Attachment - Ia and Ib.pdf

Attachment Ia

Statement of Work PPW Vault 102 Upgrades

USDA, Ames, IA 5/7/24

Background:

The Pumped Pretreated Waste system (PPW) on the USDA campus in Ames, Iowa, carries waste from various buildings to the campus wastewater treatment plant. At locations along the PPW line, there are concrete vaults that house isolation valves, drain ports, decontamination ports, vent piping, and leak detection components. The existing piping that is inside the vaults is carbon steel with stainless-steel valves. Due to moisture entering the vault, the valves and piping have degraded to the point of needing to be replaced. The scope of this project is for the contractor to replace all the carbon steel piping components within a single vault (PPW Vault 102) with stainless steel, replace all existing valves with new stainless-steel, full-port ball valves, insulate all piping in the vault, and seal the PPW concrete vault to prevent further condensation and groundwater issues inside the vault.

Project Requirements. The Contractor shall provide all labor, piping, fittings, equipment, mounts, accessories, hardware, transportation, storage, and disposal of existing components as required to perform all work in accordance with these specifications. Piping sections shall be replaced at separate scheduled times/dates to alleviate the disruption of the wastewater processes and daily operations and to reduce the shutdown timeframe. These sections will be designated as “Building 9 section” and “Building 20, 21 section”. Refer to drawings for details. The contractor shall:

1. Work within the constraints of the facility’s ability to schedule downtime. Contractor shall replace only one section at a time to alleviate shutdown timeframe. The replacement of each section shall occur on separate days.

2. Replace all waste line piping and associated components inside PPW Vault 102 with stainless steel piping and components. See drawings for details.

3. Insulate all new stainless-steel piping once hydrostatic testing is completed and passed.

4. Correct the slope of the concrete floor of PPW Vault 102 via grouting material to allow water to flow to the sump discharge and prevent pooling of water inside the vault.

5. Seal the concrete walls, ceiling, and corrected floor of PPW Vault 102.

6. Ensure PPW Vault 102 is clean and free of all debris before project is completed.

1) Work within the constraints of the facility’s ability to schedule downtime.

a. This work will impact lab research that is required to follow a very precise schedule. All work must be coordinated in advance and schedules must be maintained throughout the project.

b. Each section of pipe may only be down for a maximum of 8 hours, on separate days.

The 8-hour timeframe shall include the three (3) hours required for the USDA to complete the decontamination process. The contractor will then have five (5) hours

Attachment I to complete their repair. An extension of decontamination time will not reduce the time frame allowed for the contractor. However, the contractor may use any time saved during the decontamination process, as long as the shutdown does not extend beyond the eight hours.

c. Contractor shall only replace one section at a time to reduce shutdown timeframe.

d. Each section shall be scheduled separately and on different days.

e. The dates of the scheduled shutdowns must be coordinated and evaluated regularly, beginning at the kickoff meeting.

i. The wastewater restrictions and shutdown timeframes included in the contractor’s schedule will include the time (3 hours) needed for the USDA staff to properly decontaminate each section.

ii. Upon first scheduled submission, the proposed shutdown dates must be included. The USDA and contractor will then evaluate these dates mutually and determine an appropriate time.

iii. An updated schedule will then be provided. Deviations from the planned shutdowns will not be acceptable. An inability to meet the mutually agreed upon dates provided in the schedule may result in a month’s long delay for project completion for rescheduling.

2) Replace all waste line components inside PPW Vault 102 with stainless steel components.

a. Coordinate all wastewater restrictions and shutdowns with the Contracting Officer’s Representative (COR) before beginning any work.

b. Schedule piping section replacements with COR as described in item 1.

c. Decontamination of the piping section will be completed by USDA staff prior to any replacement work being performed by the contractor.

d. Replacement of waste components shall match existing configuration.

e. Prefabrication of spools by the Contractor shall be used in this replacement to reduce the length of water restrictions/outages.

f. All joints shall be welded except where valves and flanges are connected.

g. Prefabricated spools shall undergo hydrostatic testing by the Contractor at 90psi for 1 hour without leaks prior to installation into the waste line.

h. Prefabricated spools shall be welded per specifications attached to this SOW. Sections are indicated on the drawings.

i. Verify all components and sections will fit properly before installation.

j. Any damage to the existing Reinforced Fiberglass piping shall be repaired/replaced

IMMEDIATELY by the Contractor at no extra cost to the Government.

k. All hardware used to connect all piping components and valves together shall be stainless steel.

l. USDA staff will be responsible for removing and reinstalling the existing leak detection assembly. Contractor shall replace the 1” carbon steel nipple with a new stainless-steel nipple of same size and length. See drawings for details.

3) Insulate new stainless-steel piping.

a. Protect and cover all valves, leak detection equipment, pit floats, bolts, etc. to prevent overspray.

b. Once new stainless-steel piping is installed and has passed the hydrostatic testing, apply the recommended primer product per the manufacturer’s instructions.

c. Once primer has cured properly, apply recommended insulating material per manufacturer's instructions.

d. Once insulating material has cured properly, apply the preferred top coating material per manufacturer's instructions.

e. Ensure all valving is operational and free of any material that was used inside the vault.

All threaded bolts used to connect piping sections shall be free from any of the products used to seal concrete floor, walls, and ceiling and to insulate piping.

4) Correct the slope of the floor of PPW Vault 102.

a. Concrete floor of PPW Vault 102 shall be thoroughly cleaned and prepared in accordance with floor sloping material manufacturer’s recommendations before applying sloping material.

b. Revise the slope of the concrete floor to positively affect drainage to the sump pit with no ponding or pooling in the vault.

c. Seal the floor after the sloping is completed using the same product used on walls and ceiling.

