all lubrication information required to assure proper equipment startup and subsequent bearing maintenance. 1.15 Rotors All induction motors shall be constructed with copper bar or cast aluminum squirrel-cage rotors. Copper bar rotors shall be provided for motors NEMA 449T frame size and larger. Fabricated aluminum rotors are not acceptable. 1.16 Shafts The output shafts of motors furnished with sleeve bearings shall be circumscribed with permanent marks indicating the motor magnetic center and end float limits when level and running uncoupled with rated voltage and frequency applied. A permanent, identified reference point shall be indicated or attached to the bearing housing or shaft seal. 1.17 Torque Characteristics Motors shall have torques and locked-rotor current in accordance with NEMA MG 1, Part 12. Breakdown torque shall be greater than 190% of full load torque. 1.18 Temperature Detectors All temperature detectors shall be ungrounded. A grounding terminal for each temperature detector shall be included with the detector lead terminals. The grounding terminals shall be provided with internal wiring to a common ground connection. The internal wiring shall be removable. Thermocouple type temperature detectors shall be dual element ungrounded, of the ISA type specified in Section 60.0100 of these Contract Documents. Thermocouple extension wire shall be solid 18 AWG or larger. The detector temperature-sensitive tip shall be hermetically sealed and held in intimate contact with the outside diameter of the bearing Babbitt not over 1/8 inch from shaft surface of bearing Babbitt for sleeve bearings and on the outer race or in close proximity to the bearing metal for antifriction bearings. Thermocouple type detectors for bearings shall be insulated with magnesium oxide packed in a stainless steel protective sheath. 1.19 Sound Level The motor sound level shall be selected by the Supplier to conform to the overall motor driven equipment assembly sound level requirements. 2.0 Quality Control Tests and Inspections Each motor shall be tested and inspected at the manufacturer’s factory to determine that it is free from electrical or mechanical defects and to provide assurance that it meets these requirements. Test Source: 21000, 2011 Technical Supplemental Specifications 60.0220 - 460 Volt Integral Horsepower Motor Requirements Page 266 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 procedures shall be in accordance with IEEE No. 112 Test Procedure for Polyphase Induction Motors and Generators. 2.1 Tests and Inspections Routine tests as listed in NEMA MG 1 shall be performed on each motor. The following additional tests and inspections shall be performed on each motor rated 100 horsepower and larger if required by the Supplier to guarantee the performance of the motor.     Measurement of winding resistance. Inspection of bearings and bearing lubrication system. Measurement of efficiency at full, three-fourths and one-half load. Measurement of power factor at full, three-fourths and one-half load. 3.0 Manufacturers Motors shall be by one of the following manufacturers:               Motors 50 HP and above: ABB* Baldor Electric* General Electric Co. Reliance Electric* Siemens Energy and Automation, Inc. TECO Westinghouse Toshiba US Motors WEG Motors < 50 HP Baldor Electric Reliance Electric US Motors 4.0 Design and Construction Each horizontal motor shall be designed and constructed in accordance with the following requirements. Type Squirrel-cage Induction Voltage 460 volts, 3-phase, 60 hertz Mounting Horizontal Ambient temperature range As required for the environment in which the motor is installed Enclosure type Totally enclosed fan cooled or dust ignition proof (UL approved for Class II, Group F locations) as required for the environment in which the motor is installed Motor enclosure surface temperatures under maximum load and overload conditions shall be as indicated in this Section for motors for Class II, Group F locations. A temperature sensing device shall be furnished as indicated in this Section for motors for Class II, Group F locations. Source: 21000, 2011 Technical Supplemental Specifications 60.0220 - 460 Volt Integral Horsepower Motor Requirements Page 267 of 280 Calaveras Coal Yard 186144.77.1000 Insulation Compressed Air Equipment Construction Bid Issue 2Mar2015 Sealed The motors with NEMA 180 frame size and larger shall be furnished with space heaters Bearing type and bearing lubrication system Grease lubricated antifriction bearings in NEMA 440 Series frame sizes and smaller; oil ring lubricated self-cooled split sleeve bearings in frame sizes larger than NEMA 440 Series Shaft Solid Each vertical motor shall be designed and constructed in accordance with the following requirements. Type Squirrel-cage induction Voltage 460 volts, 3-phase, 60 hertz Mounting Vertical Ambient temperature range As required for the environment in which the motor is installed Enclosure type Totally enclosed fan cooled or dust ignition proof (UL approved for Class II, Group F locations) as required for the environment in which the motor is installed Motor enclosure surface temperatures under maximum load and overload conditions shall be as indicated in this Section for motors for Class II, Group F locations. A temperature sensing device shall be furnished as indicated in this Section for motors for Class II, Group F locations. Insulation Sealed The motors with NEMA 180 frame size and larger shall be furnished with space heaters Bearing types and bearing lubrication system Grease lubricated angular contact thrust bearings and deep groove radial guide bearings in frame sizes smaller than NEMA 440 Series; oil lubricated spherical roller thrust bearings and deep groove radial guide bearings in frame sizes from NEMA 440 Series through NEMA 500 Series Shaft Solid Source: 21000, 2011 Technical Supplemental Specifications 60.0220 - 460 Volt Integral Horsepower Motor Requirements Page 268 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Section 60.0230 - Motor Control The ac motor starters specified to be furnished with the equipment shall conform to the requirements herein and shall be manufactured to the standards identified herein. The general requirements apply to all standards. 1.0 General Requirements A motor starter for the air compressor (CCAD-CMP-4) shall be provided by the Supplier. The air compressor shall not use a reduced voltage starting scheme. A separate field disconnect (off skid) for the air compressor shall be provided by the Purchaser. Incoming power shall land on the breaker lugs of the skid mounted motor starter. Terminal blocks will not be provided for power termination points. Additional auxiliary contacts beyond what is required for the control interface on the air compressor are not required. The interrupting capacity of each combination starter (direct on-line starter, unless otherwise specified) shall be sufficient for the available fault current without damage to the breaker or to the starter. Each 3-phase, ac single-speed starter shall be furnished with one 3-phase set of manually reset thermal overload relays. Each 3-phase, ac two-speed starter shall be furnished with two 3-phase sets of manually reset thermal overload relays. Each overload relay shall have a trip class suitable for proper operation and protection of the equipment served by the starter. For each ac starter, a dry type control power transformer shall be furnished complete with each primary lead fused and one secondary lead fused with the other secondary lead grounded (earthed). The primary leads shall be connected to two phases of the power conducting circuits. Large ac size starters which require line voltage to energize the operating starter coils shall be equipped with auxiliary interposing relays for use in the operating coil circuit. These interposing relays shall be operated from the low voltage circuit of the control transformers. Two-speed starters and reversing starters, where required, shall be mechanically and electrically interlocked so that only one set of contacts can be closed at any one time. Unless otherwise specified, any starter that uses remote control from the Purchaser’s control system shall be provided with an interposing relay to interface with the contactor coil if the contactor coil inrush exceeds 600 volt-amperes. Single-phase ac starters shall be similar to 3-phase starters, except that a single-phase set of manually reset thermal overload relays shall be provided and control power transformers will not be required if the line voltage is the same value as the specified control voltage. AC contactors shall be similar to ac starters, except that no overload protection shall be required. 2.0 Combination AC Motor Starters Combination ac motor starters shall be in accordance with NEMA ICS 2 and shall consist of the following:    An isolating device consisting of a 3-phase molded (moulded) case adjustable magnetic trip only circuit breaker. Contactors with manually reset thermal overload relays. Ac operating coils at specified control voltage. Unless otherwise specified, the following criteria apply to the starters specified to be furnished: Standard to Which Motor Starters Shall Be Manufactured Source: 21000, 2011 NEMA Technical Supplemental Specifications 60.0230 - Motor Control Page 269 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction AC Motor Starter Control Voltage 120 volts, 60 hertz W Spare Terminal Points 20% Source: 21000, 2011 Technical Supplemental Specifications 60.0230 - Motor Control Bid Issue 2Mar2015 Page 270 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Section 60.0400 - Quality System Requirements These requirements do not supersede any requirements of the purchase order. If the Supplier believes that an inconsistency exists between this document and the specification(s) and referenced codes and standards, the Supplier shall immediately notify Purchaser for resolution. 