1159 Rockridge Pump Station Replacement_Pump Station Specification.pdf

FACTORY-BUILT BOOSTER PUMP STATION

PART 1: GENERAL REQUIREMENTS

SCOPE OF WORK

The contractor shall furnish and install one (1) factory-built, factory delivered, water booster pump station in a modular building with base frame with all necessary internal piping, valves, fittings, supports, meter, pumps, motors, controls and other necessary appurtenances as specified herein.

The booster pump station shall be complete when delivered and will not require internal contractor construction except to install the power service through the service conduit opening provided for that purpose, to connect the main water service to the required points and other work as may be listed in the section for CONTRACTORS INSTALLATION

REQUIREMENTS.

CONTRACTOR INSTALLATION REQUIREMENTS

The contractor shall be required to provide a crane to set the station on the foundation designed by the engineer. The foundation shall be built by the contractor as directed by the engineer. Following setting of the station, the contractor will be required to anchor the station to the foundation. The contractor shall supply the anchor bolts. The installing contractor shall be responsible for interfacing with any components not included with the station, including the power and signal wires for the field located electric butterfly valve actuator as provided by others on the project site.

MANUFACTURER’S RESPONSIBILITY FOR PERFORMANCE

The specifications and drawings for the factory-built equipment do not necessarily include all the details for the design and fabrication of the equipment. The drawings are generally schematic, but the specifications call out strict requirements to known methods, components and assemblies that must be in a full, complete and functional pump station. As such, the manufacturer shall accept and hold complete responsibility for the functionality of the booster pump station and its workings.

BASIS OF DESIGN MANUFACTURER

The BASIS OF DESIGN station is by EFI-Solutions, having been deemed to represent the minimum level of quality, performance and service acceptable for this equipment. EFI- Solutions is represented by Mr. Chris Horneck of Hydrosol, telephone 303-692-0825.

PRE-BID SUBMITTAL DOCUMENTS

1. All manufacturers proposing on the equipment set forth in these documents shall provide the below-listed PRE-BID SUBMITTAL documents for the booster pump station. These manufacturers shall take no exceptions to the contract documents. Manufacturers must provide a submittal to the Engineer of Record at least ten (10) days prior to the bid date in order to be eligible to provide proposals for this equipment to bidding contractors. The Engineer of Record will publish an addendum three (3) days prior to the bid date indicating which manufacturers have met the submittal requirement and are approved to submit proposals for this equipment.

2. MANUFACTURERS AND BIDDING CONTRACTORS ARE HEREBY

NOTIFIED THAT THIS SUBMITTAL MUST BE SPECIFIC TO THIS

PROJECT AND COMPLETE AS IT WILL BE REVIEWED FOR

PURPOSES OF APPROVING MANUFACTURERS TO BE ELIGIBLE TO

SUBMIT PROPOSALS AND TO IMMEDIATELY PROVIDE APPROVAL OF

THIS EQUIPMENT FOR FABRICATION POST BID. THERE WILL BE NO

POST BID SUBMITTAL.

SUBMITTAL DOCUMENTS

Equipment submittal shall be provided bound in a minimum of two (2) hard paper copies or electronic format as determined by the engineer. The submittal shall contain a minimum of two (2) full size drawings, size 24" x 36"; one (1) each covering the station mechanical and the electrical control schematic. The station drawing shall be specific to this project, in at least three (3) different views, be to scale and illustrate the National Electrical Code (NEC) clearances per Section 110-26 of the code. The submittal will be complete with data sheets covering all major components provided with the station, the UL/ETL file number under which the manufacturer is listed, service department personnel statement as detailed in the specifications and be complete with the manufacturer's formal warranty policy. The submittal shall be complete with a full-size photocopy of the manufacturer's combination UL/manufacturer logo Packaged Pumping Systems label.

The equipment submittal shall contain at a minimum:

1. “D” sized only, station mechanical drawing sheets fully to scale and fully annotated showing;

a. A PLAN VIEW of all mechanical equipment, piping and devices necessary to system operation and with NEC Electrical Clearances;

b. A SECTION VIEW;

c. A PLAN VIEW of the station top structure;

d. A complete STRUCTURAL PLAN VIEW of the steel base for the station.

2. “D” sized only sheets showing;

a. A POWER ONE LINE DIAGRAM annotated and showing all power components;

b. A PROCESS & INSTRUMENTATION DIAGRAM (P&ID) showing all components, devices and circuits for the control and monitoring equipment.

3. A detailed drawing of the building to be used to house the station including anchoring and assembly methods.

PRE-BID SUBMITTAL documents will not be accepted after the date set. It is the bidding contractors’ responsibility to determine which manufacturers have provided the required PRE-BID SUBMITTAL documents and been approved by the engineer to provide an equipment proposal.

The Engineer of Record shall review the PRE-BID SUBMITTALS for adherence to the contract documents.

QUALITY ASSURANCE

The equipment furnished shall be designed, constructed, and installed in accordance with the best practices and methods and shall operate satisfactorily when installed as shown on the contract drawings and operated per manufacturer's recommendations.

THIRD PARTY INSPECTION LISTING

The station manufacturer shall be required to affix to the station an UNDERWRITERS LABORATORIES (UL) LABEL attesting to the compliance of the station equipment under the PACKAGED PUMPING SYSTEMS (QCZJ) UL Listing Category and/or INTERTEK TESTING SERVICES (ETL) LABEL attesting to the compliance of the station equipment under PACKAGED PUMPING SYSTEMS. The ETL label shall state the station conforms to UL STD 778 and is certified to CAN/CSA STD C22.2 NO. 108.

