Geotechnical Construction and Testing to Home Improvements B41

General Construction Specifications

PART 1 - GENERAL

01 DESCRIPTION OF WORK

A. Under this item the Contractor shall furnish, test and place in operation a complete and operational instrumentation system as shown and as specified. The system shall include pump control systems, level sensing equipment, flow metering equipment, combustible gas analyzer, annunciators, telemetry system, interconnecting tubing and or wiring and such accessories as may be shown and or required to provide the functions indicated.

B. Submittals shall be made to the Owner or to his designated Representative in accordance with the General Conditions of the Contract. Submittals are often made under the general term of "Shop Drawings" but include all items listed in the General Conditions.

C. Some submittal requirements listed in the General Conditions or within the specifications are not ordinarily termed as Shop Drawings but still must be submitted as above.

D. The instrumentation section states a number of requirements which must be met. These include tests, certifications, calibrations, guarantees, etc. Such prepared data and reports shall be submitted in addition to:

1. Wiring diagrams

2. Instrument loop diagrams

3. Materials of construction

4. Panel layouts

5. Model numbers and catalog cuts

6. Outline dimensions

B. The instrumentation as specified in this section shall be supplied by the pump manufacturer. The pump manufacturer shall have total system responsibility.

1.02 REFERENCES

A. I.S.A. Instrument Society of America

B. Hydraulic Institute

C. ANSI - American National Standards Institute

D. NEMA - National Electrical Manufacturers Association

E. UL - Underwriters Laboratories

F. NEC - National Electric Code

1.03 PERFORMANCE - GENERAL REQUIREMENTS

A. The instrumentation equipment shall be furnished by a manufacturer regularly engaged in the manufacture of process instrumentation equipment and systems for water and wastewater treatment facilities. The instrument manufacturer shall produce detailed drawings for the complete coordination and installation of the various system components; shall provide the services of a qualified engineer to supervise the installation, and shall test and make any adjustments required, at no additional cost to the Owner, to the extent that the system initially functions as intended by this specification to the satisfaction of the Owner.

B. Owner's Representative will check after the Contractor certifies that all the instruments are installed and are operating as per intended specification. The Contractor shall be required to correct, at no extra cost to the Owner, all deviations and/or deficiency from the intended use of the instruments individually as well as the system in its entirety, which the Owner's Representative may find during the detail checkup of the system(s).

C. Each instrument shall be furnished in complete compliance with the specifications. The instrument supplier may propose substitutions and submit complete technical data on the same. If, in the opinion of the Owner the proposed substitute is indeed equal in the particular application proposed, he may approve the substitution. In evaluating a substitution, performance durability, availability of spare parts, inventory requirements, and ease of maintenance with existing personnel and plant will be considered.

D. Functional system data is shown diagrammatically on the Instrumentation Loop Schedules and details. All elements shall be provided as shown. Additional elements such as power supplies, pneumatic volume boosters, current repeaters, lighting/surge protection on all outdoor installed equipment, and other such elements as may be required to complete the system shall be provided even though not shown.

All digital and analog signals for the telemetry system required in Section 2.05, C., shall be supplied as isolated signals from any other control signals. The instrument manufacturers shall coordinate with the telemetry equipment supplier.

E. Equipment shall be located and installed so that it will be readily accessible for operation and maintenance. The Contractor shall examine the architectural, structural, mechanical, electrical and shop drawings for the various pieces of equipment in order to determine the exact routing and final terminations for conduits and signal lines. Instrumentation work shall be carefully coordinated between the various trades in order to secure the best arrangement of the work as a whole. No changes in the work shall be made without written acceptance of the Owner.

F. The Instrument Contractor shall submit evidences of his prior experience, technical skill, capacity to handle a project of the volume and reference of other clients for whom he has performed similar installations.

G. Services by Manufacturer and Guarantee

1. Certification sheets shall be prepared by the Instrumentation Manufacturer to guarantee that each component and loop has been calibrated and commissioned prior to start-up. Certification sheets shall be signed and dated by the Instrumentation Manufacturer and by the Owner or his Representative. All instruments shall be calibrated by an instrument traceable to a primary standard. All instruments shall be calibrated to within the accuracy stated by the manufacturer. Each instrument shall be checked for zero and full span and in addition, a check shall be made a minimum of 5 points between 10 and 90% of the actual span for each analog instrument. The certification sheets shall show "as found" and "as left" readings.