1.0 General Quality System Requirements 1.2 Quality System The Supplier and subtier suppliers shall define and implement a detailed and documented quality management system that is compliant with the International Organization for Standardization (ISO) 9001:2000 Quality Management System requirements. The Supplier's quality management system shall ensure that all equipment, services and commodities supplied are in conformance with the contract drawings and/or specifications and shall meet the requirements set forth in this document. The quality management system shall provide assurance that design, procurement, materials, manufacturing process, inspection and testing of equipment, shipping, storage and related services comply with the requirements of the purchase order. This quality management system shall be available to the Purchaser for review and/or audit. 1.3 Quality System Manual The quality management system shall be documented in the Supplier's quality system manual. One quality system manual shall be submitted to the Purchaser within 30 days after contract award. If the Supplier's program has been certified by a registered certification agency as satisfying the requirements of ISO 9001, a copy of the Certification Letter or Certification of Authorization shall be submitted along with the quality system manual. Revisions to the quality system manual shall be submitted to the Purchaser throughout the life of this purchase order. If the Supplier has previously submitted a controlled quality system manual to the Purchaser, the Supplier shall submit (in writing) the following information:      Title and number designation of the document, e.g., QP 500 Quality Assurance Manual. Applicable location(s). Revision level and date of the manual that is currently being used. Controlled manual number. Project name for which the document was initially provided. 1.4 Subtier Suppliers The Supplier shall obtain the Purchaser's approval in writing prior to using subtier suppliers for manufacturing activities. Material suppliers are exempted from these requirements. All applicable requirements of the purchase order (i.e., technical, quality and administrative) shall be passed on to the applicable organizations within the Supplier and subtier supplier's company. The Supplier shall ensure that subtier suppliers have the capabilities to fulfill purchase order requirements. Suppliers shall submit required procedures, drawings and/or other submittals when required for approval and/or information of subtier supplier's capabilities, processes, or in-process work involving the fabricating and manufacturing of equipment and commodities for the Purchaser. In accordance with this Supplemental Specification, subtier supplier qualification and monitoring are the responsibility of the Supplier to ensure adherence to the same quality standards of the Supplier. When deemed necessary, the Purchaser has the authority to perform quality audits and inspections and monitor and/or review subtier supplier processes and facilities. 1.5 Inspection and Test Plan In accordance with the Schedule of Contract Submittals, a detailed inspection and test plan (i.e., a Quality Assurance/Quality Control Plan) for the work/equipment shall be submitted to the Purchaser as specified in the purchase order prior to starting fabrication. The Purchaser will designate any test witness points or other inspection points required. The inspection and test plan shall identify the inspection and testing Source: 21000, 2011 Technical Supplemental Specifications 60.0400 - Quality System Requirements Page 271 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 points, including the acceptance criteria, for major components of the work and it shall be maintained current throughout the contract. The plan shall include the Supplier's strategy for inspecting subtier supplier's work, including inspection by the Supplier at his subtier supplier's facilities. The Supplier shall inspect the work of subtier suppliers to the extent necessary to ensure that proper materials and equipment are furnished and that fabrication and assembly are accomplished in accordance with the contract documents. Commercial, off-the-shelf, manufactured items may be exempted from these requirements. The Supplier shall keep the Purchaser informed of the progress of the work and shall notify the Purchaser at least 10 working days in advance of the appropriate times for inspections and testing, when such inspection and test points have been designated by the Purchaser as witness and/or hold points. The work shall not progress past the Purchaser's designated hold point until the Purchaser has verified the work or witnessed the designated test. A witness point is an important step in manufacturing in which the Supplier is obligated to notify the Purchaser in advance of the performed operation so that it may be witnessed. If the Purchaser is not present at the time and date specified by the Supplier, the Supplier may proceed. A hold point is a designated stopping place during or following a specific activity at which the Purchaser's inspection or witness is required before further work can be performed. The Supplier may not proceed beyond the hold point without inspection or witness by the Purchaser unless prior written authorization is obtained from the Purchaser. The Purchaser may waive the witness of tests; waivers for hold points shall be in writing. Waivers in no way absolve or relieve the Supplier of complying with contractual requirements. If the Supplier has notified the Purchaser defining the specific test date and time and the Supplier is not ready to conduct the test at the stated date and time, the Supplier shall be accountable for expenses incurred by the Purchaser. 1.6 Inspections by Purchaser The Purchaser may elect to perform assessments, quality audits, or witness testing at any time during the manufacturing process. The Purchaser may designate an authorized agent for assessments, witness testing, or quality audits. Authorized agent may be an employee of the Purchaser or an outside agency. When an outside agency is designated as an authorized agent for the Purchaser, such designation will be in writing with a copy provided to the Supplier. Hereinafter, when the term "Purchaser's representative" is used, it may also mean the Purchaser or the authorized agent. The following requirements shall apply for Purchaser's inspection at the Supplier's mill, factory, yard, warehouse, or subtier supplier's facilities. 1.7 Access The Purchaser shall have the right to access the Supplier's and subtier supplier's work and related documents during the manufacturing process without delaying the schedule. The Supplier shall provide, without cost, reasonable facilities including tools, personnel and instruments for demonstrating acceptability of the work. 1.8 Surveillance Activities In accordance with the purchase order designated hold points for witnessing, mill and/or factory tests shall be performed in the presence of the Purchaser's representative unless waived in writing by the Purchaser's representative. The Supplier shall bear all costs for such tests, except the compensation and expense of the Purchaser's representative. 1.9 Control of Special Processes It is Supplier's responsibility to ensure that qualified personnel are employed to perform special processes such as welding, nondestructive examination (NDE), coating, painting, etc. If special processes were Source: 21000, 2011 Technical Supplemental Specifications 60.0400 - Quality System Requirements Page 272 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 conducted by unqualified employees, the Purchaser has the right to validate and test the product at Supplier's expense and/or reject the product. 1.10 Corrective Action Upon identification of a noncompliance with the requirements of the purchase order, the Supplier shall document the noncompliance issue. For noncompliance issues where the nonconforming characteristic can be restored to a condition such that the capability of an item to function reliably and safely is unimpaired, even though that item still does not conform to the original requirement, the Supplier shall submit the noncompliance to the Purchaser for approval. During witness and hold point activities, if the Purchaser's representative identifies a noncompliance issue, the Supplier shall document the noncompliance issue and provide a copy of the report to the Purchaser's representative. If the Supplier disagrees and does not document the noncompliance, the Purchaser's representative shall issue a corrective action report to the Supplier for disposition and action. The Supplier shall correct, in a timely manner, all deficiencies identified. 1.11 Rejection If any items or articles are identified that do not meet the requirements of the specifications, the lot, or any faulty portion thereof, may be rejected. Before offering specified materials or equipment for shipment, the Supplier shall inspect the material and equipment and eliminate any items that are defective or do not meet the requirements of the purchase order. The fact that equipment or materials have been previously inspected, tested and accepted does not relieve the Supplier of responsibility in the case of later discovery of flaws or defects. 1.12 Receipt Inspection Materials or equipment purchased under this purchase order may be inspected at the specified receiving points and will either be accepted or rejected. Receipt inspection will include testing to determine compliance with the purchase specifications. Initial receipt inspection acceptance tests will be performed by the Purchaser at the Purchaser's expense. Items found to be defective may be returned to the Supplier for correction at the Supplier's expense, including shipping cost or the cost to correct and inspect the item will be charged to the Supplier. 