SHIPPING AND DELIVERY

The specified equipment shall be delivered by the manufacturer FOB DESTINATION and the station manufacturer shall hold full responsibility for the condition and completeness of the equipment upon its delivery.

The Engineer and/or Owner shall hold the right to inspect the equipment prior to unloading and setting so as to assure the quality and condition of the equipment is in no way deficient.

If, in the view of the Engineer or Owner, the equipment is deficient when delivered, delivery shall be refused.

SPECIFIED COMPONENTS

Within this specification, certain components are listed by name and/or model number for at least one (1) manufacturer’s specific product. As such, no “OR EQUAL” is listed or allowed for these specific products.

These listed components have been chosen because of the Engineer’s and Owner’s knowledge of and experience with the components.

No other components other than those listed are acceptable.

FACTORY START-UP AND TRAINING SERVICE

Without exception, the station manufacturer is directly responsible for station start-up and operator training. Third party contractors, agents or representatives are not to be allowed to start up the station nor the equipment therein. As such;

1. Start-up Factory Service Technician shall be a regular employee of the station manufacturer.

2. The booster pumping system manufacturer and controls integrator shall provide two (2) electronic O & M’s in pdf format containing as built final system drawings, I/O listings, wiring diagrams, and operating and maintenance information. The submitted manuals shall be sufficient to facilitate the operation, removal, installation, programming, and configuration, adjustment, calibration, testing and maintenance of each and all components and instruments. Final software listings of the operational ladder logic shall be provided herewith.

MANUFACTURER'S WARRANTY

The warranty is the sole responsibility of the station manufacturer and shall be provided in written form, being placed in both the submittal documents covering the specified equipment and the O&M manuals provided with that equipment.

It is required the station warranty provide the Owner with a single source responsibility for all components specified herein and the system as a whole. That single source shall be none other than the station manufacturer. Third party suppliers, service contractors, “Pass-through” warranties and service by the representative are not acceptable.

Said manufacturer's warranty shall at a minimum cover:

1. A period of one (1) year commencing upon successful start-up, after authorized manufacturer's start-up, not to exceed eighteen (18) months from the date of manufacture completion.

2. The warranty period shall be inviolate regardless of any component manufacturer's warranty for equipment and components within the station.

3. The manufacturer's warranty shall cover all equipment, components and systems provided in or with the station by the manufacturer of the station, exclusive of those components supplied by and/or installed by others independent of the manufacturer of record for this station.

4. The warranty shall provide for the station manufacturer to bear the full cost of labor and materials for replacement and/or repair of faulty or defective components so there shall be no cost incurred by the Owner for this work during the warranty period.

5. The manufacturer's warranty policy is amended only by the items considered consumable, i.e., light bulbs, pump seals, pump packing, lubricants and other maintenance items consumed by usage.

6. No assumption of contingent liabilities for any component failure during manufacturer's warranty is made.

7. The warranty pertains only where the equipment has been operated in strict accordance with the manufacturer’s instructions and requirements. Evidence of misuse or modification to the equipment voids the warranty.

If the submitted written manufacturer's warranty does not meet the minimum requirements set forth above, that submittal will forthrightly be rejected.

GENERAL LIABILITY INSURANCE

The water distribution station manufacturer shall furnish premises/operations and products/completed operations general liability insurance from an insurance company with a rating of A-V according to the most recent Best's Key Rating Guide, in an amount equal to $1,000,000 per occurrence and up to $11,000,000 total with Umbrella.

The insurance certificate must be included with the manufacturer's submittal. The coverage must be provided by an insurance carrier licensed and admitted in the state of manufacture.

PART 2: PRODUCTS AND COMPONENTS

BUILDING DESIGN CRITERIA

The station building enclosure shall be a factory assembled, modular structure of one

(1) compartment all attached to the station base structure and requiring no additional assembly at the job site.

The building design criteria shall be: (1.) To withstand snow load based on ASCE 7-10 Ground Snow Loads for the state and county of installation (2.) To withstand wind loads based on ASCE 7-10 for wind speeds; (3.) Be designed for site specific seismic requirements based on local conditions as dictated by the Available Ground Motion Parameters according to ASCE 7 and IBC established by zip code and a live floor load of 125 PSF; (4) Be designed to IECC 2015 version of the energy code.

The modular building enclosing each of the stations is shown at its minimum size so that National Standards mandated clearances are maintained above, below and around equipment for proper and safe servicing, removal and reinstallation of this equipment.

The building specified shall be of the size shown on the drawings. Building sizes less than those shown will not be allowed.

STATE OF COLORADO

By State of Colorado Law, all Modular Buildings Manufactured in or imported into the state must have Model Plan Approval by the industrialized buildings/mobile structures program administered by the Colorado Department of Local Affairs, Division of Housing. An authorized Manufacturer will be a current registered Industrialized Building Systems/ Mobile Structures Manufacturer with the State of Colorado. Each unit will bear a serialized label certifying it is in Compliance with the current codes adopted by the State of Colorado. The pump station Manufacturer will be required to provide the serialized label attached to the station before leaving the manufacturing facility. Stations lacking this serialized label at time of delivery will not be accepted.

BUILDING CONSTRUCTION

The materials specified are specifically chosen to be resistant to moisture degradation and infestation and to be maintainable.

Insulation values for the walls and roof structure shall be a minimum R-21 in the walls and the roof. Insulation within the roof and wall panels shall be foam-in-place polyurethane material applied between the interior and exterior sheathing forming a closed cell bounded by the steel framing. The insulation shall have a minimum density of 2.0 lbs/cu. ft. nominal and shall be applied to the thickness required to provide a minimum R value of 21. The insulation shall have an ASTM E-84 flame spread Class 1 < 25 and smoke development Class 1 < 450.