2. After all tests and adjustments have been made, the manufacturer shall fully instruct the Owner's Representative in all details of operation and maintenance of equipment installed under his work.

3. The Contractor and his surety shall guarantee in writing for a period of one year from date of final acceptance that all materials, equipment and labor furnished by him are free from defects. The

Contractor shall further guarantee that if any piece is found to be defective within the guarantee period because of faulty manufacturing, faulty installation or workmanship, in the opinion of the Owner's Representative, the Contractor will replace and install such material or equipment without any additional expense to the Owner.

4. At least three copies of all manufacturer's guarantees and certificates which are obtained by the Contractor shall be furnished to the Owner.

5. The manufacturer shall have service and maintenance available at 24 hour notice.

H. Change of Scope Omissions

1. It shall become the responsibility of the Contractor working in conjunction with the Owner's Representative to perform any changes to the process system not covered by this or other Contracts, due to accidental omissions or change in work scope.

I. Installation, Calibration, Commissioning and Start-Up Assistance

1. Work Included

a) Install, calibrate, commission and assist in the start-up of instrumentation and controls including those furnished with purchased equipment in accordance with this specification section, the applicable design drawings and other Contract Documents.

b) Furnish and install all necessary instrumentation materials and piping required to perform the work.

c) Furnish and install all one inch and small transmission control and process sensing piping with required valves, tubing, fittings, hangers and supports.

2. System Description

a) The required instrumentation and control system shall be defined on the following documents:

1) An Instrument List listing all instruments, controls and panels purchased for the project with cross reference to piping, electrical and instrument drawings.

2) Piping and instrument routing drawings showing location of instruments, controls and panels. Each item is identified by the tag number shown on the Instrument List.

3) Instrument installation details and electrical drawings showing the required method of installing and connecting the instruments.

4) Manufacturer's recommended installation instructions and drawings.

b) Locations shown on the drawings shall not be changed without the written approval of the Engineer.

J. Delivery, Storage and Handling

1. Receive, uncrate, inspect and store instruments, controls, control panels, tubing, piping and miscellaneous instrumentation materials.

2. Check all items for proper tagging, general physical condition and missing parts including all items previously received at the project site by others. Promptly report all incomplete shipments, missing parts and evidence of breakage or damage in transit, or in prior handling for corrective action.

3. Protect instruments, tubing, piping and miscellaneous instrument materials from water, foreign material and injury from time of receipt until final acceptance of the work. Be responsible for and repair or replace all items damaged from time of acceptance at the job site to item of completion of the work handled under this specification section.

K. Materials

1. Piping and Pipe Fittings

a) Materials shall conform to Section 15060, Piping and Fittings, and as shown on the drawings.

b) The minimum schedule thickness for pipe nipples 12 inch and shorter shall be as follows:

Size Schedule

Steel Pipe

1/4 inch thru 1 inch 40

A. Instrument Installation

1. Install in accordance with the installation details given on the drawings.

B. Tubing and Piping Installation

1. Protect capillary tubing for filled system temperature and pressure instruments by installing in channel supports, with capillary attached to channel with clips. Excess capillary shall be coiled and secured at the instrument.

1.02 GENERAL INSTRUMENT CONSTRUCTION

A. Transmission and Circuit Arrangement

1. Signal transmission between electronic instruments shall be 4-20 mA.

B. Attachments and Supports

1. All instrumentation and electrical equipment shall be securely supported. It shall be the responsibility of the Contractor to provide adequate support for all equipment he installs. Methods of support shall be subject to the approval of the Engineer.