5) Seal the concrete walls, floor, and ceiling of PPW Vault 102.

a. New stainless-steel piping sections shall be installed BEFORE any sealing work is performed.

b. Concrete sealant shall be applied to the ceiling and all 4 walls of PPW Vault 102.

c. All required preparation to ensure sealant is effective is the responsibility of the contractor. This may include, but is not limited to, patches, spot repairs, and material enhancements at the intersection of the ceiling and wall.

d. Follow all manufacturer’s instructions for application of product including all preparation instructions.

e. Sealant material shall not be applied to piping and valving to avoid any issues with piping insulation materials, but the Contractor shall ensure complete coverage. Floor shall be sealed after the sloping material is installed.

6) Ensure PPW Vault 102 is clean and free of all debris.

a. Contractor is responsible for disposing of all old piping, hardware, flanges, spools, etc.

removed from PPW Vault 102. This includes all materials used in the application of sealants and coatings.

b. Remove all construction debris and thoroughly clean the entire concrete vault before project is completed.

c. Ensure that all valves operate as designed after the application of the insulation material.

Preferred Products:

Preferred Product Manufacturer of coating for walls, ceiling, and floor.

A. Preferred wall, floor and ceiling coating shall be Series 66 Epoxoline™ by Tnemec or an approved equivalent.

B. Preferred floor sloping material shall be Epoxytec Mortarec-Ceramico™ by Tnemec or an approved equivalent.

C. Any substitutions shall be equal to or greater than the preferred Tnemec product and will need to be approved by the COR prior to ordering of the material.

See “Rehabilitation and Lining for Concrete Wastewater Structures with Ultra-high Build Structural Epoxy” specification attached to this SOW.

Preferred Product Manufacturer for insulating of stainless-steel piping.

A. Preferred primer shall be Series 1224 Epoxoline™ WB by Tnemec or approved equivalent.

B. Preferred insulating material shall be Series 971 Aerolon™ Acrylic Insulating Coating

System by Tnemec or approved equivalent.

C. Preferred top coating shall be Series 1094 Endura-Shield™ by Tnemec or approved equivalent. Note: Substituted material must be able to withstand the decontamination solution used by the USDA staff inside the PPW vaults.

D. Any substitutions shall be equal to or greater than the preferred Tnemec product and will need to be approved by the COR prior to ordering of the material.

See “Product Guide Specification for Fluid-Applied Insulation Coating” specification attached to this SOW.

Project Specifications and Preferred Product Data Sheets for each application process are attached separately to this SOW.

General Requirements

Work Restrictions & Conditions

a. The finished product and all of its components shall provide a complete operational and functional system per this Scope of Work and the manufacturer’s specifications.

b. Anything mentioned in the Scope of Work and not shown on the drawings or shown on the drawings and not mentioned in the Scope of Work, shall be of like effect as if shown or mentioned in both.

c. The Contractor shall site verify any and all dimensions and shall carefully examine the project site and shall make all necessary investigations to become thoroughly aware of the existing conditions and all difficulties involved in the completion of the work in accordance with the contract documents prior to the submission of bid.

d. The completed installation shall comply with all applicable provisions of the Manufacturers Requirements, and the SOW (Drawings and Specifications), enclosed and/or attached.

e. All work will be performed by qualified personnel as defined by OSHA and as applicable per manufacturer’s specifications.

f. Contractor shall verify all equipment is operational and ensure that contractor’s quality control inspections and corrections have been accomplished before calling for the final inspection!

Site Security Access

a. Access to the construction site is controlled by a security fence and visitor/contractor check-in/check-out system. All contractor/sub-contractor employees shall sign in and out at the main site entrance gate and wear a contractor/visitor identification badge at all times while on the site. The ID badges will be turned in at the end of the workday. A current government-issued identification with a picture ID is required for entry.

b. All visitors must be pre-registered prior to coming onto campus. It is the responsibility of the contractor to ensure that the USDA is notified in the appropriate timeframe of any personnel that are performing work onsite and dates that work will be performed.

c. Contractor’s vehicles shall be parked in the building 9 parking spaces or in the gravel path leading up to PPW Vault 102. All vehicles and equipment must not impede traffic or affect building 9 operations. Parking areas will be designated by the COR prior to commencement of work. Vehicle badges shall be displayed at all times while the contractor is on site.

d. The Contractor shall use only the service roads and access routes approved by the Contracting Officer’s Representative.

e. Work shall be confined to the areas identified on the Drawings. Unless accompanied by a NCAH/USDA employee, the Contractor, sub-contractors, and their employees shall not enter buildings or facilities not specifically part of this project. Reasons included, but are not limited to, disease control and health requirements.

f. Additional security requirements may be imposed when the Federal Government raises the Homeland Security Alert Level. Additional directions will be provided if the situation occurs.

g. Failure to comply with access requirements shall be adequate grounds for removal of the Contractor/sub-contractor employees from the site and barring further site access to individuals.

Normal Work Hours

a. Construction work hours for the site are 7:00AM to 3:30PM, Monday through Friday, excluding Government holidays. Requests for exceptions to this schedule shall be made in writing forty-eight (48) hours in advance and approved by the Contracting Officer's Representative.

b. The piping section replacements shall occur at a scheduled date/time to be determined by facility needs and will be coordinated by the COR, facility staff and the contractor.

c. The application of the coatings for the walls, floor, and ceiling, along with the piping insulation shall be performed anytime between the hours listed above. New stainless-steel piping sections shall be installed BEFORE any sealing work is performed.

Work Outside Normal Work Hours

a. Any other work scheduled outside regular work hours including late hours, Saturdays, Sundays, and Government holidays requires the Contracting Officer’s Representative’s (COR) approval in advance. Make application to the COR at least 5 calendar days prior to such work to allow arrangements to be made by the Government for access to the work area and inspection & monitoring arrangements. Requests shall include the exact dates, hours, location, and purpose of the exception. If approved, the COR will coordinate access with the site security office.

b. Construct work in such a manner as to accommodate Owner’s use of premises during construction period. Coordinate construction schedule and operations with Contracting Officer’s Representative (COR).

c. Contractor shall coordinate use of premises under direction of the COR. Contractor shall confine construction equipment, storage of materials and equipment and operations of workers to areas permitted by law, ordinances, permits, or requirements of Contract Documents, and shall not unreasonably encumber premises with construction equipment or other material or equipment.