Building framing materials shall comply with the A.I.S.I. Specification for the Design of Cold-formed Steel Structural Members and to Standards ASTM C-955, ASTM C-1007, ASTM C-645, ASTM C-754 and ICBO 4782P. and 4784P. A framing design incorporating the members covered by the listed specifications and standards shall develop a structure meeting or exceeding the building design criteria listed previously.

Metal-clad, foam insulated panels or SIPS will not be allowed.

The building structure shall be fabricated using steel C-studs as wall framing members and C-joists for roof support. The size, placement and spacing of studs and joists shall be in accordance with the design criteria and material standards. The wall C-studs shall be a minimum 2" x 3 5/8" size of 16 gauge material minimum. The roof C-joists shall be a minimum 1-5/8" x 8" size of 16 gauge material minimum.

The exterior wall sheathing shall be 1" thick, 15 psi polystyrene foam board insulation with an R-5 insulative value.

The exterior roof sheathing shall be 5/8" thick, exterior, CDX grade plywood.

The interior wall and ceiling sheathing shall be 3/4" thick, exterior, CDX grade plywood.

All interior wall & ceiling surfaces shall be covered with .090" thick FRP (fiberglass reinforced plastic) sheeting of pebble grain, gloss, white finish. The individual wall faces shall be covered with one continuous sheet. The FRP sheets shall be glued to the sheathing requiring no fasteners. Corner moldings of like FRP material shall be installed & finished in a workmanlike manner.

Openings in the sidewalls and/or roof shall be as shown and be fully framed out and supported using single or multiple framing members sufficient to support and fasten those devices or equipment items requiring a framed opening, these being access hatches, HVAC equipment, pipe passages, conduit passages, door and window openings and other special purpose openings as might be shown and required. The attaching of devices or equipment to the building at a framed opening shall be done fully according to the device manufacturers mounting instructions.

The building shall be warranted by the station manufacturer for a period of ten (10) years from the date of delivery.

HEAVY DUTY STEEL DOORS

Doors, single and double leaf and of the size shown, are manufactured of 18-gauge galvanealed steel. All doors shall be full flush construction and 1-3/4 inches thick. Doors shall be reinforced, stiffened, insulated, and sound deadened with a solid polystyrene foam board permanently bonded to the inside of each face skin. The lock and hinge edge of each door shall be welded with a center hairline seam the full height of the door. The lock edge shall be reinforced full height by a 14-gauge continuous one-piece channel extruded templating. The hinge edge shall be reinforced full height by a 14-gauge continuous one-piece channel, formed and tapped for hinges. Top and bottom of the door shall be closed with 16-gauge channels. Doors shall be thoroughly cleaned and receive an iron phosphate treatment prior to receiving one coat of prime paint. Door closures and rim panics are reinforced with 14-gauge channels.

Doors shall be fully-mounted in frames produced for pre-hanging of commercial 1-3/4" doors. Frames are formed to 16-gauge commercial quality cold rolled steel conforming to ASTM A366 or A620 and A568. Frames are produced in two welded units, to be mechanically joined during installation. The base side is prepared for all required hardware.

Both units, base and trim, are furnished with welded mitered faces. Frame anchoring includes compression anchors and stud screws. Door hinges shall be continuous gear hinges, fabricated of extruded 6063-T6 aluminum alloy/temper with pinless assembly. The doors shall have a lockset, exterior handle, and top mounted-door closer with hold-open device.

Doors and frames shall be finished with a two-component, aliphatic/acrylic polyurethane coating, white in color, with a high gloss finish. The coating shall be resistant to a wide range of solvents and chemicals under splash and spill conditions. The coating system is V.O.C. compliant.

MOUNTING AND FASTENING

The building shall be fabricated up from and securely attached to a framework fabricated of 2" x 6" steel tubing welded at each corner to form a base frame serving as a stable base for handling and transporting the building prior to attaching the building to the station base skid. To hold the building framing to the 2" x 6" base frame, 5/8" anchor studs will be welded to the base frame. In assembling the building framing to the base frame a 3 1/4" x 4" x 1/4" thick anchor plate under a flat washer, lock washer and 5/8" nut shall be used to fasten the building framing to the framing base as shown. The base frame shall be grit blasted to a SP-6 finish and coated with the specified coating material.

The building enclosure shall be firmly and securely attached to the steel base structure by lag bolting from inside the station, through evenly spaced 9/32" holes pre-drilled into a 2" by 1-1/2" by 1/8" thick angle piece that has been continuously welded to the steel floor. The lag bolts shall screw into the 2" x 6" tubular base frame upon which the building has been built.

The lag bolts shall be plated steel, size 5/16" diameter x 2" long. The number and location of the lag bolts shall be as determined by structural analysis so as to maintain the live load and wind load ratings as specified and to resist shearing and tearing in the process of transporting and placing the finished station.

EXTERIOR TREATMENT-VERTICAL BOARD & BATTEN METAL SIDING

The exterior sheathing shall be covered with James Hardie ® Panel Siding with

Hardie® Trim Batten Boards. The siding and trim are to be Cedarmill finish in Mountain Sage color. The battens are to be Rustic Grain finish in Mountain Sage color.

METAL ROOF SYSTEM

The roof sheathing shall be covered with a 26 gauge metal panel system to form a standing seam roof as shown. The panels shall have a Galvalume® substrate with a Kynar 500® finish. The panels shall meet UL Standard 2218, Class 4 impact resistant and Class A fire resistant rating. The system shall be complete with fascia and soffit. The minimum roof slope shall be 3:12.