2.0 ASME Boiler and Pressure Vessel Code Compliance 2.1 Quality System In addition to the provisions of Article Q001.1, the Supplier's quality system shall comply with and be based on the applicable quality system requirements of the ASME Boiler and Pressure Vessel Code. 2.2 Quality System Manual The quality system shall be documented in a quality system manual. One controlled manual shall be submitted to the Purchaser along with a copy of applicable ASME Certificates of Authorization. Revisions to the quality system manual shall be submitted to the Purchaser throughout the life of this purchase order. If the Supplier has previously submitted a controlled quality system manual, the Supplier shall provide (in writing) the following information:     Title and number designation of the document, e.g., QP 500 Quality Assurance Manual Applicable location(s). Revision level and date of the manual that is currently being used. Controlled manual number. Project name for which the document was initially provided. Source: 21000, 2011 Technical Supplemental Specifications 60.0400 - Quality System Requirements Page 273 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Section 60.0500 – Shop and Field Welding Requirements 1.0 General This Section covers shop and field welding of all equipment and materials furnished under these Contract Documents. If requirements stated herein are in conflict with the detailed equipment and material requirements, the detailed requirements shall govern to the extent of such conflict. Detailed requirements for welding of equipment and materials are included in the following sections.   Section 60.0500A – Carbon and Low Alloy Steel Welding Section 60.0500B – Pressure Vessel Welding 2.0 Application The welding requirements described herein shall apply to all equipment, materials, components and construction described in the Technical Requirements of these contract documents. The welding requirements shall be applicable to any and all welding performed by Contractor, his subcontractors, equipment or material suppliers, vendors, or other persons performing welding for Calaveras coal yard. Where the term Contractor is used in this section, the same requirements shall apply to his subcontractors, equipment or material suppliers, vendors, or other persons performing welding. Welding performed to standards other than ASME, such as JIS or DIN standards, shall meet the requirements of those standards, as well as general requirements of Section 60.0500. 3.0 Procedures for Welding Procedures for all the types of welding, welding controls, material controls and heat treatment described herein shall be submitted to Owner for review in accordance with the requirements described in Section 60.0050 of these Contract Documents for compliance submittals. These include the following.           Welding Procedure Specifications (WPS) for each welding process used including all supplemental Procedure Qualification Records (PQR) shall be submitted prior to the start of work and are subject to Owner’s review. Pressure part welders furnished by Contractor for this work must be certified in accordance with ASME and AWS guidelines. A copy of welder certification for each welder must be on file with Contractor and available for Owner’s review at all times before he/she is allowed to weld. Under no circumstances shall any welder without certification documents in Contractor’s file be allowed to weld on any pressure parts. Production welds are not to be used for welder certification. Any welds made by welder(s) without certification documents on file shall be removed and re-welded at Contractor’s expense. A dedicated, full time, QA/QC inspector shall be present at all times when welding is being performed. Electrode storage and handling procedure. Procedure for the detection of free iron contamination. Root side gas purging procedure. Post weld heat treatment procedure. Solution heat treatment procedure. Contractor shall maintain a weld map for all pressure part welds. The map shall contain the welder’s name(s), the date of welding, the inspection method (x-ray, visual, etc.), inspection date and if the weld passed inspection. A copy of the up-to-date map shall be maintained in Contractor’s office for Owner to review at any time. One copy of the weld map shall be provided to Owner upon project completion. Welding shall not begin until Owner’s review of procedures is complete. 4.0 Testing and Inspection Owner may make periodic visits to Contractor’s facilities for the purpose of inspecting welds, welding operations, welding records, material certifications, NDE personnel qualification and welder qualification Source: 21000, 2011 Technical Supplemental Specifications 60.0500 – Shop and Field Welding Requirements Page 274 of 280 Calaveras Coal Yard Bid Issue Compressed Air Equipment 186144.77.1000 Construction 2Mar2015 records. All weld testing and inspection shall meet the requirements of ASME, AWS and NBIC standards. In addition to the standards, the testing and inspection shall meet the following requirements. Compliance with the requirements of ASME B31.1 shall be verified by a recognized insurance company or inspection company. Compliance with the requirements of the ASME Boiler and Pressure Vessel Code shall be verified by an authorized code inspector. Tests and inspection data for all of the types of welding described herein shall be maintained by Contractor for a period of one (1) year after commercial operation, at this time the Contractor shall turn all documentation over to Owner. This includes the following.       Welder qualification test records submitted prior to start of work. Nondestructive test procedures. Nondestructive test reports. Visual inspection test records. Post weld heat treatment recorder charts. Solution heat treatment recorder charts. Contractor shall radiograph a minimum of 10% of all factory and field made pressure part welds and shall radiograph a minimum of 15% of all P91/T91 factory and field made pressure part welds. Welds to be radiographed will be selected by Owner. Radiographing shall include a minimum of 10% of each welder’s work. All tube weld radiographs shall be doublewall. If unacceptable welds are found Contractor shall notify Owner, repair the failed weld and radiograph an additional 10% per failed weld (of the total number of welds made up to that time and of that type) at Contractor’s expense. This process shall continue until no unacceptable welds are found. As stated above, one (1) year after commercial completion, the developed film and related documentation shall be supplied to Owner at no cost to Owner. All testing shall be performed while work is in progress. Personnel responsible for inspection and acceptance of welds shall be qualified and certified at Level II per ASNT-TC-1A. Radiography shall meet the acceptance criteria of ASME Section I and V. Radiography of pressure part welds shall occur after post weld heat treatment. Personnel performing welding inspection shall be responsible for verifying that all aspects of the welding operation are in accordance with the requirements of ASME and AWS. Owner will observe fieldwork while in progress. Owner may order welding tests in addition to those required herein. If the weld is defective, the laboratory costs shall be paid by Contractor. If the weld is not defective, the laboratory costs shall be paid by Owner. Repair of defective welds and re-inspection shall be at Contractor’s expense. Weld quality standards shall be as set forth in the referenced codes, standards and these documents. A defective weld shall be any weld that requires correction under the terms of the referenced codes, standards and these documents. Owner will make every effort not to impede Contractor’s work with additional testing and observation; however, Contractor is expected to accommodate Owner at no additional cost. Source: 21000, 2011 Technical Supplemental Specifications 60.0500 – Shop and Field Welding Requirements Page 275 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Section 60.0500A - Carbon and Low Alloy Steel Welding 1.0 General This Section covers the welding of carbon and low alloy steel components except welding of sheet metal and piping components. Except as otherwise defined, all welding of steel components shall be performed in accordance with the following requirements. All welders, welding operators and tackers shall be qualified in accordance with Section 60.0500. Testing and documentation shall be performed in accordance with the Supplier’s D/B Contractor approved procedures. All test records and qualification records shall be made available to the D/B Contractor and their representatives. 2.0 Joints Joint details for the welding processes used on the austenitic stainless steel and high nickel alloy shall be included in the written Welding Procedure Specifications. 3.0 Filler Metal All welds shall be made with the addition of filler metal. Filler metal for ASTM A588 and similar corrosion-resistant plate, sheet, shapes and tubular materials shall be in accordance with the requirements of Table 4.1.4 of the referenced AWS code. Only the filler metal in Table 4.1.4 may be used. Exceptions in the AWS code shall not apply All welding shall be performed using only joint details which have pre-qualified status in the referenced AWS code, unless otherwise defined herein. The Supplier shall provide for care and maintenance of filler metals to prevent damage from the atmosphere or misapplication of the filler metals. Filler metal shall be selected to be of a low hydrogen characteristic. Any special requirements for heating, storage, or handling of filler metal or fluxes shall be defined by the Supplier in the written Welding Procedure Specifications or in a separate electrode storage and handling procedure. The storage conditions shall be as recommended by the electrode manufacturer. 