Contractor shall:

� Assume full responsibility for protection and safekeeping of items stored on site.

� Move any stored items, under Contractor’s control, which interfere with operations of Owner or separate contractor.

� Obtain and pay for use of additional storage or Work areas needed for operations.

� Transport all materials needed to the site. No deliveries shall be made to the USDA warehouses.

USDA shall refuse any deliveries to the USDA warehouse that are scheduled for this project.

Security Clearance Requirements

Use of Premises

a. Do not disturb portions of site beyond areas in which the work is approved. If land is disturbed due to stage or other reasons, the contractor is required to return the condition back to pre-construction condition or better at no cost to the government.

b. Keep driveways, entrances, walkways, and doorways serving premises clear and available to the Government, employees, visitors, and emergency vehicles at all times. Do not use these areas for parking or storage of materials.

c. The contractor shall provide a list of all staff employees that will be working on the project to the Contracting Officer’s Representative (COR) a minimum of five days in advance.

Adherence to Security Policies and Procedures

a. The Contractor shall adhere to all Site, APHIS and USDA security policies and procedures including Code of Federal Regulations Requirements, Standard Operating Procedures, Security Directives, Security Procedures, General Orders, Post Orders and any applicable Government Policies and Procedures.

b. Failure to adhere to or violation of any above listed requirements, procedures, directives, orders and/or policies may result in criminal prosecution or contractor representative or contractor employee (violator) removal.

Intent of Contract Drawings

a. Government provided drawings, henceforth referred to as “Contract Drawings”, do not attempt to show complete details of construction that may affect installation. Government provided diagrams of proposed systems are for reference only and do not necessarily show physical arrangement of all equipment and/or maximum number of devices. Minimum system requirements are shown.

b. Devices are shown diagrammatically only. System layout does not necessarily show maximum number of system components and should not be used for obtaining quantities for linear runs of conduits and wires. The contractor shall provide all conduits and wire wherever needed to complete installation of specific equipment required and provided by the Contractor.

c. Locations of existing and Government concept devices are approximate and may be distorted for clarity in representation.

Regulatory Requirements

The equipment materials, installation, workmanship, and operation shall conform to the most stringent applicable requirements of the most recent editions of the associated publications, in the below section and in the attached specifications unless otherwise noted:

1. American Concrete Institute, (ACI)

a. ACI 301 – Specifications for Structural Concrete

2. ASTM International, (ASTM)

a. ASTM C 868 – Standard Test Method for Chemical Resistance of Protective Linings

b. ASTM C 1583/1583M – Standard Test Method for Tensile Strength of Concrete

Surfaces and the Bond Strength or Tensile Strength of Concrete Repair and Overlay Materials by Direct Tension (Pull-off Method)

c. ASTM D 4060 – Standard Test Method for Abrasion Resistance of Organic Linings by the Taber Abraser

d. ASTM D 4414 – Standard Practice for Measurement of Wet Film Thickness by Notch Gages

3. International Concrete Repair Institute, (ICRI)

a. Guideline No. 310.1R – Guide for Surface Preparation for the Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion

b. Guideline No. 310.2 – Selecting and Specifying Concrete Surface Preparation for Sealer, Linings, and Polymer Overlays

4. Profiles Using Replica Putty

a. International Concrete Repair Institute, (ICRI)

b. Guideline No. 310.1R – Guide for Surface Preparation for the Repair of Deteriorated

Concrete Resulting from Reinforcing Steel Corrosion

c. Guideline No. 310.2 – Selecting and Specifying Concrete Surface Preparation for

Sealer, Linings, and Polymer Overlays

5. NACE International, (NACE)

a. NACE SP0188 – Standard Practice for Discontinuity (Holiday) Testing of Protective Linings

b. NACE No. 6/SSPC-SP13 – Surface Preparation of Concrete

6. Occupational Safety and health Administration, (OSHA)

a. Safety and health Standards (29 CFR 1910/1926)

7. SSPC: The Society for Protective Coatings, (SSPC)

a. SSPC-SP13/NACE No. 6 – Surface Preparation of Concrete

b. SSPC-Guide 12 – Guide for Illumination of Industrial Painting Projects

8. National Fire Protection Association (NFPA)

9. NFPA 101 – Safety to Life from Fire in Buildings and Structures.

10. NFPA 1 – Uniform Fire Code

11. NFPA 5000 – Building Construction and Safety Code

12. Underwriters Laboratories, Inc. (U.L.)

13. Appropriate U.L. Standards

14. State and Local Building Codes as adopted by the Authority Having Jurisdiction (AHJ).

15. The Uniform Federal Accessibility Standards (UFAS)

16. Equipment Manufacturer Printed Instructions

Coordination

a. The contractor shall coordinate all work with the Contracting Officer's Representative.

b. The contractor shall submit an installation schedule for review and approval by the

Contracting Officer's Representative within ten (10) days of task order award.

c. The prime contractor shall be solely responsible for coordinating work with all sub-contractors.