The ridgeline of the roof shall be covered end to end with a broken edge panel open along the sides to create a roof vent along both sides of the entire ridge line. The top of the broken edge panel along the ridge line shall cover over the top of the standing seams to provide a finished appearance. The roof metal panels and trim color is “To Be Determined” by the customer.

REGISTERED PROFESSIONAL ENGINEER REVIEW

The building and the means of attaching the building to the foundation shall be reviewed and stamped by a Colorado Registered Professional Engineer.

BUILDING SUBSTRUCTURE

The base/floor system substructure shall be made up of steel plate and standard structural steel shapes of the sizes and weights sufficient to bear the loading placed on the base by shipping and operation.

The substructure shall be designed to support the building live and dead loads plus the burden imposed by loading, transporting and unloading of this equipment.

All steel plates used in the substructure shall meet or exceed the requirements of ASTM-A36. The structural shapes (channels and angles) shall be of the thickness/weight as shown on the plans for this item and shall meet or exceed the requirements for ASTM A-36.

The structural rectangular or square tubing shall be of the wall gauge as shown on the plans for this item and shall meet or exceed the requirements for ASTM A-500 Grade B.

On the substructure floor plate, indented approximately 6”,there shall be welded a 1- 1/2” x 2” x 1/8” steel angle iron with drilled holes. This angle steel piece shall be the bracket through which the building is attached to the base substructure.

SKID INSULATION

The steel skid underside shall be insulated with a isocyanurate (flame retardant urethane) foam insulating material. The insulation shall be applied in each of the spaces between the structural members and the interior perimeter of the skid by spray and other approved methods. The insulation shall be 2 inches thick and have a minimum density (compressibility) of 1.7-1.8 lbs/cu. ft. nominal. The insulation shall have a ASTM E-84 flame spread rating of less than 30.

FLOOR DRAINS

The floor drains shall be a 4” grated opening with 4” I.D threaded hub for connection of a drain line up under the station floor.

PIPING FLOOR PENETRATIONS

Where suction and discharge piping, or any other pressure piping, passes through the station floor plate and base sub-structure, that area of the floor shall be provided with a grout sleeve made up of steel pipe of 9” height and of sufficient annular diameter to pass a full size pipe flange for the pipe size shown.

The steel sleeve shall be welded into the floor plate with a 1” projection above the floor in the station. Following installation of the inlet and outlet pipes, the installing contractor shall be responsible for furnishing and installing grout to close the opening around the installed pipe.

SAFETY FLOOR MATTING

The walkway areas (that space from the entrance ladder to the control panel and the entire NEC clearance area) shall be covered with a rubber drainage runner. The runner shall be medium duty, 1/2 inch minimum thickness of open slot design allowing fluids to drain understanding or walking surfaces. The runner shall have a tread design to promote sure footing. The underside of the runner shall have a raise knob design to permit aeration and drainage, and to reduce runner fatigue. The runner shall not be glued to the floor.

PUMP OPERATING CONDITIONS - PUMP STATION

The pump station shall be capable of delivering the fluid medium at the following capacities and heads when operating at 0 feet minimum suction pressure.

PUMPS #1, #2 AND #3

The pumps shall be Close Coupled End Suction by Cornell Pump Company, Inc., model 2YH-CC NSF-61

Design Point: 325 GPM @ 300 feet TDH;

Maximum Point: 422 GPM @ 250 feet TDH;

NPSHr: 14.8 feet;

Discharge Pressure: 149 PSI;

Pump Efficiency at Design Point: 70.4% Pump Power: Non-overloading for 39.6 rated h.p.

Rated Motor Power: 50 hp.

Motor Speed: 3600 rpm nominal.

Electrical Power: 480 volt 3 phase, 60 cycle.

PUMPS – CLOSE COUPLED HORIZONTAL END SUCTION, CENTRIFUGAL

The pumps employed within the pump station shall be of the close coupled, horizontal end suction, centrifugal configuration.

The pumps shall be of close grain ductile iron construction complete with bronze trim.

The pumps shall conform to the detailed specifications as set forth below:

The pumps shall be Volute style, with the pump casing double bolted to the adapter and a recessed lock fit to ensure alignment. No stud or bolt holes are tapped through the casing to liquid ways. Tapping openings are provided for priming, venting, draining, and suction and discharge gauge connections. Piping connections are to be as shown on the pump data sheets.

Impellers are to be single suction type, cast in one piece. All impellers are to be statically balanced to ensure smooth operation, also hydraulically balanced except in some small sizes where end thrust is but a minor factor.

Wearing rings shall be renewable, be set on both the impeller and body and be set maintain proper running clearance with impeller hubs to minimize leakage between the suction and discharge.

Shaft sleeves shall be shouldered onto the shaft to cover the full length of the shaft from the impeller hub to the motor end bracket by being in compression over the shaft protecting the shaft from contact with liquid.

The stuffing box shall be cast integral with the pump casing. The stuffing box shall contain a single face type mechanical seal. The seal shall have a carbon rotating head against a Ni-Resist stationary face and be complete with a Buna-N boot with a stainless steel spring and spring retainer.

The motor adaptor shall maintain a rigid, bolted, registered assembly between motor and the casing by a machined lock between adapter and motor end bracket keeping the adapter and casing in permanent alignment with motor and motor shaft.

Motor configuration shall be as a close-coupled assembled as an integral part of the complete units. The extended motor shaft carries the impeller and shaft sleeve. Motor bearings are ball bearing type, designed to carry all radial and thrust loads, and are installed in sealed housings which retain lubricant and exclude dirt and moisture.