4.0 Welding Procedure Specifications Written Welding Procedure Specifications and Procedure Qualification Test reports shall be provided for the carbon and low alloy steel materials. All welds, welding and related operations for fabrication of carbon steel and low alloy steel shapes, plates and bars shall be in conformance with the latest AWS D1.1 Structural Welding Code – Steel. Welding procedure and qualification format shall comply with the latest AWS D1.1 Structural Welding Code – Steel. Welding of materials or combinations of materials not provided for in the referenced AWS code shall be subject to welding procedure qualification testing in accordance with Section 5 of the AWS code or ASME Section IX. The maximum diameter electrode used for the shielded metal arc welding process shall be 5/16 inch. Welding electrodes, welding filler metal and welding processes shall be of a type that will minimize exposed hydrogen gas around the molten weld pool. Weld deposits shall be made with welding electrodes that will have a minimum tensile strength that meets the requirements of the design. The maximum diameter filler rod used for the gas tungsten arc welding process shall be 3/32 inch. Source: 21000, 2011 Technical Supplemental Specifications 60.0500A - Carbon and Low Alloy Steel Welding Page 276 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction All welds shall be properly identified and sized on detailed shop drawings. If a conflict exists between symbols specified in AWS D1.1 and AWS A2.4, the requirements of AWS D1.1 shall govern. Welds shall be sized to develop the full strength of the least strength component involved in the connection. All tack welds shall either be incorporated into, or removed from, the final assembly. All temporary welds used for erection, lifting lugs, etc., shall be removed as well as weld splatter and the area ground flush, primed and finish painted. Components to be welded shall be accurately positioned and shall be rigidly secured during welding. All pre-qualified butt weld, corner joints and grooved T-joints shall be full penetration welds. All welds shall be chipped and sandblasted or wire brushed to remove all flux, scale and spatter. 5.0 Welding Methods Only the following welding methods will be permitted subject to proper code qualification.     Shielded metal arc welding (SMAW). Gas tungsten arc welding (GTAW) (With addition of filler metal only. Short-circuiting transfer mode not acceptable). Flux cored arc welding (FCAW) (With external shielding gas only). Submerged arc welding (SAW). The short-circuiting transfer mode of the gas metal arc welding process is not permitted. Other welding processes may be used provided they are qualified by applicable tests as prescribed in the AWS D1.1 and approved by D/B Contractor prior to use. For the use of any other welding process, Supplier shall prepare and submit to D/B Contractor for approval, a qualified welding procedure specification and the procedure qualification test results. 6.0 Testing and Inspection The Supplier shall be responsible for the inspection of the work to ensure conformance to the requirements of these documents. Testing and Inspection shall be performed in accordance with Section 60.0500 and all applicable codes. Personnel performing welding inspection shall be responsible for verifying that all aspects of the welding operation conform to the Supplier’s written Welding Procedure Specifications and the applicable codes. 6.1 Beam Connection Angles The first 15 shear loaded beam connection angles as identified on the Supplier’s fabrication drawings shall receive 100% magnetic particle testing. Unless otherwise required herein, testing shall meet the qualifications and inspection requirements of the referenced AWS code. If none of the first 15 connections require welding repairs, inspection shall be continued randomly at the rate of one inspection per 50 connections produced. If welding repairs are required due to defects disclosed, then testing shall be continued for every connection until 15 consecutive connections are found to be non-defective. Thereafter, testing shall be at the rate of one test per 50 connections. Source: 21000, 2011 Technical Supplemental Specifications 60.0500A - Carbon and Low Alloy Steel Welding Page 277 of 280 Calaveras Coal Yard 186144.77.1000 Bid Issue 2Mar2015 Compressed Air Equipment Construction Section 60.0500B – Pressure Vessel Welding 1.0 General This Section covers the welding of carbon and low alloy steel pressure vessels and vessel parts. Except as otherwise required, all welding of vessel components shall be performed in accordance with the following requirements. All welds, welding and related operations for fabrication of pressure vessels shall be in strict conformance with the requirements of the latest edition of the ASME Boiler and Pressure Vessel Code and the supplementary requirements described herein. Welds shall be properly identified and sized on the Supplier’s drawings. Welding electrodes, filler metal and welding processes shall be of a type that will minimize exposed hydrogen gas around the molten weld pool. 2.0 Qualification and Procedures All welding procedures, welders and welding operators shall be qualified in accordance with the requirements of Section IX, Welding and Brazing Qualifications, of the ASME Boiler and Pressure Vessel Code. The welding procedures shall be written in conformance with the code edition and addenda stated. The welding procedures shall include the joint design details, welding current and voltage values to be used. All welders, welding operators and tackers shall be qualified in accordance with Section 60.0500. Testing and documentation shall be performed in accordance with the Supplier’s D/B Contractor approved procedures. All test records and qualification records shall be made available to the D/B Contractor and their representatives. 3.0 Welding Methods All welding shall be performed using an electric arc welding process which has been qualified in accordance with the rules of the code. Only the following welding processes will be permitted.      Shielded metal arc (SMAW). Gas tungsten arc (GTAW) (with addition of filler metal only). Flux cored arc (FCAW) (with external shielding gas only). Gas metal arc (GMAW) (short-circuiting transfer mode not acceptable). Submerged arc (SAW). 4.0 End Preparation Butt weld ends to nozzles and other connections that are welded by other contractors shall be machined in accordance with the requirements of the latest revision of ANSI B16.25, Butt welding Ends. 5.0 Filler Metal The Supplier shall provide for care and maintenance of filler metals and submerged arc flux to prevent damage from the atmosphere or misapplication of the filler metals. When low hydrogen electrodes are specified in welding procedures, they shall be stored and handled during use in a manner that will maintain their low hydrogen characteristics. The method used for storage, issuance, handling and reconditioning shall be described in a detailed procedure and made available to appropriate shop personnel. For the SMAW process, all filler metal shall be of the low hydrogen type. Source: 21000, 2011 Technical Supplemental Specifications 60.0500B – Pressure Vessel Welding Page 278 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Multi-pass welds made with the submerged arc welding process shall be made with an essentially neutral flux. 6.0 Preheat and Interpass Temperature Preheat and interpass temperature shall be maintained in accordance with the qualified welding procedure and the guidelines in ASME Section VIII. Electric or gas heat sources which provide a uniform application of heat over the weld area shall be used. The same preheat temperatures required for specific welds is also required prior to arc gouging of those welds or their base materials. Preheat and interpass temperatures shall be checked by the use of temperature indicating crayons, thermocouples, or surface contact type pyrometers. 7.0 Postweld Heat Treatment Stress relief of all welds shall be performed in accordance with the applicable requirements of the qualified welding procedure and the referenced code. Detailed instructions for post weld heat treatment shall be given in a post weld heat treatment procedure. The procedure shall include in its instructions the approximate locations of thermocouples used and cycle heating and cooling rates. Thermocouple placement shall include the thickest and thinnest portions of the vessel. Post weld heat treatment may be accomplished by furnace heating or local stress relief using electric induction coils or electric resistance heating elements. For both furnace and local stress relief, a complete record of the temperatures throughout the stress relieving cycle shall be made by means of a recording potentiometer. Recorder charts shall be traceable to individual welds. The charts shall be maintained by the Supplier for a period until 1 year after commercial operation. 8.0 Testing and Inspection The Supplier shall be responsible for the inspection of the work to ensure conformance to the requirements of these documents. Testing and Inspection shall be performed in accordance with Section 60.0500 and all applicable codes. Personnel performing welding inspection shall be responsible for verifying that all aspects of the welding operation conform to the Supplier's written Welding Procedure Specifications and the applicable codes. Source: 21000, 2011 Technical Supplemental Specifications 60.0500B – Pressure Vessel Welding Page 279 of 280 Calaveras Coal Yard 186144.77.1000 Compressed Air Equipment Construction Bid Issue 2Mar2015 Section 60.0600 - Compressed Air Filtered, dried, oil free compressed air will be supplied for operation of pneumatic instruments and control valves. Normal service air will be supplied for operation of other pneumatic devices. The compressed air will be supplied at receiver pressure varying from 60 to 150 psi (400 to 1,000 kPa). Pressure regulators with pressure gauges shall be provided for pneumatic devices which operate at pressure levels less than maximum receiver pressure. Where pneumatic drives operate at full receiver air supply pressure, air filters shall be furnished. Air filters shall be provided with pressure gauges. Source: 21000, 2011 Technical Supplemental Specifications 60.0600 - Compressed Air Page 280 of 280 Calaveras Coal Yard 186144.77.1000 Source: Att, 2011 Compressed Air Equipment Construction Attachments Attachments Bid Issue 2Mar2015 8 7 APPROVED 06/Feb/2015 00:08:16 GMT 6 5 4 3 2 1 REVISIONS ZONE REV ECN A DESCRIPTION ORIGINAL RELEASE DATE DWN 02/02/15 MW APPVD NP FACE OF AIR INLET & OUTLET D D 40.42 2.00 TYP 53.00 33.00 29.00 TOWER INSULATION 40.50 (4) O .56 MOUNTING HOLES 2.00 TYP C 40.42 DESICCANT FILL PORT 11.50 FACE OF AIR OUTLET C ‰ OF AIR OUTLET ‰ OF AIR OUTLET TOWER PRESSURE GAUGE ELECTRICAL ENCLOSURE NEMA 4 PURGE FLOW VALVE 2'' FPT AIR OUTLET CONNECTION 73.38 PURGE FLOW GAUGE CONTROLLER & DISPLAY PANEL (SEE TECHNICAL MANUAL FOR DETAILS) ‰ OF AIR INLET RELIEF VALVE 82.50 DUST PARTICULATE AFTERFILTER BLUE MOISTURE INDICATOR B B 1/4'' MPT AUTOMATIC DRAIN CONNECTION 2'' FPT AIR INLET CONNECTION HIGH EFFICIENCY PREFILTER 40.00 PILOT AIR FILTER 1/4'' MPT AUTOMATIC DRAIN CONNECTION DESICCANT DRAIN PORT 1/4'' NPT AUTOMATIC DRAIN CONNECTION 12.19 59.62 *NOTES: 1) MAXIMUM WORKING PRESSURE - 150 P.S.I. 2) SAFETY RELIEF VALVE SETTING - 165 P.S.I 3) PILOT AIR LINE NOT SHOWN FOR CLARITY. 