2. All fastenings, supports, hangers, clamps, and anchors shall be of the type made for the specific purpose for which they are to be used. Toggle bolts or machine bolt fastenings shall be used for hollow tile, terra-cotta, or lath construction. Machine screws shall be used for structural steel fastening. Lead expansion shield and machine screws shall be used for solid masonry fastening. Lag screws or bolts shall be used for wood fastening. All conduit and tubing shall be rigidly and firmly installed to prevent swaying, vibration or sagging by malleable or wrought steel hangers of standard design, pipe clamps, or fabricated steel supports of approved design. Hangers for horizontal conduit runs shall be adjustable clevis type. Perforated strap iron hangers are not permitted.

3. All exterior fastening devices shall be Series 300 stainless steel.

4. Panels and other equipment that is located on subgrade walls in unfinished areas or in damp locations, shall be mounted on square aluminum channel.

C. Special Tools

1. This Contractor shall furnish two sets of all special tools required for operation and maintenance of all equipment furnished under his work. The tools shall be delivered to the Owner's Representative and receipt shall be obtained.

D. Identification Nameplates

1. All sensors, transmitters, terminal and junction boxes, and similar or related items shall be identified by name, function, and/or control. Nameplates shall be at least 1 inch by 3 inches with characters not less than 1/4 inch. They shall be made up of two laminated white plastic sheets bonded with a middle sheet of black plastic and characters engraved in one white sheet to the depth of the black plastic. Nameplates shall be attached with sheet metal screws or bolts and nuts.

2. A typewritten list of nameplates shall be submitted to the Engineer for approval before ordering.

3. Plastic tape embossed nameplates will not be acceptable.

E. Instructions

1. After all tests and adjustments have been made, this Contractor shall fully instruct the representatives of the Owner in all details of operation and maintenance of equipment installed under his work.

F. Materials

1. All material shall be new, free from defects, and of the quality specified or shown. Each type of material shall be of the same manufacture throughout the work. All material shall be the product of established, reputable manufacturers normally engaged in the production of the particular item being furnished.

2. Care shall be exercised in the installation of all equipment to avoid damage or disfiguration of any kind. All equipment shall be protected from dust and moisture prior to and after installation. The panels and consoles shall be covered with a heavy polyethylene plastic sheet or laminated kraft paper having a moisture barrier during all stages of construction.

3. Equipment which is stored in unheated or open areas on the job shall be provided with thermostatically controlled heating units of sufficient size to keep the temperature of the equipment above the dew point.

4. Failure of the Contractor to protect the equipment as outlined herein shall be grounds for rejection of the equipment.

G. Indicating Scales

1. All instrument components furnished under this Contract requiring indicating scales or meters shall be furnished with the appropriate ranges and engineering units indicated on the loop diagrams. Indicating scale reading 0-100% in most cases will not be applicable unless so indicated on the loop diagrams.

H. Control Cabinets

1. The control cabinets shall be fully enclosed, with access to cabinets. The cabinets shall be completely wired at the factory and all wiring shall be in accordance with JIC standards. All wiring shall be brought out to terminal strips for field connection, except where direct connection is required for special reasons. All stranded conductors shall be lugged where connected to screw terminals. Each end of each wire shall be coded with coded marking ferrules in a uniform logical numbering system.

2. Cabinets shall include internal incandescent light, switch and duplex receptacle. A separate external circuit shall be provided for the illumination/receptacle power supply.

3. Cabinet control wiring shall be single conductor Type TW rated 90oC and shall be flame, moisture, and oil resistant polyvinyl chloride insulated No. 16 AWG minimum. Stationary conductors shall be Class B stranded. Cables crossing hinges shall be Class D stranded, and suitable means shall be provided to protect cables from chafing or undue stress when the hinged member is moved.

4. Wiring shall be tagged at all terminations with machine printed plastic sleeves. Wire shall be color coded as follows:

a) Hot: Black

b) Neutral: White

c) Ground: Green

d) Special: Blue

5. Covered channel for panel wiring made of perforated or slotted fiber or plastic shall be used to support the wiring. Wire shall be tied and laced where not supported in channel. Crimping type wire lug terminals with insulated sleeve as made by A.M.P., or equal, shall be used throughout the panel. All field connectors shall be wired to labeled terminal strips at the bottom of the panel.