PUMP/MOTOR VIBRATION ISOLATION PADS

The pump/motor assembly shall be mounted to a fabricated steel base built specifically for the pump/motor to be mounted. Each mounting or attachment point shall be complete with a vibration isolation pad. The pad will be in two (2) parts, a 1/4" base layer followed by a 5/8" upper layer and be a nominal 2" x 2" square size for pump/motor combinations weighing up to 1500 pounds.

PUMP SUPPORT STANDS

The pump support stands shall be structural steel C-channel, standard weight or steel plate bent to form a channel. The bent steel plate shall be of sufficient thickness to support the pump and motor. A plate or channel shall be welded between the pump supports to form an “H” configuration for rigidity. The base of the legs shall be continuously welded to the steel floor.

PUMP MOTOR CONFIGURATION

The pump driver shall be a NEMA Design B, three phase, alternating current, (squirrel cage) induction motor, continuous duty rated, with motor insulation as Class F for Class B Heat Rise.

Motor efficiencies shall be Premium Efficient as stated in NEMA MG 1, 2011 Part 12, Table 12-12 for the motor enclosure, open or closed.

Motor Service factor shall be 1.15 on the nameplate, reduced to 1.0 when used with variable frequency drives per NEMA MG 1 – 2011, Part 31.3.7.

The motor enclosure shall be Open Drip Proof (ODP).

Motors of 600 volts or less shall meet the requirements of NEMA MG 1 2011 Part

31.4.4.2 for ability to sustain voltage spikes when used with variable frequency drives under usual conditions

These motors are for use with variable frequency drives. Motors of 100 HP and greater shall have the motor bearings insulated to avoid voltage potential on the motor shaft flowing as current through the bearings; see PUMP SHAFT BEARING INSULATION AND

GROUNDING RINGS.

PIPING – STEEL PIPE

The piping shall conform to AWWA Standard C-200.

Piping 3 inches in diameter and above shall be steel and conform to material specification ASTM A-53(CW) for nominal pipe size four (4) inch and smaller and ASTM A- 53(ERW) Grade B for nominal pipe size five (5) inches and larger. Steel butt-welding fittings shall conform to material specification ASTM A-234 Grade WPB and to the dimensions and tolerances of ANSI Standards B16.9 and B16.28 respectively.

Forged steel flanges shall conform to material specification ASTM A-105 Class 60 and/or ASTM A-181 for carbon steel forgings and to the dimensions and tolerances of ANSI Standards B16.5 as amended in 1992 for Class 150 and Class 300 flanges.

The piping sizes shall be as shown on the drawing.

Size 10 inch and below - Schedule 40

Size 12 inch and above - Standard weight (.375" wall)

PIPE WELDING

All pipe welds shall be performed by certified welders employed by the pump station manufacturer. As part of the equipment submittal, the pump station manufacturer shall provide copies of the welding certificates of the employees who are to perform the pipe welds.

Shop welders shall be certified in accordance with ASME BPVC Section IX or AWS D1.1. Certification shall be done by an independent testing laboratory giving certification for the weld positions for which the tests were performed.

PIPE SURFACE PREPARATION

All piping inside and outside surfaces shall be prepared by grit blasting, or other abrasive blasting, prior to any welds taking place to minimum SP-6 finish.

PIPE CUTTING

Piping of 4" diameter and smaller may be cut by saw.

Piping of 6" diameter and larger shall be bevel cut, and Oxyfuel or Plasma-arc cutting techniques shall be used to assure and facilitate bevel pipe cuts.

SADDLE CUTS AND WELDS

Saddle cuts in pipe made in preparation for a saddle weld of a pipe at an angle to a pipe shall be made with numerically controlled, plasma cutting machines. Similarly, saddle end cuts to pipes to make a saddle mating piece shall be done with the same numerically controlled plasma cutting equipment.

When the two saddle cut pieces are mated and welded with the MIG process, the internal finished weld shall be smooth and free of inclusions, crevices and other corrosion sites.

PIPE WELDING TECHNIQUES

Pipe welds shall be performed by metal added, inert gas shielded arc welding (MIG) techniques wherein the weld heat settings, the wire feed speed and the traverse speed of the work below the welding are numerically set to assure proper weld fusion and penetration and repeatable welds.

In all cases, short circuit transfer, spray transfer or pulse-arc transfer modes of the gas metal arc welding process shall be used.

When utilizing the short circuit mode, shielding gas consisting of 50% carbon dioxide and 50% argon gas shall be used. When utilizing the spray or pulse-arc transfer modes, a shielding gas consisting of 5% carbon dioxide and 95% argon shall be used.

In all cases, welding wire with a minimum tensile strength of 70,000 psi shall be employed.

All flange welds and butt welds of equal size pipe shall be a single continuous nonstop weld around the complete circumference of the pipe. Whenever possible, vertical up weld passes will be applied to all pipe welds. No vertical down weld passes will be allowed.

Completed pipe welded assemblies shall create no internal obstruction, restriction or create any unintended sources of water deflection.

Piping of six (6) inch diameter and larger shall require a minimum of two (2) weld passes to complete each weld. The first pass, or root pass, shall be applied at the bottom of the bevel cut using the short circuit transfer welding mode, and the second pass, or cap pass, shall be applied over the root pass using the spray or pulse arc transfer welding modes to insure that at a minimum the total weld thickness shall be equal to thinnest of the two pieces being welded together.

The pipe shall be sand blasted, as specified elsewhere, before pipe weld and after pipe weld, before fusion bonded epoxy is applied.