Special Provisions

a. All surfaces that have been altered for the installation of the new stainless-steel piping and coatings shall be refinished to match original condition by skilled personnel of the trades involved at no additional expense to the Government.

b. Finished surfaces of existing facilities that are affected, marred, scratched, or damaged by the contractor shall be refinished to match original condition.

c. Patching material shall be of the same type, style, and thickness, and shall be finished to match existing adjacent surface construction in color and texture.

d. Patching material, paint color, paint material and paint application methods shall be approved in advance by the Contracting Officer’s Representative.

e. Any damage resulting from contractor's operation shall be brought to the attention of the Contracting Officer's Representative immediately.

f. The contractor shall take all necessary and reasonable measures to keep the work site clean of trash and debris. Work areas shall be cleaned immediately as work in that area is completed, and before moving to a new work site. Place all trash and debris in OSHA approved containers, remove, and dispose of trash off site daily.

g. The contractor shall move all materials, and equipment, including ladders and scaffolding from the site at the completion of each day's operation unless otherwise approved by the Contracting Officer's Representative.

h. The contractor shall provide proper safety equipment to workmen and ensure a safe environment for employees and the general public at all times. The contractor shall work to ensure free, unobstructed, and safe access to and about the work area.

Temporary Facilities

Utilities: The Contractor will need to provide and utilize a generator for any power needs for this work.

There are no nearby electrical services. Contractor shall be allowed to use water services on site.

Contractor will need to provide tank or suitable container to transport water to project site.

Telephones: The Contractor shall equip all his foremen and work leaders with cell phones as necessary to coordinate the work effort. The Government will not provide any phone service to the project.

Toilet Facilities: The Contractor will be permitted to use the toilet facilities located inside the Utility Plant, Building 154.

Construction Material Storage Trailer: The Contractor may locate a construction material storage trailer to the site. Location shall be coordinated with the COR prior to delivery of any materials and/or construction beginning on site.

Confined Space Program

a. The Contractor and/or subcontractor employees who will be entering Confined Spaces shall be adequately trained and equipped for access and extraction. The Contractor shall provide all ventilation equipment, air quality monitoring, harnesses, and other safety equipment as appropriate for OSHA compliance. The Contractor’s Confined Space program shall substantially conform to the NCAH plan.

b. The Contractor shall submit a written copy of their plan(s) for acceptance by the COR prior to entry into any confined spaces.

c. The Contractor shall provide copies of entry logs and monitoring to the Owner’s Representative at any time requested during the project effort.

Lock-out/Tag-out Program:

a. The Contractor and/or sub-contractor employees who will be working on the job will apply a lockout/tagout (LOTO) process to control dangerous energy sources. The Contractor/sub-contractor shall have a LOTO program established and use Contractor LOTO locks, tags, and procedures.

b. The Contractor/sub-contractor shall review their LOTO program with NCAH F.E.U. personnel to coordinate LOTO programs before implementing LOTO.

Submittal & Shop Drawings Procedures

Submittal Register:

a. At the beginning of the project, the Contractor shall provide a Submittal Register identifying all the items called out in the Specifications for submittal to the COR for approval. The Contractor shall update and maintain the Submittal Register to show the current status of all required submittals.

Submittal Requirements

Format:

a. There is no formal submittal transmittal or format for this project other than the documents shall be submitted as PDF files, scanned, or created in documents that can be easily read when printed on 11x17 sheets.

b. Exceptions for larger sheet sizes will be considered by the COR. Failure of the Contractor to provide legible submittals will be adequate grounds for rejection.

Identification:

a. Submittals shall be labeled and marked for this project. The identification shall include Contractor/sub-contractor’s name, date of submittal, description of item, specification section, and details on product data that are marked clearly for this project.

Submittal Procedures:

a. All submittals will be posted in PDF by the Contractor and sent to the USDA for review. This same submittal process will be used for RFIs, Change Bulletins, etc.

Approved Submittals:

a. The approval/acceptance of submittals is not to be construed as a complete check.

Approval or acceptance will not relieve the Contractor of the responsibility for any error which may exist.

Other Submittal items for this project:

1. Prefabricated spools drawings

2. 2” stainless steel valves

3. 4” stainless steel valves

4. Stainless steel bolts, nuts, washers

See section 1.3 “Submittals” of attached specification labeled “ Rehabilitation and Lining for Concrete Wastewater Structures with Ultra-high Build Structural Epoxy” for details of Epoxy sealants and mortar.

Warranty Documentation

a. Warranty List: Provide a warranty summary sheet in spreadsheet format with all the warranties listed by section, description, supplier, warranty contact, start date, end date.

Provide electronic copy to the COR and place printed copy in the front of the Warranty Binder.

b. Warranty Copies in Binder: Provide one signed & dated copy of all warranties for the equipment and products installed on the project. The Warranty binder shall be divided by Specification Section and shall be provided to the COR. An electronic (scanned) copy of the Warranty Binder in a PDF file shall be submitted with the final close-out documentation.

Warranty Items:

5. Stainless Steel Valves, piping, and components

6. See section 1.7 of attached specification for warranty details of Epoxy sealants and mortar.

Operation & Maintenance Manuals:

a. Contractor shall provide a printed copy of all Operation & Maintenance documentation provided with the new stainless-steel valving installed in the project and place the manuals in an organized binder.

b. The O&M Manuals shall be organized by specification section and shall have an index at the front of the binder.

c. The Contractor shall also provide a PDF version of the Manuals to be submitted with the close-out documentation.

Record Drawings

Redline Specifications:

a. During the construction period the Contractor shall keep an updated & marked-up or “redline” copy of the project specifications on the jobsite.

b. The redline set shall include notes on changes, RFI responses, and other field notes.

c. At the end of the project the Contractor shall electronically scan the redline specifications and provide an electronic copy in PDF and AutoCAD to the Owner along with the close-out documentation.

Redline Drawings:

a. During the construction period the Contractor shall keep an updated “redline” or “conformed” copy of the project drawings on the jobsite.

b. The redline set shall include notes on changes, RFI responses, and other field notes.

c. At the end of the project the Contractor shall electronically scan the redline drawings at full-size and in color and provide an electronic copy in PDF to the Owner along with the close-out documentation.