4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE'S LATEST EDITION. UNLESS OTHERWISE SPECIFIED, ALL DIMENSIONS ARE IN INCHES, TOLERANCES ARE: FRACTIONS ± X/XX DECIMALS ± .50 ± X.XXX ANGLE ± X.X° D O N OT SCAL E 8 7 FACE OF AIR INLET 40.42 A 6 5 17.00 ‰ OF AIR INLET 20.81 PROPRIETARY NOTICE THIS DRAWING CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION, IS THE PROPERTY OF INGERSOLL-RAND CO., AND IS GIVEN TO THE RECEIVER IN CONFIDENCE. THE RECEIVER BY RECEPTION AND RETENTION OF THE DRAWING ACCEPTS THE DRAWING IN CONFIDENCE AND AGREES THAT, EXCEPT AS AUTHORIZED IN WRITING BY INGERSOLL-RAND CO. IT WILL (1) NOT USE THE DRAWING OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE SECRET INFORMATION THEREIN; (2) NOT COPY THE DRAWING; (3) NOT DISCLOSE TO OTHERS EITHER THE DRAWING OR THE CONFIDENTIAL OF TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE NEED TO RETAIN THE DRAWING, OR UPON DEMAND, RETURN THE DRAWING, ALL COPIES THEREOF, AND ALL MATERIAL COPIED THEREFROM. 4 REMOVE ALL BURRS AND SHARP CORNERS CAD GENERATED DRAWING, NO MANUAL REVISIONS ALLOWED A NOUN CODE THIRD ANGLE PROJECTION DRAWN TITLE DATE MW 02/02/15 CHECKED COPYRIGHT @ 2006 INGERSOLL-RAND COMPANY ALL RIGHTS RESERVED 3 SIZE ESTIMATED WEIGHT B APPROVED NP 02/02/15 SCALE: 2 NONE UNIT: GENERAL ARRANGEMENT HL6001HGSCHZ01 SO# 81961255 DRAWING NO. 47531357 REVISION A SHEET 1 OF 1 1 120.11 Dryer General Arrangement and Foundation Plan Calaveras Coal Yard Compressed Air Equipment CCAD-DRY-4 HL DESICCANT DRYER HL6001HGSCHZ01 Compressed Air Systems and Services Davidson, NC 28036 DATE: 6-Feb-15 CANCELS: All Previous ENGINEERING DATA -40⁰F Inlet Capacity (scfm) Purge (SCFM Desiccant per Tower (lbs) Tower Diameter (inches) Electrical MCA / MOP (amps) Air In/Out Connections (inches) Width (inches) Depth (inches) Height (inches) Shipping Weight (lbs) HL600 600 88 374 16 115/1/60 4/5 2" NPT 60 55 83 1750 Capacity on all models is based on 100⁰F, 100 psig. Maximum allowable inlet temperature is 120⁰F. Maximum inlet pressure is 150 psig. Safety valve setting is 165 psig. NEMA cycle time for -40⁰F is 10 min. / 5 min. each vessel. 120.14 Dryer Data Sheet Calaveras Coal Yard Compressed Air Equipment CCAD-DRY-4 APPROVED 06/Feb/2015 00:08:16 GMT 120.23 Dryer Electrical Schematics Calaveras Coal Yard Compressed Air Equipment CCAD-DRY-4 140.10 Receiver General Arrangement Calaveras Coal Yard Compressed Air Equipment CCAD-TNK-4 BLACK & VEATCH CORPORATION BLACK & VEATCH CORPORATION ...\PLT_CY\Cy\Ed_Jks\capne1026.dgn 12/2/2014 3:14:41 PM Coating System 3301 Epoxy, Fusion Bonded (EPB) Project Energy-Std-2-03880-01420 Description Fusion bonded epoxy Surfaces Carbon steel or stainless steel First Coat Touchup Second Coat VOC Limits 2.83 lb/gal (340 g/L) N/A N/A Approved Products Coating manufacturers and products other than those listed herein are subject to Engineer's review/approval. Manufacturer First Coat Touchup 3M 6233 323 Jotun Corro-Coat EP-F 1010HW 120T640 Surface Preparation SSPC-SP10/NACE No. 2 Near White Blast Cleaning (Carbon Steel) SSPC-SP16 Brush-Off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steel, and Non-Ferrous Metals (Stainless Steel) Profile depth 2 to 4 mils (50 µm to 100 µm) Remarks Profile to be verified by Contractor using ASTM D4417 Method C. Welds to be prepared in accordance with NACE RP0178, Appendix C, Replica "E." Second Coat Dry Film Thickness (DFT) Generic Coating Type Minimum DFT Maximum DFT Shop (S) or Field (F) Applied First Coat EPB 14 mils (350 m) 20 mils (500 m) S Touchup SPC 25 mils (625 m) 28 mils (700 m) S, F Second Coat N/A Completed System 14 mils (350 m) REV DATE REVISIONS AND RECORD OF ISSUE BLACK & VEATCH BY SSPC-SP11 Power Tool Cleaning. Dry film thickness to be verified in accordance with NACE RP0394. Holiday testing required in accordance with NACE RP0490. 28 mils (700 m) APP Remarks 2 1 0 07/12/13 06/30/09 06/01/08 Expanded to Stainless Product Update Initial Issue GMA GRL BPL RHW RHW RHW REV DATE REVISIONS AND RECORD OF ISSUE BY APP COATING SYSTEM DATA SHEETS - SYSTEM 3301 Drawing No. 81113-DM-0664 Rev 2 Epoxy Coal Tar (EPT)/ Epoxy Coal Tar (EPT) Project Energy‐Std‐2‐03880‐01420 Description Epoxycoaltarprimerwithepoxycoaltarfinish Surfaces Carbonsteelorstainlesssteel Coating System 3311 FirstCoat Touchup SecondCoat VOCLimits 2.83lb/gal(340g/L) 2.83lb/gal(340g/L) ApprovedProducts CoatingmanufacturersandproductsotherthanthoselistedhereinaresubjecttoEngineer's review/approval. Manufacturer FirstCoat Touchup SecondCoat PPGAmercoat 78HB 78HB Carboline Bitumastic300M Bitumastic300M Sherwin‐Williams TarGuard TarGuard Tnemec Series46H Series46H Surface Preparation SSPC‐SP10/NACENo.2NearWhiteBlastCleaning(CarbonSteel) aapc‐sp16BrushoffBlastCleaningofNonferrousMetals(StainlessSteel) Profiledepth2to4mils(50µmto100µm) Remarks ProfiletobeverifiedbyContractorusingASTMD4417MethodC. WeldstobepreparedinaccordancewithNACERP0178,AppendixC,Designation"E." DryFilmThickness(DFT) MaximumDFT Shop(S)or Field(F) Applied Remarks 8mils(200m) 12mils(300m) S N/A SecondCoat EPT 8mils(200m) 12mils(300m) S Completed 16mils(400m) 24mils(600m) Dryfilmthicknesstobe verifiedinaccordancewith SSPC‐PA2. Generic Coating Type MinimumDFT FirstCoat EPT Touchup System Holidaytestingrequiredin accordancewithNACESP0188. REV DATE REVISIONS AND RECORD OF ISSUE BLACK & VEATCH BY APP 2 1 0 12/29/14 08/31/11 06/01/08 General Revision General Revision Initial Issue JTD GMA BPL RHW RHW RHW REV DATE REVISIONS AND RECORD OF ISSUE BY APP COATING SYSTEM DATA SHEETS ‐ SYSTEM 3311 Drawing No. 81113‐DM‐0665 Rev 2 Polyamide Epoxy (EPX)/Acrylic Waterborne (ACW) Coating System 1112 Project Energy‐Std‐2‐03880‐01420 Description Polyamideepoxywithacrylicfinish Surfaces Carbonsteel FirstCoat Touchup SecondCoat VOCLimits 2.83lb/gal(340g/L) 2.83lb/gal(340g/L) 2.83lb/gal(340g/L) ApprovedProducts CoatingmanufacturersandproductsotherthanthoselistedhereinaresubjecttoEngineer's review/approval. Manufacturer FirstCoat Touchup SecondCoat Carboline Carboguard880 Carboguard880 Carbocrylic3359DTM Hempel Hempadur45880 Hempadur45880 Hemucryl58030 International Intergard345 Intergard345 Intercryl530 Jotun JotacoteUniversal JotacoteUniversal WaterfineTopcoat PPGAmercoat 385 385 220 Sherwin‐Williams RecoatableEpoxyPrimer RecoatableEpoxyPrimer Sher‐CrylHPA Tnemec SeriesN69 SeriesN69 Series1028 Surface Preparation SSPC‐SP6/NACENo.3CommercialBlastCleaning Profiledepth1to2mils(25µmto50µm) Remarks ProfiletobeverifiedbyContractorusingASTMD4417MethodC. WeldstobepreparedinaccordancewithNACESP0178,AppendixC,Designation"E." DryFilmThickness(DFT) MaximumDFT Shop(S)or Field(F) Applied Remarks 4mils(100m) 6mils(150m) S EPX 4mils(100m) 6mils(150m) S,F SSPC‐SP3PowerToolCleaning (NonrustedAreasOnly). SSPC‐SP11PowerTool CleaningtoBareMetal(Bare MetalorRustedAreas). SecondCoat ACW 2mils(50m) 3mils(75m) S,F Completed System 6mils(150m) 9mils(225m) Dryfilmthicknesstobe verifiedinaccordancewith SSPC‐PA2. Generic Coating Type MinimumDFT FirstCoat EPX Touchup REV DATE REVISIONS AND RECORD OF ISSUE BLACK & VEATCH BY APP 2 1 0 12/29/14 09/19/11 06/01/08 General Revision Corporate Merger Initial Issue JTD GMA BPL RHW RHW RHW REV DATE REVISIONS AND RECORD OF ISSUE BY APP COATING SYSTEM DATA SHEETS ‐ SYSTEM 1112 Drawing No. 81113‐DM‐0667 Rev 2 BLAST MEDIA B1 Application Abrasive Blast Cleaning Potential Exposure N/A Substrate Steel or Concrete Surface1,2 Preparation Refer to Coating System Data Sheet for degree of surface preparation and surface profile required. As a minimum, steel surfaces shall be prepared to SSPC-SP6 and concrete surfaces shall be in accordance with SSPC-SP13. Generic Product Blast media shall be limited to cut steel wire (SAE J441), steel grit or shot, or other media acceptable to the Engineer. The blast media used shall contain no more than 1.2 percent complexed silica and no free silica. Notes: 1 Product data sheets on the blast media proposed by the Supplier shall be submitted to the Purchaser for review and acceptance prior to its use. Product data sheets shall include an ultimate analysis of the product indicating elemental silica content. 2 The Supplier shall be responsible for immediate and complete removal of ALL blast media from the component(s) before they are shipped to the jobsite, or before they are placed into service if blast occurs in the field. This includes all field cleanup costs incurred by the Purchaser if blast material is not completely removed by the Supplier. Approved Products Manufacturer Material Manufacturer Material Pan Abrasives PanaGrit (Steel Grit) CrystalGrit CrystalGrit PanaShot (Steel Shot) Premier Shot Co. Carbon Steel Cut Wire WireBlast Blast media manufacturers and products other than those listed herein are subject to Engineer's review/approval. Blast media product data sheets with chemical composition identifying complexed and free silica content must accompany any request for approval. REV DATE REVISIONS AND RECORD OF ISSUE BLACK & VEATCH BY APP 1 0 10/01/05 05/23/03 Product Update Initial Issue REV DATE REVISIONS AND RECORD OF ISSUE BLAST MEDIA DATA SHEETS - SYSTEM B1 BPL JPG RHW RHW BY APP Drawing No. 81113-DM-0700 Rev 1 CLIENT NAME PROJECT NAME PROJECT NUMBER 31CC2X SERVICES: Utility Air (AU) DESIGN CODE: RATING CLASS: MATERIAL/SPEC: C.A.: NOTES: ASME B31.3-2012 150 RF, ASME B16.5, GROUP 1.1 CS / A53 B ERW (0.85 Ej) 0.063 in G01 PRESSURE – TEMPERATURE RATINGS -20 - 100 200 300 TEMP F 285 260 230 PSIG 400 200 REMARKS: 1. This PMC is designed for the full flange rating within the temperature limit.. 2. 