WELD STANDOFFS

No welding shall be performed on fusion bonded coated piping after the coating process has been performed.

Where any piping is to be welded after the application of fusion bonded epoxy coating to the inside of the pipe, at the point of the weld, a weld standoff must be welded to the pipe prior to the coating. The weld shall be made to the standoff and not onto the pipe.

PIPE SUPPORTS

Pipe supports by minimum sizing for:

- 8" and smaller piping shall be 2" x 3" x 3/16" wall rectangular tubing;

- 10" and larger piping shall be 3" x 4" x 1/4" wall rectangular tubing;

- 6" and larger piping shall be provided with "kick" bracing projecting fully from the underside of the pipe to the floor at an angle of no less than 15 degrees from vertical out at a right angle to the run of the pipe being supported. These "kick" braces shall be in addition to the vertical pipe supports called out above.

Pipe supports are to be fully welded at both end points to the pipe and steel floor where required.

Where components are to be supported and may require disassembly at some time, the supports for these components shall be welded at the bottom and bolted at the top by use of a bolt yoke welded to the top of the support and bolted into the flange connection picking up at least two bolts.

RISER PIPE VERTICAL SUPPORTS

All of the inlet and outlet vertical riser pipes shall be provided each with, two (2) structural steel, angle pipe support welded to the weldment plates on the vertical riser pipe to down to the floor. These supports shall be opposed by at least 120 degrees around the pipe.

The minimum member size for these supports shall be 2” x 3” x ¼” structural steel tubing for piping sized 8” and below and 3” x 4” x ¼” structural steel tubing for piping 10” sized 10” and above.

FUSION BONDED EPOXY INTERNAL PIPE COATING

The internal surfaces of piping to be fusion bonded coated shall be grit blasted to an SP-10 finish with the finish profile required by the coating material manufacturer.

The internal, wetted surfaces of the steel transmission piping shall have applied to it a Fusion Bonded Epoxy Coating on the interior pipe surface. The coating shall be applied and meet the testing requirements of Table 1 and Table 2 with the exception of Table 2 section 7 per AWWA C-213.

The powder coating product shall be National Sanitation Foundation (NSF) Standard 61 certified material.

Prior to shipment of the station, the station manufacturer shall provide in writing to the Engineer certification that the fusion bonded epoxy coating has been applied to all internal surfaces of the steel piping using the proper method. Said certification shall show under the station manufacturer's letterhead:

- Date of application;

- Material manufacturer and product designation including a product data sheet for the coating;

- Applier of the fusion bonded coating, name, address and phone number;

- Notarized signature of an officer of the station manufacturing company stating the fusion bonded epoxy coating was applied to AWWA Standard C213-91 or the latest revision.

COATINGS - CORROSION PROTECTION

All interior and exterior surfaces of the exposed steel structure, transmission piping, and fittings shall be gritblasted equal to commercial blast cleaning (SSPC-SP6). Following fabrication all exposed surfaces of the station, interior and exterior, shall be coated according to the following requirements.

WELDMENT PRIME COATING

All weldments will be pretreated by hand to provide additional corrosion protection using the same product as the base coat. Following the pretreatment full coating application shall take place.

BASE COATING

The base coating shall take place immediately after surface preparation. The protective coating shall consist of a two-component, high solids, high build, fast drying epoxy system for protection and finishing of steel and having excellent corrosion resistant properties. The epoxy system shall be self-priming and require no intermediate coatings.

TOP COATING

Following the base coating application, a full finish coating application shall take place. The protective coating shall consist of a two-component, high solids, high build, fast drying epoxy system for protection and finishing of steel and having excellent corrosion resistant properties. The epoxy system shall be self-priming and require no intermediate coatings. The base and finish coats shall provide a total dry mil thickness of 8.0 mils. The finish shall be “flint gray” in color.

FLOOR COATING AND CORROSION PROTECTION SYSTEM

The exposed surfaces of the structural steel base shall have a non-skid coating of a two-component, 100% high performance aromatic polyurea spray elastomer system with zero VOC (Volatile Organic Compounds), 100% solid. The coating shall offer outstanding performance and superior elastomeric protection for various substrates. The coating shall be designed as a user-friendly product for moisture insensitive applications because of its pure polyurea chemistry, and offer exceptional adhesion properties for properly prepared substrates. The high performance formulation shall produce an excellent skin formation for chemical resistance and moisture protection. The coating shall be dark gray in color.

Both the Iso “A” Side and Resin “B” Side shall be preconditioned between 70-90°F before application. Iso “A” and Polyol “B” components must be pumped by low-pressure transfer pumps to a suitable high-pressure proportional pumping system.

Temperature Settings:

Iso “A” Block Heater: 140-160°F

Resin “B” Block Heater: 140-160°F Hoses (Iso and Polyol) 140-150°F

Equipment Hydraulic Pressure: 2,000-2,500PSI

CHEMICAL TECHNICAL DATA:

Mix Ratio by Volume: Gel Time: 1A:1B 6-9 Sec Tack Free Time: 9-12 Sec Viscosity (cps) @ 77°F “A” Iso Side: 1,000±100 “B” Resin Side: 370±50 Material Density (lbs/gal) @ 77°F “A” “A” Iso Side: 9.5 lbs/gal “B” Resin Side: 8.4 lbs/gal.

BASIC PHYSICAL PROPERTIES:

All tests are performed by OCM Test Laboratories.