END OF SECTION

Location Coordinator:Contracting Officer Rep.:Contracting Officer:Engineering Project Manager:

Task

Order #:

Drawing Title:PROJECT TITLE:

FEU Project #:

Drawing Number:

Agricultural Research Service U.S. Department of Agriculture

NCAH

1920 Dayton Avenue Ames, Iowa 50010

Revision:

Client:

Sheet: Of

Designer:

Date:

Date:

Ben A'Hearn TBD Brandon Keith

PPW Vault 102 Upgrades

Title Page

4/29/2024

Brandon Keith P01

23005 1 9

UNITED STATES DEPARTMENT OF AGRICULTURE

AGRICULTURE RESEARCH SERVICE

NATIONAL CENTERS FOR ANIMAL HEALTH

PPW Vault 102 Upgrades

INDEX OF DRAWINGS

P02

Title Page

PPW Vault 102 details

P03

P04

PPW Vault 102 piping details

P01

PPW Vault 102 one line

P06

Exterior Pictures

Leak Detection Details

P07

P08

Vault Interior Sections

P05

Valve Details

Interior WallsP09

Construction Area

Order #:

Drawing Title:PROJECT TITLE:

FEU Project #:

Drawing Number:

Agricultural Research Service U.S. Department of Agriculture

NCAH

1920 Dayton Avenue Ames, Iowa 50010

Revision:

Client:

Sheet: Of

Designer:

Date:

Date:

Ben A'Hearn TBD Brandon Keith

PPW Vault 102 Upgrades

PPW Vault 102 details

4/29/2024

Brandon Keith P02

23005 2 9

Highlighted Areas to be replaced with new

For reference only

Sump Pit

FRP to remain in place, No work.

FRP to remain in place, No work.

FRP to remain in place, No work.

Replace with Stainless steel

Building 9 Section

Building 20,21 Section

PPW102, Looking south PPW102, Looking east

PPW102, Overhead view

Order #:

Drawing Title:PROJECT TITLE:

FEU Project #:

Drawing Number:

Agricultural Research Service U.S. Department of Agriculture

NCAH

1920 Dayton Avenue Ames, Iowa 50010

Revision:

Client:

Sheet: Of

Designer:

Date:

Date:

Ben A'Hearn TBD Brandon Keith

PPW Vault 102 Upgrades

PPW Vault 102 piping details

4/29/2024

Brandon Keith P03

23005 3 9

For reference only

Leak Detection piping assembly shall be removed by USDA staff. Contractor shall remove 1" Carbon Steel pipe from Fiberglass and replace with a new 1" stainless steel nipple of the same size. USDA staff will reinstall new leak detection assembly.

Order #:

Drawing Title:PROJECT TITLE:

FEU Project #:

Drawing Number:

Agricultural Research Service U.S. Department of Agriculture

NCAH

1920 Dayton Avenue Ames, Iowa 50010

Revision:

Client:

Sheet: Of

Designer:

Date:

Date:

TO

PPW-101B

FROM PPW-103.

LARGE ANIMAL

HEALTH FACILITY

LINE.

TO

PPW-101B

FROM PPW-103.

FUTURE NEW LAB

BLDG. LINE

2" AIR VENT

2" VIS-17

2" VIS-15

2" VIS-16

2" PWS-10

4" PWS-01

2" PWS-04

4" PWD-02

2" PWS-03

4" PWD-01

2" VIS-06

2" PWS-08

4" PWD-04

2" PWS-07

2" VIS-13

4" PWS-05

4" PWD-03

2" VIS-03

2" VIS-10

L

L

DPH

DPH

DPL

DPL

LDS

LDW-02

LDS

LDW-01

ODD

VAULT-01

OVERALL IMAGES

OF VAULT.

LS-02

LS-01

4" VIS-07

2" VIS-042" VIS-05 2" VIS-012" VIS-02

4" VIS-14

2" VIS-112" VIS-12 2" VIS-082" VIS-09

Building 9 Section

Building 20, 21 Section

Ben A'Hearn TBD Brandon Keith

PPW Vault 102 Upgrades

PPW Vault 102 one line

4/29/2024

Brandon Keith P04

23005 4 9

INSTRUMENTATION ABBREVIATION

BW BIOTEST WELL

CO CLEANOUT

COS CLEANOUT SITE W/ VALVE

CNP CONTROL PANEL

CT COOL TANK

DCW DOMESTIC COLD WATER

EM ELECTRIC MOTOR

ES ELECTRIC STARTER

HF HEPA FILTER

FF FILTER, OTHER

PF FILTER PIPE STRAINER

HX HEAT EXCHANGER

LDC LEAK DETECTION SENSOR

ODD OTHER DEVICE

PWD PIPE WASTE DOUBLE WALL

PWS PIPE WASTE SINGLE WALL

PMP PUMP

SNS SENSOR

STP STEAM TRAP

ST STORAGE TANK

LS SWITCH LEVEL

PS SWITCH PRESSURE

FT TRANSMITTER FLOW

LT TRANSMITTER LEVEL

PT TRANSMITTER PRESSURE

TT TRANSMITTER TEMPERATURE

VCH VALVE CHECK

VCN VALVE CONTROL

VIS VALVE ISOLATION

PRV VALVE PRESSURE REDUCING

PSV VALVE SAFETY RELIEF

VFD VARIABLE FREQUENCY DRIVE

T

EM

XXX

BW

INSTRUMENTATION DIAGRAMS SYMBOL LEGEND

PIPE CROSSOVER

BIOTEST WELL

BLIND FLANGE

CLEANOUT/COVER

CONTROL SENSOR

CONTINUATION

DIRECTION OF FLOW

ELECTRIC MOTOR

FLEXIBLE CONNECTION

FLOOR DRAIN

GOOSENECK VENT

PRESSURE GAUGE

PRESSURE SAFETY RELIEF VALVE

PUMP

VALVE, CHECK

VALVE, CONTROL

VALVE, ISOLATION

STEAM TRAP

STRAINER

THERMOMETER

VACUUM BREAKER

For reference only

Order #:

Drawing Title:PROJECT TITLE:

FEU Project #:

Drawing Number:

Agricultural Research Service U.S. Department of Agriculture

NCAH

1920 Dayton Avenue Ames, Iowa 50010

Revision:

Client:

Sheet: Of

Designer:

Date:

Date:

Ben A'Hearn TBD Brandon Keith

PPW Vault 102 Upgrades

Exterior Pictures

4/29/2024

Brandon Keith P05

23005 5 9

Manhole Lid

Vent

2" discharge Pipe from sump

Abandoned

To Be replaced with Stainless Steel piping and Valve

External View, PPW102, looking south

Order #:

Drawing Title:PROJECT TITLE:

FEU Project #:

Drawing Number:

Agricultural Research Service U.S. Department of Agriculture

NCAH

1920 Dayton Avenue Ames, Iowa 50010

Revision:

Client:

Sheet: Of

Designer:

Date:

Date:

Ben A'Hearn TBD Brandon Keith

PPW Vault 102 Upgrades

Leak Detection Details

4/29/2024

Brandon Keith P06

23005 6 9

Leak Detection piping assembly shall be removed by USDA staff. Contractor shall remove remaining 1" Carbon Steel pipe from Fiberglass and replace with a new 1" stainless steel nipple of the same size. USDA staff will reinstall new leak detection assembly.

Leak Detection System (To be Removed by USDA staff)

Pit Float System (To be Removed by USDA staff)

Order #:

Drawing Title:PROJECT TITLE:

FEU Project #:

Drawing Number:

Agricultural Research Service U.S. Department of Agriculture

NCAH

1920 Dayton Avenue Ames, Iowa 50010

Revision:

Client:

Sheet: Of

Designer:

Date:

Date:

Ben A'Hearn TBD Brandon Keith

PPW Vault 102 Upgrades

Vault interior sections

4/29/2024

Brandon Keith P07

23005 7 9

Building 9 Section

Building 20, 21 Section

Internal View of PPW102, looking east

Order #:

Drawing Title:PROJECT TITLE:

FEU Project #:

Drawing Number:

Agricultural Research Service U.S. Department of Agriculture

NCAH

1920 Dayton Avenue Ames, Iowa 50010

Revision:

Client:

Sheet: Of

Designer:

Date:

Date:

Ben A'Hearn TBD Brandon Keith

PPW Vault 102 Upgrades

Valve Details

4/29/2024

Brandon Keith P08

23005 8 9

2 inch drain pipe and valves inside PPW102 4 inch pipe and valves inside PPW102

Order #:

Drawing Title:PROJECT TITLE:

FEU Project #:

Drawing Number:

Agricultural Research Service U.S. Department of Agriculture

NCAH

1920 Dayton Avenue Ames, Iowa 50010

Revision:

Client:

Sheet: Of

Designer:

Date:

Date:

Ben A'Hearn TBD Brandon Keith

PPW Vault 102 Upgrades

Interior Walls

4/29/2024

Brandon Keith P09

23005 9 9

North Wall East Wall

North Wall

SPECIFICATIONS

PUMPED PRETREATMENT WASTE PIPING

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASME INTERNATIONAL (ASME)

ASME B16.5 (B16.5a) Pipe Flanges and Flanged Fittings NPS 1/2 thru NPS 24

ASME B16.9 Factory-Made Wrought Steel Buttwelding Fittings

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A 105 Carbon Steel Forgings for Piping Applications

ASTM A 234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM F593-22 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

ASTM A 53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)

MSS SP-58 Pipe Hangers and Supports - Materials, Design and Manufacture

MSS SP-69 Pipe Hangers and Supports - Selection and Application

1.2 DESCRIPTION

This Section covers all of the piping systems in the PPW (Pumped Pretreatment Waste) manholes including those marked "PPW", "Drain", and "Air Vent".

DOUBLE WALL CONTAINMENT FOR PRETREATMENT WASTE.

PART 2 PRODUCTS

2.1 Fluid Description

The liquid that will be in the pipes mostly consists of wastewater from animals, laboratory services, and related substances. The liquid also includes chemicals that decontaminate the waste from the biological toxins. The liquid contains solids that tend to sludge and harden on rough surfaces. For design purposes, the specific gravity of the liquid shall be considered to be 1.15.

2.2 Design Basis

The maximum design conditions shall be 225 PSIG at 225 degrees F. Normal operating conditions are 60 PSIG at 105 degrees F.

Attachment 1b

2.3 Pipe

4-inch piping shall be stainless steel, A312-TP304L S/40s. 2 inch piping shall be stainless steel, A312- TP304L S/80s.

2.4 Joints

Joints 2 inches and smaller shall be socket welded except where threaded is specifically called out on a Contract Drawing detail (includes connections to casing system for level switches).

Joints 2-1/2 inches and larger shall be butt welded. All sizes shall be flanged where shown on the Contract Drawings or where required to connect to flanged valves, fittings, or equipment. Backing rings are prohibited.

2.5 Fabrication and Erection

All piping shall be fabricated and erected per ASME B31.3 Process Piping Code. All welding shall be per Section 15216, WELDING PRESSURE PIPING.

2.6 Testing

Testing (including welding and hydrostatic) shall follow Section 15216, WELDING PRESSURE PIPING per ASME B31.3 Process Piping Code. All (100%) socket weld joints for "PPW" piping shall be tested per liquid dye penetrant or magnetic particle. All (100%) buttweld joints for "PPW" piping shall be tested per radiography.

2.7 Flanges

Flanges shall be stainless steel, 4” flanges shall be A182-F304L S/40s 150# RF weld-necks and 2” flanges shall be stainless steel, A182-F304L S/80s 150# RF. Welding neck flanges shall be bored to match the same ID as the attached pipe.