6. Each termination of each wire in the panel shall be labeled with a plastic sleeve having a printed number. The wire numbers shall be assigned by the panel builder and shown on the schematic diagrams and the connection diagrams.

7. The cabinet builder shall provide complete and detailed connection diagrams for use by the electrician. These diagrams shall show all connections between the main control panel, the motor control center and to remote devices. The external connection diagrams shall be prepared and submitted for approval by the Engineers as part of the shop drawing submittal.

1.03 TESTING, CALIBRATION AND COMMISSIONING

A. As preparation for the calibration and commissioning of the instrumentation, the Contractor shall:

1. Inspect visually electrical devices and connections for compliance with specifications, drawings and manufacturer's recommended installation practice.

2. Remove all shipping stops and install components such as charts, mercury, etc., which have been supplied separately but are integral parts of the instruments.

3. Operationally check all instruments, including those provided with equipment and marked on the "piping and Instrument Diagrams". After, or during checking, each instrument shall be calibrated and commissioned.

4. Furnish and report forms recording the calibration of all devices and settings of all final adjustments.

5. Check calibration of all instruments with respect to zero, span and linearity. Calibrate instruments individually. Attach a calibration sticker to each item after calibration. Furnish a signed calibration report each instrument.

a) If, during calibration procedures, any reason is discovered to question the conformance of any device or installation with applicable codes and regulations, the Engineer shall be notified so that corrective measures may be taken.

b) When doubt exists as to the correct method of calibrating an instrument, the manufacturer's printed recommendations shall be used.

1.04 START-UP ASSISTANCE

A. After completion of calibration and commissioning operations, the Contractor will provide start-up assistance. It shall include but not be limited to the following:

1. Adjust controls for stability.

2. Reset limit switches as required, but only after approval has been obtained.

3. Clean out blocked or restricted impulse lines.

1.05 SUBMITTALS

A. The instrumentation section states a number of requirements which must be met. These include tests, certifications, calibrations, guarantees, etc. Such prepared data and reports shall be submitted in addition to:

1. Materials of construction

2. Model numbers and catalog cuts

3. Outline dimensions

1.06 SHOP DRAWING

A. Shop drawings submission procedures shall be in accordance with Section 01340. Specific requirements for instrumentation are as follows:

B. Complete shop drawings shall be submitted for acceptance prior to manufacture of any instrument equipment. Drawings shall be submitted on 8-1/2 by 11 inch, 11 by 17 inch or 24 by 36 inch paper and shall show dimensions, materials of construction, schematic electrical and pneumatic connections, calibrations, ranges, scales, and specification data. Manufacturer shall furnish loop diagrams of professional quality with each loop shown completely on a single point-to-point wiring and/or piping drawing. Typical wiring or piping diagrams of individual components shall not be acceptable in lieu of the specified loop diagrams. All components, component terminals and/or ports shall be accurately and clearly identified on the loop diagrams. The Contractor shall verify all existing equipment wiring and show all existing equipment on the loop diagrams as required for system operation.

C. Individual control diagrams shall be made for each separate annunciator point and status light. Control diagrams shall detail the logic relationship between the field device and microprocessor.

1.07 RECORD DRAWINGS AND INSTRUCTION MANUALS

A. Record drawing preparation and instruction manual submissions shall be in accordance with the General Requirements. Specific requirements for instrumentation are as follows:

1. The Contractor shall maintain a neatly marked set of record drawings showing installed location and/or routing of interconnecting conduits, cables and tubing. Drawings shall be kept current with the work and shall be subject to inspection by the Owner at any time.

2. Prior to acceptance of the work, the Contractor shall deliver to the Owner two sets of neatly marked record drawings showing the information required in the foregoing paragraph, and record reproducible prints of all instrumentation wiring and tubing diagrams required under "Shop Drawings".

3. The Contractor shall provide the Owner with three complete sets of manufacturer's operating and maintenance instructions and recommended spare parts lists for all instrumentation equipment furnished.