• ISO 17025 Certified

• American Association for Laboratory Accreditation (A2LA) Test Name Test Methods Value

Hardness Shore D ASTM D2240 60±1 Coefficient of Friction ASTM D1894 Static 0.305 Kinetic 0.127 Dielectric Const. ASTM D150 3.6 Dissipation Factor ASTM D150 0.031 Volume Resistance ASTM D257 2.3x1014 ohm cm Elongation ASTM D412 162% Flexural Strength ASTM D790 2,630 PSI Flexural Modulus ASTM D790 0.056 MSI Fungus Test MIL-STD 810F Pass Pull-off Test–Adhesion ASTM C297 To Metal – No Primer 1,800 PSI To Metal – XPM Primer 1,910 PSI To Metal – LXSF515 Primer 1,870 PSI Taber Abrasion ASTM D4060 0.06980 (gm Loss/1000 cycles) Tear Strength ASTM D624 783 ppi Tensile Strength ASTM D412 3,432 PSI Water Vapor Trans. ASTM E96 0.499 Grains/Hr Sq.Ft.

The chemical resistance testing for the coating shall be per ASTM D543 for immersion in fluids methods. Additional product certifications shall include USFDA Coatings for Incidental Food Contact Applications Certified by Keller and Heckman LLP and MIL-STD- 810F.

SERVICE CONNECTIONS ON INTERNAL PIPING

All plumbed devices within the station eventually requiring service, such as meters, control valves, pumps and like equipment, shall be easily removed from the piping by the presence of appropriately placed and sufficient quantity of adaptors and couplings as shown on the drawings; no less than the quantity of couplings and adaptors shown shall be allowed.

RESTRAINING POINTS

The main inlet and outlet piping to the station shall each be provided with four (4) restraining points as welded on "eyes" or similar device welded to the underside of the base structure framing as shown to facilitate the attachment of joint restraint tie rods or other device to be used in retarding any pipe movement at the connections.

COMPRESSION COUPLINGS

The station piping shall include a variety of compression type, flexible coupling to prevent binding and facilitate removal of associated equipment. These couplings are to be where shown on the plans. In lieu of a compression coupling, a flanged coupling adapter (FCA) may be used.

Grooved fittings may not be used under any circumstance.

All compression couplings or flanged coupling adapters (FCA), and flexible connectors/expansion joints shall include a minimum of two (2) zinc coated steel threaded rods across the joint with appropriate bolted restraining points.

ELASTOMER PIPE CONNECTOR

The inlet side of each booster pump shall include an elastomer connector to help isolate vibration and noise in the piping system. The elastomer connector shall be of single sphere design, constructed of neoprene and nylon with bias-ply tire reinforcing cord to provide a 225 psi working pressure rating to a minimum of 120 degrees F. The elastomer connector shall pass through the plate steel flanges designed to grip the connector so the connector seals without gaskets when the flange bolts are drawn up.

A control joint limiting pipe connector movement shall be supplied with each pipe connector.

LINE PRESSURE GAUGES

Combination pressure gauges shall have a built-in pressure snubber and have 4-1/2" minimum diameter faces and aluminum finished, surface mounted, back flanged case with a stainless steel ring, and a clear glass window. The movement shall be rotary; the bourdon tube shall be bronze with a lead-free brass socket. The gauge shall have a 1/4" MNPT lower mount process connection. Combination pressure gauge range and scale graduations shall be in psi and feet of water as follows:

Gauge ranges shall be established by the Engineer for each of the suction and discharge gauges for each pump station.

All gauges will be panel mounted off the pipeline and be connected to their respective sensing point. The gauge trim tubing shall be complete with both isolating and vent valves and the tubing shall be so arranged as to easily vent air and facilitate gauge removal.

Gauges mounted directly to the pipeline or at the sensing point will not be accepted.

Gauge ranges, markings and gauge location shall be identified in the submittal documents.

STATIC AND SENSING LINES

All gauge, switch and transmitter sensing lines shall be minimum 1/4” OD Type L rigid copper, run from the sensing point and a ball valve to the point of device mounting.

The alignment and organization of the sensing lines shall be straight runs with 90 degrees bends and be continuously rising.

The pilot tubing shall be run in a workmanlike manner with right angle bends and elastomeric/stainless steel mounting straps to securely hold the tubing to be free of stress and vibration.

SAMPLE TAP

A single, right angle outlet, smooth nose, brass sample tap shall be affixed to the manual vent ball valve for the low suction lockout and suction pressure gauge assembly.

HOSE BIBB WITH VACUUM BREAKER

There shall be provided a standard hose bibb with valve and vacuum breaker on the suction piping. The hose bibb connection shall be through a pressure regulator if the header pressure would exceed 60 psi.

BALL VALVES

The ball valves will be 2-piece, full-port design with blow-out proof stem. The seats, packing and seal shall be PTFE. Ball valves shall be provided with an adjustable stem packing nut. The body and retainer shall be lead free brass (DZR). The ball shall be lead free brass (DZR), chrome plated for sizes ¼”-1” and 316SS for sizes 1-1/4”-4”. The handle shall have a distinctive white “lead free” handle grip and blue “lead free” hanging tag. The valves will be NPTxNPT threaded pattern. Maximum working pressure shall be 600 psi up to 2” and 400 PSI for sizes 2-1/2” to 4”.

BUTTERFLY VALVES

Valve body shall be one-piece lug design with extended neck to allow for 2" of piping insulation. Flange hole drilling per international flange standard as specified. A non-corrosive bushing and a self-adjusting stem seal shall be provided. No field adjustment shall be necessary to maintain optimum field performance.

The disc edge and hub on metal discs shall be spherically machined and hand polished for torque and maximum sealing capability. Disc shall be Nylon 11 coated ductile iron or 316 stainless steel.