2.8 Fittings

Fittings 2 inches and smaller shall be 3000-pound socket-weld in accordance with ASME B16.11.

Material shall conform to ASTM A 105. 2” fittings shall be butt-welded A403-WP304L S/40s.

Fittings 2-1/2 inches and larger shall be steel butt-weld type in accordance with ASME B16.9 with Schedule "XS" wall thickness. Material shall conform to ASTM A 234, Grade WPB.

Mitered branches are not allowed. Use regular "tee" fitting or forged fittings for reduction.

2.9 Bolting Materials

Bolting materials shall all be stainless steel, hexagonal head bolts with heavy hexagonal nuts conforming to ASTM F593-22.

2.10 Unions

Unions 1-1/2 inches and smaller shall be 3000 pound, threaded, with steel-to-steel seats. Material shall conform to ASTM A 105. Note that the use of unions shall be minimized as much as possible.

Unions 2 inches and larger shall be made with flanges.

2.11 Gaskets

Gaskets shall be Flexitallic spiral wound, Type 304 stainless steel with non-asbestos filler material and carbon steel outer ring. Gaskets shall be 1/16 inch thick and conform to the flange face on which they are used.

2.12 Valves

All stainless-steel valves 1-1/2 inches and smaller shall be Class 250, bronze body, one piece ball valves with stainless steel ball and Teflon seats.

All stainless-steel valves 2 inches and larger shall be ball valves with regular port, top entry, wedge seated ball style with Class 150 flanges. Body material shall be 316SS, seat shall be TFE, and trim shall be 316SS. Provide lockable lever hardware. Valves shall be McCanna Figure Number S151-S6-T-S6 or Velan Figure F-006T13-BAA.

2.13 Specialties

Hose end drain shall be that currently used on the site - creamery style, twist lock, gasketed connection.

2.14 Supports

Support all piping with standard manufactured supports per MSS SP-58 and MSS SP-69. Hardware shall be stainless steel.

PART 3 EXECUTION

3.1 INSTALLATION

Install piping and piping components to ensure proper and efficient operation of equipment and in accordance with manufacturer's printed instructions.

3.1.1 Water Piping

ASME B31.3.

3.2 PIPING SYSTEMS

3.2.1 Flanged Joints

Faced true, square, tight, and provided as indicated and where necessary for normal maintenance. Mate with valves and various equipment connections. Remove raised faces when used with flanges having a flat face.

3.2.2 Threaded Joints

Clean threads and apply suitable amount of Teflon tape or Teflon pipe dope prior to making joint.

3.2.3 Pipe Bends

Pipe bends shall have a uniform radius of at least five times the nominal pipe diameter. Pipe bends shall be free of any flattening, wrinkling, or thinning of pipe walls other than minor external surface distortions.

3.2.4 Reducing Fittings

Make branch connections with tees except that factory-made-forged-steel welding branch outlets or nozzles having integral reinforcements and conforming to ASME B31.3 may be provided when the nominal diameter of piping system branch does not exceed one nominal pipe size less than nominal size of piping segment containing fitting.

3.2.5 Insulation

Follow manufacturer’s installation instructions.

3.2.6 Pipe Hangers and Supports

Installation including spacing shall conform to ASME B31.3.

3.3 PPW PIPING AND ALL RELATED SYSTEMS IN PPW MANHOLES

Chilled Water, and Condenser Water Piping:

3.3.1 Fabrication and Assembly of Piping and Components

Welding shall conform to ASME B31.3 and as specified herein. Piping shall follow general arrangement shown, cut accurately to measurements established for the work by the Contractor, and worked into place without springing or forcing. Piping and equipment within manholes shall be entirely out of the way of electrical conduit, and manhole entrance.

Provide adequate clearance from walls, ceilings, and floors to permit welding of joints; at least 6 inches for pipe sizes 4 inches and less, 10 inches for pipe sizes over 4 inches, and in corners provide sufficient clearance to permit the welder to work between pipe and one wall. Provide for expansion and contraction of pipelines. Make changes in size of water lines with reducing fittings. Protect materials and equipment from weather. Do not miter pipe to form elbows, or notch straight runs to form full-sized tees, or utilize any similar construction. Except where shown otherwise, run vertical piping plumb and straight and parallel to walls. Plug or cap open ends of mains during shutdown periods. Do not leave lines open at any place where foreign matter might accidentally enter.

3.3.1.1 Valves

a. Install valves as indicated, according to manufacturer's written instructions.

b. Install valves with unions or flanges at each piece of equipment arranged to allow servicing, maintenance, and equipment removal without system shutdown.

c. Locate valves for easy access and provide separate support where necessary.

d. Install valves in horizontal piping with stem at or above the center of the pipe.

e. Install valves in a position to allow full stem movement.

3.4 FIELD INSPECTIONS

Prior to initial operation examine and inspect piping systems for conformance to plans and specifications, ASME B31.3. Equipment, material, or work rejected because of defects or nonconformance with plans, specifications, and ANSI Codes for pressure piping shall be corrected as directed by the Contracting Officer Representative.

3.5 FIELD TESTS

After completion of piping installation and prior to initial operation, conduct tests on piping system.

Furnish materials and equipment required for tests. Correct defects disclosed by test. Perform test after installation and prior to acceptance in presence of the Contracting Officer Representative and subject to his approval.

3.5.1 PPW Manhole Piping

Hydrostatically test in accordance with requirements of ASME B31.3. Test piping system at 1-1/2 times the design pressure with water not exceeding 100 degrees F. Before tests, remove or isolate apparatus in new system and existing piping system which may be damaged. Repair leaks by tightening or renewing pipe or fittings. Do not caulk joints. Install a calibrated, test pressure gage in system to observe loss in pressure. Maintain required test pressure for a sufficient amount of time to enable an inspection of joints and connections. Correct defects disclosed by test.