3. NPS 0.5 to 24 SIZE RANGE: NONE PWHT: INSP. CLASS: -20°F to 400°F TEMP LIMIT: None SPECIAL REQ.: 500 600 700 800 900 1000 1100 A NO Doc: File: DATE REVISIONS AND RECORD OF ISSUE XXXXXX-0000-M0100 – 31CC2X XXXXXX.56.4610 / 31CC2X BY CHK APP Page 1 of 4 CLIENT NAME PROJECT NAME PROJECT NUMBER 31CC2X Item Notes NPS1 SCH1 / Rating 0.5 -2 NPS2 SCH2 / Rating Ends Description XS PE 2.5 - 24 STD BE CS, SMLS, ASTM A106-B, (Ej=1.0) CS, ERW, ASTM A53-B, (Ej=0.85) G04 0.5 -2 XS PxT Swage (CONC) Swage (CONC) Swage (CONC) Swage (ECC) Swage (ECC) Swage (ECC) FITTINGS Sockolet Thredolet 90 ELL 45 ELL TEE Tee (RED) Plug G04 0.75 -2 XS 0.5 – 1.5 XS PxT 2.5 – 4 STD 0.5 – 2 XS BxP G04 2.5 – 4 STD 0.5 – 2 XS BxT G04 0.75 -2 XS 0.5 – 1.5 XS PxT 2.5 – 4 STD 0.5 – 2 XS BxP 2.5 – 4 STD 0.5 – 2 XS BxT 2.5 - 24 2.5 - 24 0.5 -2 0.5 -2 0.5 -2 0.5 -2 0.5 -2 CL 3000 CL 3000 CL 3000 CL 3000 CL 3000 CL 3000 0.5 -2 0.5 -2 Plug G03 Stockcode PIPE NIPPLES G04 G04 SW THRD SW SW SW SW THRD 0.5 – 1.5 0.5 -2 PE Coupling Coupling (RED) Cap Union 0.5 -2 0.75 - 2 CL 3000 CL 3000 0.5 -2 0.5 -2 CL 3000 CL 3000 SW SW 90 LR ELL 2.5 - 24 STD BW 45 LRELL 2.5 - 24 STD BW TEE 2.5 - 24 STD BW Tee (RED) 3 – 24 STD 2.5 – 20 STD BW Reducer (CONC) Reducer (ECC) CAP 3 – 24 STD 2.5 – 20 STD BW 3 – 24 STD 2.5 – 20 STD BW 3 - 24 STD Weldolet FLANGES Long Weld Neck Socket Weld 3 - 24 STD Doc: File: F04 2.5 - 20 XS XXXXXX-0000-M0100 – 31CC2X XXXXXX.56.4610 / 31CC2X CS, ASTM A105, MSS SP-97 CS, ASTM A105, MSS SP-97 CS, ASTM A105, ASME B16.11 CS, ASTM A105, ASME B16.11 CS, ASTM A105, ASME B16.11 CS, ASTM A105, ASME B16.11 CS, ASTM A105, ROUND HEAD, ASME B16.11 CS, ASTM A105, MANUFACTURER’S STD, 3 IN BAR STOCK CS, ASTM A105, ASME B16.11 CS, ASTM A105, ASME B16.11 STD BW CS, ASTM A105, ASME B16.11 CS, ASTM A105, INTEGRAL SEAT, MSS SP-83 CS, ASTM A234-WPB, ASME B16.9 CS, ASTM A234-WPB, ASME B16.9 CS, ASTM A234-WPB, ASME B16.9 CS, ASTM A234-WPB, ASME B16.9 CS, ASTM A234-WPB, ASME B16.9 CS, ASTM A234-WPB, ASME B16.9 CS, ASTM A234-WPB, ASME B16.9 CS, ASTM A105, MSS SP-97 CL 150 RF CS, ASTM A105, ASME B16.5 CL 150 RF CS, ASTM A105, ASME B16.5 BW 1.5 0.5 -2 SW SW 0.5 – 1.5 CS, SMLS, ASTM A106-B, (Ej=1.0) CS, ASTM A234-WPB-S, MSS SP-95 CS, ASTM A234-WPB-S, MSS SP-95 CS, ASTM A234-WPB-S, MSS SP-95 CS, ASTM A234-WPB-S, MSS SP-95 CS, ASTM A234-WPB-S, MSS SP-95 CS, ASTM A234-WPB-S, MSS SP-95 Page 2 of 4 CLIENT NAME PROJECT NAME PROJECT NUMBER 31CC2X Item Notes NPS1 Socket Weld Socket Weld Weld Neck Weld Neck Weld Neck Blind Pair WN Orifice GASKETS G03 G02 0.5 -2 0.5 -2 2.5 - 24 2.5 - 24 2.5 - 24 0.5 -24 3 - 24 STD 0.5 - 24 G03 G02 G03 G02 BOLTING Stud Bolts VALVES Ball Ball Ball Ball Gate Gate Globe Globe Lift Check Swing Check Dual PLT Check SCH1 / Rating XS XS STD STD STD NPS2 SCH2 / Rating CL 150 CL.300 CL 150 CL 150 CL 300 CL 150 CL 300 Ends Description FF RF RF FF RF RF RF CS, ASTM A105, ASME B16.5 CS, ASTM A105, ASME B16.5 CS, ASTM A105, ASME B16.5 CS, ASTM A105, ASME B16.5 CS, ASTM A105, ASME B16.5 CS, ASTM A105, ASME B16.5 CS, ASTM A105, ASME B16.36, 0.5 inch SW TAPS CL 150 RF 0.5 - 24 CL 150 FF 0.5 - 24 CL 300 RF FLAT RING, 1/16” THICK, NONASBESTOS, INORGANIC FIBER, ASME B16.21 for ASME B16.5 FLANGE FULL FACE, 1/8” THICK, NONASBESTOS, INORGANIC FIBER, ASME B16.21 for ASME B16.5 FLANGE SPIRAL WOUND, 1/8” THICK, 304 SS OCR, INNER RING AND WINDING, FLEXIBLE GRAPHITE FILLER, ASME B16.20 for ASME B16.5 FLANGE 0.5 - 24 Stockcode ASTM A193 GRADE B7 STUD W/ 2 HEAVY HEX HEAD NUTS ASTM A194 GRADE 2H G02 G03 0.5 – 2 0.5 – 2 0.5 – 2 CL 150 CL 150 CL 150 G02 1–2 2.5 - 12 14 - 24 0.5 – 2 2.5 - 12 0.5 – 2 2.5 - 24 2.5 - 24 CL 300 CL 150 CL 150 CL 800 CL 150 CL 800 CL 150 CL 150 SW SW SW x THRD RF RF RF SW RF SW RF WAFER CS BODY w/ 316 SS TRIM CS BODY w/ 316 SS TRIM, FP CS BODY w/ 316 SS TRIM BA01CB402 BA01CB403 BA01CB252 CS BODY w/ 316 SS TRIM CS BODY w/ 13CR TRIM, HF ST CS BODY w/ 13CR TRIM, HF ST CS BODY w/ 13CR TRIM, HF ST CS BODY w/ 13CR TRIM, HF ST CS BODY w/ 13CR TRIM, HF ST CS BODY w/ 13CR TRIM, HF ST CS BODY, w/410 SS DISK, ST BA01CB601 GA01CB501 GA01CB501 GL08CB300 GL01CB500 CL08CB300 CS01CB500 CD01CB700 NOTES: Doc: File: G01 Addition or substitution of components (material A vs. material B, welded vs. seamless, etc.) in this piping class requires approval from the Piping Engineer. G02 Component shall only be used when indicated on P&ID G03 Secondary component. Shall be used only when necessary. G04 Threaded components are permitted only at outlet of vent, drain, and instrument valves, and to match equipment. F04 Long weld neck flanges shall only be used for temperature instrument connections. XXXXXX-0000-M0100 – 31CC2X XXXXXX.56.4610 / 31CC2X Page 3 of 4 CLIENT NAME PROJECT NAME PROJECT NUMBER 31CC2X BRANCH 90° BRANCH CONNECTION 24 20 18 16 14 12 10 8 6 4 3 2.5 2 1.5 1 .75 .50 T R R R R W W W W W W W S S S S S 24 T R R R R W W W W W W S S S S S 20 T R R R W W W W W W S S S S S 18 T R R R W W W W W S S S S S 16 T R R R W W W W S S S S S 14 T R R W W W W S S S S S 12 T R R W W W S S S S S 10 R S T W = = = = T R W W W S S S S S 8 T R W W S S S S S 6 TEE (REDUCING) SOCKOLET TEE WELDOLET T R R S S S S S 4 T R S S S S S 3 T S S S S S 2.5 T R R R R 2 T R R R 1.5 T R R 1 T R .75 T .5 HEADER Doc: File: XXXXXX-0000-M0100 – 31CC2X XXXXXX.56.4610 / 31CC2X Page 4 of 4 CLIENT NAME PROJECT NAME PROJECT NUMBER SERVICES: Instrument Air (AI) DESIGN CODE: RATING CLASS: MATERIAL/SPEC: C.A.: NOTES: ASME B31.3-2012 150 RF, ASME B16.5, GROUP 2.3 SS A312-TP304, ERW (0.85 Ej) None G01 PRESSURE – TEMPERATURE RATINGS -20 - 100 200 300 TEMP F 230 195 PSIG A NO Doc: File: DATE 400 REMARKS: 1. This PMC is designed for the full flange rating within the temperature limit.. 2. NPS 0.5 to 4 SIZE RANGE: NONE PWHT: INSP. CLASS: -20°F to 200°F TEMP LIMIT: None SPECIAL REQ.: 500 REVISIONS AND RECORD OF ISSUE XXXXXX-0000-M0100 – 31SANX XXXXXX.56.4610 / 31SANX 31SANX 600 700 800 900 BY CHK 1000 1100 APP Page 1 of 4 CLIENT NAME PROJECT NAME PROJECT NUMBER Item Notes NPS1 SCH1 / Rating Ends Description 0.5 -2 40S PE 2.5 - 4 40S BE SS, SMLS, ASTM A312-TP304, (Ej=1.0) CS, ERW, A312-TP304, (Ej=0.85) G04 0.5 -2 40S PxT G04 0.75 -2 40S 0.5 – 1.5 40S PxT 2.5 – 4 40S 0.5 – 2 40S BxP G04 2.5 – 4 40S 0.5 – 2 40S BxT G04 0.75 -2 40S 0.5 – 1.5 40S PxT 2.5 – 4 40S 0.5 – 2 40S BxP 2.5 – 4 40S 0.5 – 2 40S BxT 2.5 - 24 40S 0.75 CL 3000 SW 0.5 -2 0.5 -2 0.5 -2 0.5 -2 0.5 -2 10S 10S 10S 10S PIPE NPS2 SCH2 / Rating 31CC2X Stockcode NIPPLES Swage (CONC) Swage (CONC) Swage (CONC) Swage (ECC) Swage (ECC) Swage (ECC) FITTINGS Sockolet G04 SS, SMLS, ASTM ASTM A312TP304, (Ej=1.0) SS, ASTM A403-WP304-S, MSS SP-95 SS, ASTM A403-WP304-S, MSS SP-95 SS, ASTM A403-WP304-S, MSS SP-95 SS, ASTM A403-WP304-S, MSS SP-95 SS, ASTM A403-WP304-S, MSS SP-95 SS, ASTM A403-WP304-S, MSS SP-95 PxP PxP SS, ASTM A182-F304, MSS SP97 SS, ASTM A182-F304 SS, ASTM A182-F304 SS, ASTM A182-F304 SS, ASTM A182-F304 SS, ASTM A182-F304, ROUND HEAD, ASME B16.11 SS, ASTM A182-F304, MANUFACTURER’S STD, 3 IN LONG BAR STOCK SS, ASTM A182-F304 SS, ASTM A182-F304 10S PxP SS, ASTM A182-F304 10S 10S PxP PxT SS, ASTM A182-F304 SS, ASTM A182-F304 0.5 -2 10S PxT SS, ASTM A182-F304 0.5 -2 10S PxP SS, ASTM A182-F304 0.5 -2 10S PxP SS, ASTM A182-F304 2.5 - 4 40S BW 45 LRELL 2.5 - 4 40S BW TEE 2.5 - 4 40S BW Tee (RED) 3–4 40S 2.5 – 3 40S BW Reducer (CONC) Reducer (ECC) 3–4 40S 2.5 – 3 40S BW 3–4 40S 2.5 – 3 40S BW SS, ASTM A403-WP304, ASME B16.9 SS, ASTM A403-WP304, ASME B16.9 SS, ASTM A403-WP304, ASME B16.9 SS, ASTM A403-WP304, ASME B16.9 SS, ASTM A403-WP304, ASME B16.9 SS, ASTM A403-WP304, ASME B16.9 90 ELL 45 ELL TEE Tee (RED) Plug Plug G03 Coupling Reducer (CONC) Cap Union Male THRD Adapter Female THRD Adapter Weld Adapter Flange Adapter 90 LR ELL Doc: File: 0.5 – 1.5 10S 0.5 -2 PxP PxP PxP PxP THRD PE 0.5 -2 0.75 - 2 10S 10S 0.5 -2 G04 0.5 -2 0.5 -2 G04 0.5 – 1.5 XXXXXX-0000-M0100 – 31SCNX XXXXXX.56.4610 / 31SCNX 10S Page 2 of 4 CLIENT NAME PROJECT NAME PROJECT NUMBER Item Notes CAP 3-4 SCH1 / Rating 40S Weldolet 3-4 40S FLANGES Long Weld Neck Weld Neck F04 Weld Neck Weld Neck NPS1 NPS2 2.5 – 3 1.5 SCH2 / Rating Ends Description BW 40S BW SS, ASTM A403-WP304, ASME B16.9 SS, ASTM A182-F304, MSS SP97 CL 150 RF 2.5 - 4 40S CL 150 RF G03 2.5 - 4 40S CL 150 FF G02 2.5 - 4 40S CL 300 RF CL 150 RF CL 300 RF Blind 0.5 - 4 Pair WN Orifice GASKETS Flange 3-2 40S 0.5 - 4 CL 150 RF Flange G03 0.5 - 4 CL 150 FF Flange G02 0.5 - 4 CL 300 RF BOLTING Stud Bolts VALVES Ball Ball Ball Ball Swing Check 0.5 - 4 G03 31CC2X Stockcode SS, ASTM A182-F304, ASME B16.5 SS, ASTM A182-F304, ASME B16.5 SS, ASTM A182-F304, ASME B16.5 SS, ASTM A182-F304, ASME B16.5 SS, ASTM A182-F304, ASME B16.5 SS, ASTM A182-F304, ASME B16.36, 0.5 inch SW TAPS FLAT RING, 1/16” THICK, NONASBESTOS, INORGANIC FIBER, ASME B16.21 for ASME B16.5 FLANGE FULL FACE, 1/8” THICK, NONASBESTOS, INORGANIC FIBER, ASME B16.21 for ASME B16.5 FLANGE SPIRAL WOUND, 1/8” THICK, 304 SS OCR, INNER RING AND WINDING, FLEXIBLE GRAPHITE FILLER, ASME B16.20 for ASME B16.5 FLANGE ASTM A193 GRADE B7 STUD W/ 2 HEAVY HEX HEAD NUTS ASTM A194 GRADE 2H 0.5 – 2 CL 150 0.5 – 2 2.5 - 4 2.5 - 4 2.5 - 4 CL 150 CL 150 CL 150 CL 150 SW x THRD SW RF RF RF SS BODY w/ 316 SS TRIM BA01SA250 SS BODY w/ 316 SS TRIM SS BODY w/ 316 SS TRIM SS BODY w/ 316 SS TRIM CS BODY w/ 13CR TRIM, HF ST BA01SA300 BA01CB600 BA01SR601 CS01SR600 NOTES: Doc: File: G01 Addition or substitution of components (material A vs. material B, welded vs. seamless, etc.) in this piping class requires approval from the Piping Engineer. G02 Component shall only be used when indicated on P&ID G03 Secondary component. Shall be used only when necessary. G04 Threaded components are permitted only at outlet of vent, drain, and instrument valves, and to match equipment. F04 Long weld neck flanges shall only be used for temperature instrument connections. XXXXXX-0000-M0100 – 31SCNX XXXXXX.56.4610 / 31SCNX Page 3 of 4 CLIENT NAME PROJECT NAME PROJECT NUMBER 31CC2X BRANCH 90° BRANCH CONNECTION 24 20 18 16 14 12 10 8 6 4 3 2.5 2 1.5 1 .75 .50 R S T W = = = = TEE (REDUCING) SOCKOLET TEE WELDOLET T R R S S S S S 4 T R S S S S S 3 T S S S S S 2.5 T R R R R 2 T R R R 1.5 T R R 1 T R .75 T .5 HEADER Doc: File: XXXXXX-0000-M0100 – 31SCNX XXXXXX.56.4610 / 31SCNX Page 4 of 4 8 7 6 5 4 3 2 1 18,579 825,579 REVISIONS ZONE NOTES: REV ECN A 83409 DESCRIPTION ORIGINAL RELEASE DATE DRAWN APP'D 2015FEB10 M.SHOREY S.BURRIS 1. WEIGHT (APPROXIMATE): R90I - 2420 KG (5335 LBS) 3 2. COOLING AIR FLOW: 320 M /MIN (11,200 CFM) 3. PIPE CONDENSATE DRAIN LINES SEPARATELY TO AN OPEN DRAIN DUE TO DIFFERENCES IN DRAIN PRESSURES. READ OPERATIONS MANUAL AND CHECK LOCAL REGULATIONS. D D 4. LUBRICANT FILL QUANTITY: 95 LITRES (25 US GALLONS) 5. RECOMMENDED CLEARANCE ON THREE SIDES 915 MM (36 INCHES) SIDE WITH ELECTRICAL BOX 1067 MM (42 INCHES) OR MINIMUM AS REQUIRED BY LATEST NATIONAL ELECTRICAL CODE OR APPLICABLE LOCAL CODES. 