The stem shall be one-piece design. Disc to stem connection shall be and internal double "D" design with no possible leak paths in the disc-to-stem connection. External disc-to-stem connections such as discscrews or pins are not allowed. Stem shall be mechanically retained in the body neck and no part of the stem shall be exposed to the line media.

The seat shall be tongue-and-groove seat with a primary hub seal and a molded flange O-ring for weld-neck and slip-on flanges. The seat shall totally encapsulate the body isolating it from the line media and no flange gaskets shall be required.

The valve shall be rated for bubble-tight shut-off at pressures of 250 PSI for 2"-20".

Valve manufacturer:

A. Bray Series 31H B. Keystone

SILENT CHECK VALVES – GLOBE STYLE

Silent check valves shall be flanged to meet ANSI Class 250. Rated for 400 PSI CWP. The body of the check valve shall be ductile iron.

The plug and seat shall be bronze and conform to ASTM Designation B-584. The seat shall contain a Buna-N seal to provide zero leakage. The seal design shall provide for both a metal to metal low and high pressure without over-loading or damaging the Buna-N seal. The guide bushings shall be bronze copper alloy and conform to ASTM Designation B-584. The valve spring and seat retainers shall be stainless steel and conform to ASTM Designation A-313. The valve plug shall be guided at both ends by a center shaft integral with the valve plug. Alignment of the center shaft shall be provided by guide bushings.

Silent Check Valve manufacturer:

A. Val-Matic Model 1800 B. APCO Series 600A

GATE VALVES

Gate Valves shall conform to the latest version of AWWA Standard C-515 covering Resilient Seated Gate Valves for Water Supply Service.

The valves shall be 150# flanged with a ductile iron body and bonnet. The wedge shall be totally encapsulated with rubber. The sealing rubber shall be permanently bonded to the wedge to meet ASTM tests for rubber metal bond ATSM D249. Working pressure for valve sizes 2”-12” shall be 250 PSI.

Valves shall be supplied with O-Ring seals at all joints. No flat gaskets shall be allowed.

The valves shall be non-rising, opening by turning left to right. The handwheel shall have the "Open" and an arrow cast in the metal to indicate the direction to open.

Stems for NRS assemblies shall be cast bronze with integral collars in full compliance with AWWA. The stem shall operate with bronze stem nuts, independent of stem. The stem shall have (2) O-Rings located above thrust collar and (1) O-Ring below. O-Rings shall be replaceable with valve fully opened and subjected to full pressure. Stems shall also have (2) low torque thrust bearings located above and below stem collar to reduce friction during operation.

Waterway shall be smooth, unobstructed and free of all pockets, cavities and depressions in the seat area.

The body, bonnet and stuffing plate shall be coated with fusion bonded epoxy, both interior and exterior on body and bonnet. Epoxy shall be applied in accordance with AWWA C550 and be NSF61 and NSF372 certified.

Each valve shall have a maker's name, pressure rating, and year in which it was manufactured cast in the body. Prior to shipment from the factory, each valve shall be tested by hydrostatic pressure equal to requirements of AWWA.

Valves shall have all brass components cast and assembled in the USA.

Valve manufacturer:

A. Kennedy Valve B. M&H C. Clow

HYDRAULIC ACTUATED CONTROL VALVES - GENERAL

The valve configuration as shown shall be hydraulically operated, single diaphragm actuated. The valve shall consist of three major components: the body with seat installed, the cover with bearing installed, and the diaphragm assembly. The diaphragm assembly shall be the only moving part and shall form a sealed chamber in the upper portion of the valve, separating operating pressure from line pressure. Packing glands and/or stuffing boxes are not permitted and there shall be no pistons operating the main valve or pilot controls. Valve body and cover shall be epoxy coated. The stainless steel seat with integral bearing shall be of the solid, one piece design.

The diaphragm assembly shall contain a non-magnetic stainless steel stem of sufficient diameter to withstand high hydraulic pressures. The stem shall be fully guided through its complete stroke by a removable bearing in the valve cover and an integral bearing in the valve seat. No center guides shall be permitted. The stem shall be drilled and tapped in the cover end to receive and affix such accessories as may be deemed necessary.

The flexible, non-wicking, FDA approved diaphragm shall consist of nylon fabric bonded with synthetic rubber compatible with the operating fluid. The diaphragm shall be fully supported in the valve body and cover by machined surfaces which support no less than one-half of the total surface area of the diaphragm in either the fully open or fully closed position.

The pilot control system shall include CK2 isolation valves.

The pilot system shall include a X42N-2 strainer & needle valve.

The pilot tubing and fittings shall be stainless steel.

The pressure relief pilot shall be a direct-acting, adjustable, spring-loaded, diaphragm valve designed to permit flow when controlling pressure exceeds in the adjustable spring setting. The pilot control is normally held closed by the force of the compression on the spring above the diaphragm and it opens when the pressure acting on the underside of the diaphragm exceeds the spring setting. The pressure relief valve shall be supplied with the Dura-Kleen® stem (KD option).

The valve shall be equipped with One (1) body mounted limit switches with adjustable cams on the valve stem rod. The limit switches shall be 120 VAC, 24 VAC powered back through the station controls as so noted elsewhere in these specifications.

The Control Valve shall be a Cla-Val Model 50G-01BKCKD.

AIR RELEASE VALVES

Air Release Valves shall be automatic float operated valves designed to release accumulated air from a piping system while the system is in operation and under pressure.

The capacity and pressure rating of the valve is dependent on the diameter of the precision orifice in the cover. A large inlet connection is required for proper air and water exchange.

Valves shall be manufactured and tested in accordance with American Water Works Association (AWWA) Standard C512.