-- End of Section --

WELDING PRESSURE PIPING

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.

ASME INTERNATIONAL (ASME)

ASME B31.1 (2001) Power Piping

ASME B31.3 (2002) Process Piping

ASME B31.4 (2002) Piping Transportation Systems for Liquid Hydrocarbons and Other Liquid

ASME B31.5 (2001) Refrigeration Piping and Heat Transfer Components

ASME BPVC SEC I (2001) Boiler and Pressure Vessel Code; Section I, Power Boilers

ASME BPVC SEC II-C (2001) Boiler and Pressure Vessel Code; Section II, Materials, Part C - Specifications for Welding Rods, Electrodes and Filler Metals

ASME BPVC SEC V (2001) Boiler and Pressure Vessel Code; Section V, Nondestructive Examination

ASME BPVC SEC IX (2001) Boiler and Pressure Vessel Code; Section IX, Welding and Brazing Qualifications

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ASNT RP SNT-TC-1A (2001) Recommended Practice

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 (1998) Standard Symbols for Welding, Brazing and Nondestructive Examination

AWS A3.0 (2001) Standard Welding Terms and Definitions

AWS D1.1/D1.1M (2002) Structural Welding Code - Steel

AWS D10.9 (1980) Qualification of Welding Procedures and Welders for Piping and Tubing

AWS QC1 (1996) AWS Certification of Welding Inspectors

AWS Z49.1 (1999) Safety in Welding, Cutting and Allied Processes

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1926 Safety and Health Regulations for Construction

1.2 RELATED REQUIREMENTS

Section 15050, BASIC MECHANICAL MATERIALS AND METHODS, applies to this section with the additions and modifications specified herein.

1.3 DEFINITIONS

AWS A3.0 and applicable ANSI piping documents.

1.4 SUBMITTALS

Submit the following in accordance with Section 01330, SUBMITTAL PROCEDURES.

SD-02 Shop Drawings

Welding pressure piping; G

SD-07 Certificates

Welding procedures qualification; G

Nondestructive examination (NDE) procedures; G

NDE personnel certification procedures; G

Inspector certification; G

Submit inspector certification and NDE personnel certification for record.

SD-11 Closeout Submittals

Weld identifications; G

1.5 QUALITY ASSURANCE

1.5.1 Welding Pressure Piping

Show location, length, and type of welds, and indicate post weld heat treatment and nondestructive testing as required.

1.5.2 Procedures

Develop and qualify procedures for welding metals included in the work. Do not start welding until welding procedures, welders, and welding operators have been qualified. Perform qualification testing by an approved testing laboratory, or by the Contractor if approved by the Contracting Officer in accordance with the qualified procedures. Notify the Contracting Officer Representative at least 24 hours in advance of the time and place of the tests. When practicable, perform the qualification tests at or near the work site. Maintain current records of the test results obtained in welding procedure, welding operator/welder performance qualifications, and nondestructive examination (NDE) procedures.

These records shall be readily available at the site for examination by the Contracting Officer Representative. Qualify the procedures for making transition welds between different materials or between plates or pipes of different wall thicknesses. ANSI Piping requirements for branch connections may be used in lieu of detailed designs. Unless otherwise specified, the choice of welding process shall be the responsibility of the Contractor.

1.5.2.1 Previous Qualifications

Welding procedures, welders, and welding operators previously qualified by test may be accepted for the work without requalification provided that the following conditions are fulfilled:

a. Copies of welding procedures, procedure qualification test records, and welder and welding operator performance qualification test records are submitted and approved in accordance with the paragraph entitled "Submittals."

b. Testing was performed by an approved testing laboratory or technical consultant or by the Contractor's approved quality control organization.

c. The welding procedures, welders, and welding operators were qualified in accordance with ASME BPVC SEC IX or AWS D10.9, AR-2 level; and base materials, filler materials, electrodes, equipment, and processes conformed to the applicable requirements of this specification.

d. The requirements of paragraph entitled "Welder and Welding Operator Performance Qualification" for renewal of qualification were met, and records showing name of employer and period of employment using the process for which qualified are submitted as evidence of conformance.

1.5.2.2 Performance

The Contractor shall be responsible for the quality of joint preparation, welding, and examination.

Clearly identify and record materials used in the welding operations. The examination and testing defined in this specification are minimum requirements. Provide additional examination and testing as necessary to achieve the quality required.

1.5.3 Welding Procedures Qualification

Qualification of the welding procedures for each group of materials to be welded is required as indicated in ASME BPVC SEC IX. Record in detail and qualify the "Welding Procedure Specifications" for every welding procedure proposed. Qualification for each welding procedure shall conform to the requirements of ANSI Standards and to this specification. The welding procedures shall specify end preparation for welds, including cleaning, alignments, and root openings. Preheat, interpass temperature control, and post heat treatment of welds shall be as required by ANSI Piping documents, unless otherwise indicated or specified. Describe the type of backing rings or consumable inserts, if used, and, if they are to be removed, the removal process. Welding procedure qualifications shall be identified individually and referenced on the shop drawings or suitably keyed to the contract drawings.

1.5.4 Welder and Welding Operator Performance Qualification

Qualify each welder and welding operator assigned to work covered by this specification by performance tests using equipment, positions, procedures, base metals, and electrodes or bare filler wires from the same specification, classification, or group number that will be encountered on his assignment. Welders or welding operators who make acceptable procedure qualification tests will be considered performance-qualified for the welding procedure used. Determine performance qualification in accordance with ASME BPVC SEC IX, ANSI Piping Standards and as specified.

1.5.5 Renewal of Qualification

Requalification of a welder or welding operator shall be required under one or any combination of the following conditions:

a. When a welder or welding operator has not used the specific welding process for a period of 3 months.