PART 2 - PRODUCTS

02 LEVEL SENSING EQUIPMENT

A. Submersible Level Sensor:

1. The transducer shall be of the solid-state head-pressure sensing type, suitable for continuous submergence and operation and shall be installed in accordance with manufacturer's instructions. The bottom diaphragm face of the sensor shall be installed at elevation recommended by the manufacturer. The sensor shall be mounted using a stainless steel cable system in a location and as shown on the Contract Documents. The transducer shall be installed in a pipe for easy removal.

2. The transducer housing shall be fabricated of Type 316 stainless steel with a bottom diaphragm 2-5/8" diameter of heavy-duty, limp, foul-free, molded Teflon bonded to a synthetic rubber back/seal.

3. A hydraulic fill liquid behind the diaphragm shall transmit the sensed pressure to a solid-state variable-capacitance transducer element to convert the sensed pressure to a corresponding electrical value. The sensed media shall exert its pressure against the diaphragm which flexes minutely so as to vary the proximity between an internal ceramic diaphragm and a ceramic substrate to vary the capacitance of an electrical field created between the two surfaces. A stable, hybrid, operational amplifier assembly shall be incorporated in the transducer to excite and demodulate the sensing mechanism. The transducer shall incorporate laser-trimmed, temperature compensation and high quality components and construction to provide a precise, reliable, stable output signal directly proportional to the sensed pressure over a factory-calibrated range.

4. The transducer element shall incorporate high over-pressure protection and be designed to withstand intermittent over-pressures five times the full scale range being sensed. Metallic diaphragms shall not be acceptable in that they are subject to damage or distortion. Sensing principles employing LVDTs, resistive or pneumatic elements shall not be acceptable.

5. The transducer/transmitter shall include easily accessible offset and span adjustments in the upper assembly. Span shall be adjustable from 100% down to 15% of the sensor range. Fine and coarse adjustments for both span and offset shall be provided, using 25-turn potentiometers. Offset and span adjustments shall be non-interactive, for ease of calibration.

6. The internal pressure of the lower transducer assembly shall be relieved to atmospheric pressure through a heavy-duty urethane jacketed hose/cable assembly and a slack PVC bellows mounted in the Nema 3X fiberglass upper assembly. The sealed breather system shall compensate for variations in barometric pressure and expansion and contraction of air due to temperature changes and altitude as well as prevent fouling from moisture and other corrosive elements.

7. The transducer assembly shall be installed where directed by the Engineer and connected with other system elements and placed in successful operation. It shall be provided with input power and output signal transient protection, associated control elements as specified herein and in accordance with manufacturer's instructions.

8. The liquid level of the wet well shall be sensed by a Consolidated Electric Company Bulletin A1000, Model 157GSCI Submersible Level Transducer or approved equal. The transducer shall be a 4-wire type to operate on 120 VAC incoming power and produce a 4-20 mADC instrumentation signal into a 0-1,000 ohm load in direct proportion to the measured level excursion over a factory-calibrated range of zero to 40 feet of water.

9. Acceptable Equal Manufacturers:

a) EG Pump Controls

b) Healy-Ruff

2.02 PUMP CONTROL SYSTEMS

A. Scope:

1. The manufacturer of the system shall take responsibility for the proper operation/sequencing of the complete pump control system. The control system shall operate the four (4) new pumps in an integrated manner as described by the Engineer.

2. The pump control system manufacturer shall be responsible for all programming of the system, and any interface required to provide a complete operational system.

3. The pump control system shall be as manufactured by:

a) EG Pump Controls

b) Systecon, Inc.

c) Allen-Bradley

B. Design Data:

1. The pump control system shall be capable of operating (4) four new (exact pump HP to be determined by pump manufacturer) pumps in the wet-well in a variable speed mode in order to convey sewage to the central wastewater treatment plant without causing a sewage over-flow wherever possible irregardless of system demands.

2. New VFD's, solid state starters, and transformers shall be supplied for the new pumps.

3. The number of operational pumps must be able to be programmed into the system, through an English message display system, and the system must then operate accordingly to how many pumps are available.

4. The new pump control system shall receive signals from the level sensing equipment as specified for maintaining the liquid level in the wet well. The level sensing equipment to be utilized for control signals shall be operator selectable at the MCP. The pump control system shall use the second set of level controls in the wetwell for the back up system.