6. EXTERNAL PIPING SHOULD NOT EXERT ANY UNRESOLVED MOMENTS OR FORCES ON UNIT. USE PIPE OF EQUAL OR GREATER SIZE AT DISCHARGE LOCATION OF UNIT. 7. THERE SHOULD BE NO PLASTIC OR PVC PIPING ATTACHED TO THIS UNIT OR USED FOR ANY LINES DOWNSTREAM. 8. REMOVE THE ISOLATION MOUNT RESTRAINTS BEFORE THE INITIAL START. THE RESTRAINTS CAN BE DISCARDED. 9. FIELD INSTALLED DUCTING TO AND FROM COMPRESSOR CANNOT ADD MORE THAN 6MM (.25 INCH) OF WATER TOTAL AIR RESISTANCE. 10. UNIT HAS AN INTERNAL DISCHARGE CHECK VALVE, EXTERNAL CHECK VALVE NOT REQUIRED. ISOLATION VALVE REQUIRED WITHIN 915 MM (36 INCHES) OF THE COMPRESSOR DISCHARGE. C C 11. COMPRESSOR SHOULD BE BOLTED TO THE FLOOR WITH FOUR M20 (3/4 INCH) BOLTS USING HOLES SHOWN ON SHEET 4. SEAL BASE TO FLOOR WITH CORK OR RUBBER. 12. DO NOT PIPE INTO A COMMON HEADER WITH A RECIPROCATING COMPRESSOR. UNLESS RECIP COMPRESSOR UTILIZES A DISHCHARGE PULSATION DAMPENER. 13. DENOTES CENTER OF GRAVITY. 14. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY INGERSOLL-RAND IS THE RESPONSIBILITY OF THE CUSTOMER AND SHOULD BE DONE IN ACCORDANCE WITH THE INFORMATION ON THE COMPRESSOR DATA PLATE, NATIONAL AND LOCAL ELECTRIC CODES. 15. A BLANK GLAND PLATE IS PROVIDED FOR ELECTRICAL POWER INLET AS INDICATED. 16. WHEN INSTALLED INDOORS IN A CONFINED SPACE, THE COOLING AIR INLET OR EXHAUST MUST BE DUCTED AWAY FROM UNIT TO PREVENT RECIRCULATION OF HOT EXHAUST AIR. B B CONNECTION LEGEND - ALL 60 Hz CONNECTIONS ARE NPT (UNLESS SPECIFIED OTHERWISE) A. DISCHARGE AIR: 2.5 INCH (FEMALE) B. ELECTRICAL INLET: BLANK PLATE SUPPLIED C. PACKAGE AIR INLET D. PACKAGE AIR EXHAUST E. CONDENSATE DRAIN: .375 INCH NPT (FEMALE) A 615,81 402,81 GENERAL ARRANGEMENT TOLERANCES WARNING: THE EXPORT OR REEXPORT OF THIS DRAWING OR A PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT TO U.S. EXPORT ADMINISTRATION REGULATIONS AND OTHER APPLICABLE GOVERNMENT RESTRICTIONS OR REGULATIONS. ALL DIMENSIONS ARE IN MILLIMETERS [INCHES (IF SHOWN)] PROPRIETARY NOTICE THIS DRAWING CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION, IS THE PROPERTY OF INGERSOLL-RAND CO., AND IS GIVEN TO THE RECEIVER IN CONFIDENCE. THE RECEIVER BY RECEPTION AND RETENTION OF THE DRAWING ACCEPTS THE DRAWING IN CONFIDENCE UNLESS OTHERWISE SPECIFIED: AND AGREES THAT, EXCEPT AS AUTHORIZED IN WRITING BY - REMOVE ALL BURRS AND SHARP CORNERS INGERSOLL-RAND CO. IT WILL (1) NOT USE THE DRAWING OR ANY COPY - WELD SYMBOLS TO BE IN ACCORDANCE THEREOF OR THE CONFIDENTIAL OR TRADE SECRET INFORMATION WITH ANSI/AWS A2.4 THEREIN; (2) NOT COPY THE DRAWING; (3) NOT DISCLOSE TO OTHERS EITHER THE DRAWING OR THE CONFIDENTIAL OR TRADE SECRET COPYRIGHT @ 2015 INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE NEED TO RETAIN THE DRAWING, OR UPON DEMAND, RETURN THE DRAWING, ALL Ingersoll Rand COPIES THEREOF, AND ALL MATERIAL COPIED THEREFROM. ALL RIGHTS RESERVED UNSPECIFIED TOLERANCES: WHOLE .X ANGLES : : : 13.0[.50] 6.0[.25] 1 Ingersoll-Rand Industrial Technologies 18,18 DO NOT SCALE DRAWING DRAWING CONFORMS TO ASME Y14.5M - 1994 CAD GENERATED DRAWING, NO MANUAL REVISIONS ALLOWED THIRD ANGLE PROJECTION DRAWN DATE R M.SHOREY 2015FEB10 CHECKED DATE J.SCHOCH 2015FEB10 APPROVED S.BURRIS NAME DATE 2015FEB10 DRAWING TYPE General Arrangement Drawing NOMENCLATURE SIZE A1 SCALE GENERAL ARRANGEMENT, AIR COOLED (R90) ESTIMATED WEIGHT DWG NO. (KG UNLESS OTHERWISE SPECIFIED) SEE NOTES 0.13 MODEL PART NO. 49083520 R90 GENERAL ARRANGEMENT, AIR COOLED (R90) REVISION 49083520 A SHEET 1 OF 4 402,18 For Internal Use:49083520|ASSEM|A.0|Michael Shorey|11-Feb-15 09:03:52 AM|Open 8 11-Feb-2015 09:39:14 (model A.0/A.1) 7 6 5 4 UNLESS OTHERWISE SPECIFIED PRINTED DOCUMENT IS UNCONTROLLED A 825,81 3 2 1 R20.10 Compressor General Arrangement Calaveras Coal Yard Compressed Air Equipment CCAD-CMP-4 A.1 8 7 6 5 4 3 2 1 18,579 18,579 826,579 D D TOP C C B B FRONT LEFT END A A REAR 636,54 825,54 PROPRIETARY NOTICE THIS DRAWING CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION, IS THE PROPERTY OF INGERSOLL-RAND CO., AND IS GIVEN TO THE RECEIVER IN CONFIDENCE. THE RECEIVER BY RECEPTION AND RETENTION OF THE DRAWING ACCEPTS THE DRAWING IN CONFIDENCE AND AGREES THAT, EXCEPT AS AUTHORIZE D IN WRITING BY INGERSOLL-RAND CO. IT WILL (1) NOT USE THE DRAWING OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE SECRET INFORMATION THEREIN; (2) NOT COPY THE DRAWING; (3) NOT DISCLOSE TO OTHERS EITHER THE DRAWING OR THE CONFIDENTIAL OR TRADESECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE NEED TO RETAIN THE DRAWING, OR UPON DEMAND, RETURN THE DRAWING, ALL COPIES THEREOF, AND ALL MATERIAL COPIED THEREFROM. RIGHT END GENERAL ARRANGEMENT, AIR COOLED (R90) DWG NO. SIZE A1 SCALE 0.13 REVISION 49083520 PART NO. NOMENCLATURE 49083520 GENERAL ARRANGEMENT, AIR COOLED (R90) A SHEET 2 OF 4 636,18 18,18 18,18 8 11-Feb-2015 09:39:14 (model A.0/A.1) NAME 7 6 5 4 UNLESS OTHERWISE SPECIFIED PRINTED DOCUMENT IS UNCONTROLLED 3 2 1 R20.10 Compressor General Arrangement Calaveras Coal Yard Compressed Air Equipment CCAD-CMP-4 A.1 8 7 6 5 3 4 2 1 18,579 18,579 826,579 70 [2.7] 4[0.2] (TYPICAL FOR ALL LATCHED DOORS) R786 [31.0] 1430 [56.3] D D 610 [24.0] E 57 [2.3] 2 [0.1] 1466 [57.7] 1404 [55.3] 1260 [49.6] DETAIL G R786 [31.0] SCALE 1.000 SEE DETAIL G DETAIL F SCALE 1.000 TOP VIEW C 93 [3.7] R786 [31.0] C 2703 [106.4] 1213 [47.8] 1860 [73.2] 801 [31.6] 220 [8.7] 530 [20.9] AIR FLOW D C B B AIR FLOW 499 [19.6] C 1232 [48.5] 158 [6.2] 2032 [80.0] A 1232 [48.5] B 701 [27.6] 580 [22.8] A 178 [7.0] 505 [19.9] 415 [16.3] E 636,54 SEE DETAIL F 1192 [46.9] 825,54 PROPRIETARY NOTICE FRONT VIEW THIS DRAWING CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION, IS THE PROPERTY OF INGERSOLL-RAND CO., AND IS GIVEN TO THE RECEIVER IN CONFIDENCE. THE RECEIVER BY RECEPTION AND RETENTION OF THE DRAWING ACCEPTS THE DRAWING IN CONFIDENCE AND AGREES THAT, EXCEPT AS AUTHORIZE D IN WRITING BY INGERSOLL-RAND CO. IT WILL (1) NOT USE THE DRAWING OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE SECRET INFORMATION THEREIN; (2) NOT COPY THE DRAWING; (3) NOT DISCLOSE TO OTHERS EITHER THE DRAWING OR THE CONFIDENTIAL OR TRADESECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE NEED TO RETAIN THE DRAWING, OR UPON DEMAND, RETURN THE DRAWING, ALL COPIES THEREOF, AND ALL MATERIAL COPIED THEREFROM. LEFT END VIEW NAME GENERAL ARRANGEMENT, AIR COOLED (R90) DWG NO. SIZE A1 SCALE 0.10 REVISION 49083520 PART NO. NOMENCLATURE 49083520 GENERAL ARRANGEMENT, AIR COOLED (R90) A SHEET 3 OF 4 636,18 18,18 18,18 8 11-Feb-2015 09:39:14 (model A.0/A.1) A 7 6 5 4 UNLESS OTHERWISE SPECIFIED PRINTED DOCUMENT IS UNCONTROLLED 3 2 1 R20.10 Compressor General Arrangement Calaveras Coal Yard Compressed Air Equipment CCAD-CMP-4 A.1 8 7 6 5 3 4 2 1 18,579 18,579 826,579 D D SEE DETAIL H C C 2X 14 [0.6] BOTH SIDES RIGHT END VIEW 2X 305 [12.0] BOTH SIDES 2X 95 [3.8] BOTH SIDES 175 [6.9] 2X 890 [35.0] BOTH SIDES 462 [18.2] 34 [1.3] 2X 840 [33.1] BOTH SIDES REAR VIEW 6 [0.2] 36 [1.4] B 785 [30.9] 868 [34.2] 4X 23 [0.9] B 1284 [50.6] A A A BOTTOM VIEW OF BASE DETAIL H SCALE 0.500 636,54 THIS DRAWING CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION, IS THE PROPERTY OF INGERSOLL-RAND CO., AND IS GIVEN TO THE RECEIVER IN CONFIDENCE. THE RECEIVER BY RECEPTION AND RETENTION OF THE DRAWING ACCEPTS THE DRAWING IN CONFIDENCE AND AGREES THAT, EXCEPT AS AUTHORIZE D IN WRITING BY INGERSOLL-RAND CO. IT WILL (1) NOT USE THE DRAWING OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE SECRET INFORMATION THEREIN; (2) NOT COPY THE DRAWING; (3) NOT DISCLOSE TO OTHERS EITHER THE DRAWING OR THE CONFIDENTIAL OR TRADESECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE NEED TO RETAIN THE DRAWING, OR UPON DEMAND, RETURN THE DRAWING, ALL COPIES THEREOF, AND ALL MATERIAL COPIED THEREFROM. NAME GENERAL ARRANGEMENT, AIR COOLED (R90) DWG NO. SIZE A1 SCALE 0.10 REVISION 49083520 PART NO. NOMENCLATURE 49083520 GENERAL ARRANGEMENT, AIR COOLED (R90) A SHEET 4 OF 4 636,18 18,18 18,18 8 11-Feb-2015 09:39:14 (model A.0/A.1) 825,54 PROPRIETARY NOTICE 7 6 5 4 UNLESS OTHERWISE SPECIFIED PRINTED DOCUMENT IS UNCONTROLLED 3 2 1 R20.10 Compressor General Arrangement Calaveras Coal Yard Compressed Air Equipment CCAD-CMP-4 A.1 8 7 6 5 3 4 2 1 18,579 825,579 REVISIONS ZONE L1 L2 L3 PE FU10,11 L1 3L1 MCB1 3L3 L3 3L1 L1 EB T1 X1:115V H1:575V H2:460V H3:415V H4:380V H5:230V H6:220V H7:0V 100 MCB3 101 CONTROLLER 101 6A KM1-2 103 1 RC4 DI9 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 DI7 L3 L2 L1 A2 KM1 L1 L2 L3 150 KM1-1 118 110 A1 KM2 A1 RC3 FMP 105 FR1 A1 RC2 119 KM3-2 KM3 A2 KM4 A1 TX1 Gnd 111 A1 112 113 1SV 3 TX2 4 TX3 5 DI11 Gnd DI12 Gnd TX4 DI13 Gnd 6 TX5 DI14 NOTE 8 I> I> I> Gnd 115 150 KM1 9SV 7 TX6 DI15 Gnd KM4 WHI DI16 2L1 2L2 2L3 Gnd FR1 (60Hz ONLY) CT1, CT2, CT3 V+ 116 MCB5 8 TX7 Gnd Sig1 1A I> I> I> 117 150 BLK BLK W2 U2 V2 104 FU1, 2, 3 N + L - 200 201 9 TX8 10 GND V+ Gnd Sig2 V+ 1 + 2 - Gnd P10 U1 V1 W1 Sig3 V+ PSU P5 MM 2L1 2L2 2L3 KM4 NOTE 5 DI10 Gnd 120 KM2-1 A2 2 KM3-1 150 KM3 KM2 BLK 16 Gnd 105 150 X3:0V A2 WHI Gnd DI6 RC1 WHI 15 Gnd A2 C DI8 DI5 115V 150 L1 L2 L3 Gnd Gnd 105 102 P1 FM MM OV T1 CONT 1SV 4SV 5SV 9SV CDV CAB BP DOOR PSU ES-1 3L3 7 8 9 10 11 12 13 14 DI4 P3 D ECN A 83409 DESCRIPTION ORIGINAL RELEASE DATE DRAWN APP'D 2015FEB06 M.SHOREY S.BURRIS ES-2 ALTERNATE L3 REV Gnd Sig4 V+ 4L1 4L2 4L3 Gnd Sig5 V+ L1 L2 L3 PE Sig6 283 12 01 02 55 Sig7 285 216 216 BLU 217 BLU 217 Gnd P3-13 Sig2 P3-14 294 WHI WHI 294 295 BLK BLK 295 WHI ZNR CAP BLK PE Gnd 10 AO1 9 AO+ 8 COM Sig3 Gnd Sig4 Gnd Sig5 U V W Gnd 303 U W V MOTOR RUNNING CONTACT DETAIL B NOTE 6 304 CTO KM1-4 CWO 305 306 307 308 309 310 1 2 3 4 5 6 N/O Sig6 C Gnd N/C Sig7 N/O P2 FM Sig1 P4 60 Gnd P8 FD K3-1 284 18 27 V+ P7 B Gnd GND P6 MOTOR SIZE CT RATIO 90-110kW(125-150HP) 200:5 Gnd C Sig8 N/C Gnd 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 