C. Manufacturer's Experience:

1. The manufacturer of the control system shall be certified by Underwriters Laboratories (UL) as being a UL 508 listed systems panel shop certified to install a serialized label for quality control and insurance liability considerations.

2. The manufacturer of the control system must submit documentation verifying at least 5 years of experience in manufacturing and integrating AC VFD systems of a similar size and scope.

3. The manufacturer of the control system must submit to the Consulting Engineer documentation proving experience in successfully designing and manufacturing at least 5 similar systems of a similar scope.

4. Manufacturer's Quality Control: The control system shall be functionally tested at the manufacturers facility and certified as a complete system to assure proper operation per specification in order to minimize costly field changes. The Engineer and the individuals designated by the Engineer reserve the right to witness this final system functional test.

D. Shop Drawings:

1. The Engineer reserves the right to approve or disapprove any and all equipment based upon evaluation. Approval for fabrication and installation will be made only after submittal and review of all shop drawings. The information required for approval shall include the following sets as a minimum:

a) Electrical diagram of the control system.

b) Complete electrical schematics detailing every wire and connection within the system as well as all field connections.

c) Detailed drawings of the enclosure (size, construction, entry/exit, mounting).

d) Bill of Materials and Product Data Sheets.

E. Hydraulic System Analysis:

1. The supplier of the variable speed control system shall supply a complete hydraulic analysis of the system in order to verify that the system should operate without damage due to pump operation too far to the left of the curve during low speed operation, too far right of the curve during high speed operation, hydraulic overload, or inefficient / heat generation / cost prohibitive operation at various critical speeds / frequencies. The control system manufacturer shall coordinate with the pump and VFD manufacturer to obtain all necessary information.

a) Graph which shows the system input horsepower, taking into account the efficiencies of the pump, VFD, and the motor, plotted against all flows on a continuous basis from project minimum to maximum flows.

b) Graphs which plot the system curve against the pump curves at 100% speed, 90%, 80%, etc., in 10% increments, until the pump speed does not generate enough head to overcome the system static head. These curves must also show curves of constant hydraulic horsepower to verify non-overloading.

c) Tabulated data shall be provided showing the following information, starting at the pump(s) speed required to overcome the system static, in 2% speed increments:

1) % speed

2) Flow (GPM)

3) T.D.H.

4) Line H.P.

5) Cost/million gallons

6) Wire to water efficiency

d) Wet-well model detailing the following:

1) Level excursions plotted against the diurnal inflow profile on a 24 hour basis.

2) Summary of the projected run-time for the pumps.

3) Projected yearly energy consumption.

e) The current drawn by the motor and by the VFD, at all operating speeds, in order to verify that neither the VFD nor the motor will be overloaded at any point in the operating range.

f) This hydraulic analysis shall be provided to the Engineer along with the initial submittal drawings. This analysis shall again be done once the final pumps, motors, variable speed controls, piping, etc. has been approved by the Engineer to verify proper system hydraulic performance under "As-built" conditions.

F. Programmable Controller/System Controller:

1. Acceptable Manufacturers

a) Systecon Inc., Cincinnati, Ohio

b) Allen-Bradley

c) E.G. Pump Controls

2. The wetwell level control system shall utilize two (2) Systecon Model S9511 Universal Controllers for redundant control. The two universal controllers shall be designed to transfer automatically from one to the other in the event of failure of the operating controller. The control system shall maintain a constant wetwell level utilizing the wire-to-water efficiency calculations and shall add and subtract pumps based on wire-water efficiency control.

3. The Receiver/Controllers shall be flush mounted in the door of the control system enclosure and shall be microcomputer based. On-line programmable data entries, such as setpoints, calculated results, and totalization shall be stored in non-volatile memory. All data entry shall be keypad in engineering units.

4. 25% spare input and output points on the system controller shall be provided for usage directed by the Engineer if required during start-up. these points are to be prewired to a plug-in terminal strip. A minimum of 3 interposing relays and 2 time delay relays, are to be prewired and mounted for interfacing purposes. A real time clock function shall be provided.