208 209 D 213 214 FR1 212 95 215 96 216 217 FD 01 FD 02 222 223 224 225 226 227 228 229 230 231 232 233 234 235 RSP RST RLL RLE RLU AW1 C AW2 RED BLK WHI RED BLK WHI RED BLK WHI RED BLK WHI RED BLK WHI 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 1AVPT P 3APT P 4APT P 5CPT P 6CPT P B 260 261 262 263 264 265 EB EB EB WHI BLK WHI BLK WHI BLK T 2CTT T 2ATT T 4ATT 17 18 49083504 REV A SHEET 1 OF 2 A 615,81 402,81 WARNING: THE EXPORT OR REEXPORT OF THIS DRAWING OR A PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT TO U.S. EXPORT ADMINISTRATION REGULATIONS AND OTHER APPLICABLE GOVERNMENT RESTRICTIONS OR REGULATIONS. NOTES: 1. DECAL MUST CONFORM TO THE LATEST REVISION OF IR SPECIFICATION 92-8.95. PROPRIETARY NOTICE THIS DRAWING CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION, IS THE PROPERTY OF INGERSOLL-RAND CO., AND IS GIVEN TO THE RECEIVER IN CONFIDENCE. THE RECEIVER BY RECEPTION AND RETENTION OF THE DRAWING ACCEPTS THE DRAWING IN CONFIDENCE UNLESS OTHERWISE SPECIFIED: AND AGREES THAT, EXCEPT AS AUTHORIZED IN WRITING BY - REMOVE ALL BURRS AND SHARP CORNERS INGERSOLL-RAND CO. IT WILL (1) NOT USE THE DRAWING OR ANY COPY - WELD SYMBOLS TO BE IN ACCORDANCE THEREOF OR THE CONFIDENTIAL OR TRADE SECRET INFORMATION WITH ANSI/AWS A2.4 THEREIN; (2) NOT COPY THE DRAWING; (3) NOT DISCLOSE TO OTHERS EITHER THE DRAWING OR THE CONFIDENTIAL OR TRADE SECRET COPYRIGHT @ 2015 INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE NEED TO RETAIN THE DRAWING, OR UPON DEMAND, RETURN THE DRAWING, ALL Ingersoll Rand COPIES THEREOF, AND ALL MATERIAL COPIED THEREFROM. ALL RIGHTS RESERVED Ingersoll-Rand Industrial Technologies 18,18 DO NOT SCALE DRAWING DRAWING CONFORMS TO ASME Y14.5M - 1994 CAD GENERATED DRAWING, NO MANUAL REVISIONS ALLOWED THIRD ANGLE PROJECTION DRAWN DATE R M.SHOREY 2015FEB05 CHECKED DATE J.SCHOCH 2015FEB05 APPROVED DATE S.BURRIS 2015FEB05 DRAWING TYPE Detail Drawing NOMENCLATURE NAME DECAL, ELECTRICAL WIRING SCHEMATIC (FS-SD) 49083504 A1 N/A A SIZE DWG NO. ESTIMATED WEIGHT DECAL, ELECTRICAL WIRING SCHEMATIC (FS-SD) REVISION (KG UNLESS OTHERWISE SPECIFIED) 49083504 PART NO. SCALE NTS MODEL R90-160 SHEET 1 OF 2 402,18 For Internal Use:Model=49083504|PART|A.0|Michael Shorey|06-Feb-15 10:50:53 AM|Open<>Drawing=49083504|DRAW|A.1|Michael Shorey|10-Feb-15 01:50:39 PM|Open 8 10-Feb-2015 14:06:07 (model A.0/A.1) 7 6 A 825,81 3 5 4 2 1 R20.12 Compressor Low Ambient Electrical Schematic Calaveras Coal Yard Compressed Air Equipment CCAD‐CMP‐4 UNLESS OTHERWISE SPECIFIED PRINTED DOCUMENT IS UNCONTROLLED A.1 8 7 6 5 3 4 2 1 18,579 18,579 826,579 D D LEGEND B 1 - 99 POWER BLACK 100 - 199 AC CONTROL RED 100 - 199 GROUNDED AC WHITE 200 - 299 DC CONTROL BLUE 300 - 399 AUXILIARY ORANGE 400-499 AC POWER RED GND GROUND GREEN / YELLOW MCB4 402 1L1 WIRE COLOR LEGEND LABEL DESCRIPTION BLACK BLU BLUE BRO BROWN GRE GREEN PIN PINK RED RED VIO VIOLET WHI WHITE YEL YELLOW K4-1 30A 3ATS (4 C / 40 F) 406 HEATER CIRCUIT, CUSTOMER SUPPLIED 120/1/60 OR 240/1/50 KM1-3 LOW AMBIENT OPTION KM1-5 C NOTE 7 TH (29 C / 85 F) 405 403 404 403 403 403 SSH SSH DMH K4 A1 BLK 1L2/N FMH 1SVT MSHT OSH OSH OSH BLH IVH A2 C DESCRIPTION ZERO VOLTAGE INLET VACUUM PRESSURE LOAD VALVE 1SV HEAT TRACE AIREND DISCHARGE TEMPERATURE INJECTED COOLENT TEMPERATURE WET SUMP PRESSURE AMBIENT TEMP THERMOSTAT PACKAGE DISCHARGE PRESSURE PACKAGE DISCHARGE TEMPERATURE COOLANT FILTER IN PRESSURE COOLANT FILTER OUT PRESSURE MOISTURE SEPARATOR DRAIN VALVE AUTO TRANSFORMER AUXILIARY WARNING 1 AUXILIARY WARNING 2 BASE LEVEL HEATER BACKPANEL CABINET CAPACITOR COMMON TRIP OUTPUT COMMON WARNING OUTPUT Xe CONTROLLER CURRENT TRANSFORMER DRIVE MOTOR HEATER EARTHING BAR EMERGENCY STOP BUTTON FAN DRIVE FAN MOTOR FAN MOTOR HEATER FAN MOTOR PROTECTOR MAIN MOTOR OVERLOAD FUSES INLET VALVE HEATER LOW AMBIENT CONTROL RELAY MAIN CONTACTOR DELTA CONTACTOR START CONTACTOR FAN MOTOR CONTACTOR CIRCUIT BREAKERS MAIN MOTOR MOISTURE SEPARATOR HEAT TRACE OIL SUMP HEATER PROTECTED EARTH POWER SUPPPLY UNIT MOTOR WINDING THERMISTOR ARC SUPPRESSOR REMOTE LOAD ENABLE REMOTE LEAD LAG REMOTE LOAD/UNLOAD REMOTE STOP REMOTE START SOLID STATE RELAYS STARTER SPACE HEATER CONTROL POWER TRANSFORMER THERMOSTAT ZENER DIODE RC5 LABEL OV 1AVPT 1SV 1SVT 2ATT 2CTT 3APT 3ATS 4APT 4ATT 5CPT 6CPT 9SV AT1 AW1 AW2 BLH BP CAB CAP CTO CWO CONT CTx DMH EB ES FD FM FMH FMP FR1 FUIVH K4 KM1 KM2 KM3 KM4 MCB MM MSHT OSH PE PSU PTCx RCx RLE RLL RLU RSP RST SS SSH T1 TH ZNR WIRE NUMBER DESIGNATION LEGEND NUMBERS FUNCTION WIRE COLOR 410 410 410 410 B NOTES: 1. APPROVED FUSED DISCONNECT OR CIRCUIT BREAKER PER LOCAL ELECTRICAL CODES MUST BE PROVIDED BY THE CUSTOMER. 2. INDICATES OPTIONAL COMPONENTS. 3. INDICATES OPTIONAL FIELD WIRED COMPONENTS. 4. REMOVE JUMPER(S) WHEN CORRESPONDING OPTION HAS BEEN PURCHASED. 5. 60Hz WYE-DELTA STARTER UNITS REQUIRE CURRENT TRANSFORMERS (CT) TO BE USED WITH MAIN MOTOR OVERLOAD. 6. A VARIABLE SPEED DRIVE IS REQUIRED FOR 90-160kW UNITS WITH LOW AMBIENT OPTION. 7. THREMOSTAT AND TEMPERATURE SWITCH CONTACTS ARE NORMALLY CLOSED AND WILL OPEN WHEN THE TEMPERATURE MEETS OR EXCEEDS THE INDICATED SET POINT. 49083504 REV A SHEET 2 OF 2 A A 636,54 825,54 PROPRIETARY NOTICE THIS DRAWING CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION, IS THE PROPERTY OF INGERSOLL-RAND CO., AND IS GIVEN TO THE RECEIVER IN CONFIDENCE. THE RECEIVER BY RECEPTION AND RETENTION OF THE DRAWING ACCEPTS THE DRAWING IN CONFIDENCE AND AGREES THAT, EXCEPT AS AUTHORIZE D IN WRITING BY INGERSOLL-RAND CO. IT WILL (1) NOT USE THE DRAWING OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE SECRET INFORMATION THEREIN; (2) NOT COPY THE DRAWING; (3) NOT DISCLOSE TO OTHERS EITHER THE DRAWING OR THE CONFIDENTIAL OR TRADESECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE NEED TO RETAIN THE DRAWING, OR UPON DEMAND, RETURN THE DRAWING, ALL COPIES THEREOF, AND ALL MATERIAL COPIED THEREFROM. DECAL, ELECTRICAL WIRING SCHEMATIC (FS-SD) DWG NO. SIZE A1 SCALE 1.00 REVISION 49083504 PART NO. NOMENCLATURE 49083504 DECAL, ELECTRICAL WIRING SCHEMATIC (FS-SD) A SHEET 2 OF 2 636,18 18,18 18,18 8 10-Feb-2015 14:06:07 (model A.0/A.1) NAME 7 6 3 5 4 2 1 R20.12 Compressor Low Ambient Electrical Schematic Calaveras Coal Yard Compressed Air Equipment CCAD‐CMP‐4 UNLESS OTHERWISE SPECIFIED PRINTED DOCUMENT IS UNCONTROLLED A.1 Revision : October 2007 Cancels : April 2007 Davidson, NC, USA Rotary 125 hp 60 Hz Single Stage Contact Cooled Air Compressor Package GENERAL COMPRESSOR DATA Capacity FAD (1) Compressor Power Full Load Rated Package Discharge Pressure Maximum Off Line Pressure Minimum Reload Pressure Rotor Diameter Male Rotor Speed COOLING DATA - GENERAL (115ºF MAXIMUM AMBIENT) Operating Temperature Airend Injection Temperature Heat Removal Oil Cooler Oil Cooler and After Cooler Oil Flow AIRCOOLED DATA Aftercooler CTD (4) Fan Air Flow Maximum Added Static Pressure WATERCOOLED DATA Aftercooler CTD (4) Cooling Water Flow @ 50ºF (10ºC) @ 70ºF (21ºC) @ 90ºF (32ºC) @ 115ºF (46ºC) Water Temperature Rise @90°F Water Pressure Drop @ max flow rate condition (50 deg F water) Oil Cooler Oil Cooler and After Cooler Fan Air Flow Maximum Added Static Pressure LUBRICATION DATA Sump Capacity Total Lubrication System Capacity SOUND LEVELS (5) Aircooled Watercooled R90IU-100 R90IU-140 CFM (m3/min) Power (kW) psig (barg) psig (barg) psig (barg) mm RPM 647 137.5 100 103 65 ºF (ºC) ºF (ºC) 204 172 (96) (78) 201 172 (94) (78) 200 172 (93) (78) 1000 Btu/hr (1000 kJ/hr) 1000 Btu/hr (1000 kJ/hr) gal(US)/min (litre/min) 307 389 40 (324) (410) (151) 316 390 45 (333) (411) (170) 321 389 47 (339) (410) (178) ºF (ºC) CFM (m3/min) in (mm) H2O 15 13000 0.25 (8) (368) (6.4) 15 13000 0.25 (8) (368) (6.4) 15 13000 0.25 (8) (368) (6.4) ºF (ºC) 25 (14) 25 (14) 25 (14) gal(US)/min (litre/min) gal(US)/min (litre/min) gal(US)/min (litre/min) gal(US)/min (litre/min) ºF (ºC) 35 33 31 28 25 (132) (125) (117) (106) (14) 34 33 31 29 25 (129) (125) (117) (110) (14) 35 32 31 29 25 (132) (121) (117) (110) (14) psi (bar) psi (bar) CFM (m3/min) in (mm) H2O 1.9 0.36 4000 0.25 (0.13) (0.02) (113) (6.4) 2.0 0.30 4000 0.25 (0.14) (0.02) (113) (6.4) 2.1 0.32 4000 0.25 (0.14) (0.02) (113) (6.4) gal(US) (litre) gal(US) (litre) 16 25 (61) (95) 16 25 (61) (95) 16 25 (61) (95) dB(A) dB(A) ELECTRICAL DATA (2) Full Load Power - Drive Motor Full Load Power - Fan Motor Full Load Power - Package Full Load Current - Drive Motor Full Load Current - Fan Motor (Aircooled) Full Load Current - Fan Motor (Watercooled) Full Load Current - Package (Aircooled) Full Load Current - Package (Watercooled) Fan Motor Power (Watercooled) Drive Motor RPM Drive Motor Frame Size: IP55 (IEC 60034) Drive Motor Locked Rotor Current (3) Drive Motor Efficiency (Full Load) Drive Motor Power Factor (Full Load) R90IU-125 bhp (kW) bhp (kW) bhp (kW) Amps Amps Amps Amps Amps bhp (kW) RPM Amps % (18.3) (102.5) (6.9) (7.1) (4.5) 226 1804 563 137.5 125 128 65 (15.9) (102.5) (8.6) (8.8) (4.5) 226 1612 511 137.5 140 143 65 (14.5) (102.5) (9.7) (9.9) (4.5) 226 1496 75 70 75 70 75 70 380V 137.5 (102.6) 7.5 (5.6) 145 (108.2) 187.4 11.4 2.0 198.8 189.4 1.0 (0.75) 1780 280M1 1198 94.5 0.88 460V 137.5 (102.6) 7.5 (5.6) 145 (108.2) 154.8 9.4 1.6 164.2 156.4 1.0 (0.75) 1780 280M1 1182 94.5 0.88 575V 137.5 (102.6) 7.5 (5.6) 145 (108.2) 123.9 7.6 1.3 131.5 125.2 1.0 (0.75) 1780 280M1 791 94.5 0.88 (1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996 (2) Electrical data based on IP55 motors, consult factory for others (3) Star Delta starting current inrush is 33% of full voltage KVA inrush (4) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures. - ambient reference conditions are 100ºF / 38ºC inlet air at 40% relative humidity (5) Sound pressure level at the work station (+3 dB(A)) - Determined according to noise test code ISO2151:2004 and noise measurement standard ISO9614-2 :1996. (6) For weights, dimensions, and piping connections, see general arrangement drawings - 23057581 (aircooled), 23057573 (watercooled) R20.13 Compressor Engineering Data Calaveras Coal Yard Compressed Air Equipment CCAD-CMP-4

Calaveras Coal Yard - Exhibit J

Related documents

Add this document to collection(s)

Add this document to saved

Suggest us how to improve StudyLib