44 10 00.pdf

SABER Solicitation FA2517-08-R-5002

44 10 00 - 1 05/08/09

SECTION 44 10 00

AIR POLLUTION CONTROL

PART 1 GENERAL

1.1 REFERENCES

1.1.1 The latest issue of the publications listed below and referenced to thereafter by basic designations only, forms a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

1.1.1.1 AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA)

a. AMCA 210 Laboratory Methods of Testing Fans for Aerodynamic

Performance Rating

b. AMCA 300 Reverberant Room Method for Sound Testing of Fans

c. AMCA 801 Industrial Process/Power Generation Fans: Specification

Guidelines

d. AMCA 99 Standards Handbook

1.1.1.2 AMERICAN INDUSTRIAL HYGIENE ASSOCIATION (AIHA)

a. AIHA Z9.3 Spray Finishing Operations - Safety Code for Design, Construction and Ventilation

1.1.1.3 AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

a. ANSI S2.19 Mechanical Vibration - Balance Quality Requirements of Rigid

Rotors, Part 1: Determination of Permissible Residual

Unbalance, Including Marine Applications

1.1.1.4 AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING

ENGINEERS (ASHRAE)

a. ASHRAE 15 Safety Code for Refrigeration

b. ASHRAE 52.1 Gravimetric and Dust-Spot Procedures for Testing Air-Cleaning

Devices Used in General Ventilation for Removing Particulate

Matter

1.1.1.5 AMERICAN WATER WORKS ASSOCIATION (AWWA)

a. AWWA C700 Standard for Cold Water Meters - Displacement Type, Bronze

Main Case

1.1.1.6 ASME INTERNATIONAL (ASME)

a. ASME B1.20.1 Pipe Threads, General Purpose (Inch)

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b. ASME B16.1 Standard for Gray Iron Threaded Fittings; Classes 125 and 250

c. ASME B16.11 Forged Fittings, Socket-Welding and Threaded

d. ASME B16.15 Cast Bronze Threaded Fittings Classes 125 and 250

e. ASME B16.24 Cast Copper Alloy Pipe Flanges and Flanged Fittings: Classes

150, 300, 400, 600, 900, 1500, and 2500

f. ASME B16.3 Malleable Iron Threaded Fittings, Classes 150 and 300

g. ASME B16.39 Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300

h. ASME B16.5 Standard for Pipe Flanges and Flanged Fittings: NPS 1/2

Through NPS 24

i. ASME B16.9 Standard for Factory-Made Wrought Steel Buttwelding Fittings

j. ASME B31.1 Power Piping

k. ASME B31.3 Process Piping

l. ASME B31.5 Refrigeration Piping and Heat Transfer Components

m. ASME B40.100 Pressure Gauges and Gauge Attachments

n. ASME BPVC SEC IX Boiler and Pressure Vessel Code; Section IX, Welding and

Brazing Qualifications

o. ASME PTC 19.3 Temperature Measurement Instruments and Apparatus

p. ASME PTC 21 Particulate Matter Collection Equipment

q. ASME PTC 28 Determining the Properties of Fine Particulate Matter

r. ASME PTC 38 Determining the Concentration of Particulate Matter in a Gas

Stream

1.1.1.7 ASTM INTERNATIONAL (ASTM)

a. ASTM A 167 Standard Specification for Stainless and Heat-Resisting

Chromium-Nickel Steel Plate, Sheet, and Strip

b. ASTM A 240/A 240M Standard Specification for Chromium and Chromium-Nickel

Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

c. ASTM A 302/A 302M Standard Specification for Standard Specification for Pressure

Vessel Plates, Alloy Steel, Manganese-Molybdenum and

Manganese-Molybdenum-Nickel

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d. ASTM A 48/A 48M Standard Specification for Gray Iron Castings

e. ASTM A 53/A 53M Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

f. ASTM A 653/A 653M Standard Specification for Steel Sheet, Zinc-Coated

(Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the

Hot-Dip Process

g. ASTM A 733 Standard Specification for Welded and Seamless Carbon Steel and Austenitic Stainless Steel Pipe Nipples

h. ASTM A 924/A 924M Standard Specification for General Requirements for Steel Sheet, Metallic-Coated by the Hot-Dip Process

i. ASTM B 280 Standard Specification for Seamless Copper Tube for Air

Conditioning and Refrigeration Field Service

j. ASTM B 42 Standard Specification for Seamless Copper Pipe, Standard Sizes

k. ASTM B 68 Standard Specification for Seamless Copper Tube, Bright

Annealed

l. ASTM B 68M Standard Specification for Seamless Copper Tube, Bright

Annealed (Metric)

m. ASTM B 88 Standard Specification for Seamless Copper Water Tube

n. ASTM B 88M Standard Specification for Seamless Copper Water Tube

(Metric)

o. ASTM D 1248 Standard Specification for Polyethylene Plastics Extrusion

Materials for Wire and Cable

p. ASTM D 2854 Apparent Density of Activated Carbon

q. ASTM D 2862 Particle Size Distribution of Granular Activated Carbon

r. ASTM F 1139 Steam Traps and Drains

1.1.1.8 HYDRAULIC INSTITUTE (HI)

a. HI 3.1-3.5 Rotary Pumps for Nomenclature, Definitions, Applications and

Operations

1.1.1.9 INSTITUTE OF CLEAN AIR COMPANIES (ICAC)

a. ICAC EP-1 Terminology for Electrostatic Precipitators

b. ICAC EP-7 Electrostatic Precipitator Gas Flow Model Studies

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c. ICAC EP-8 Structural Design Criteria for Electrostatic Precipitator Casings

d. ICAC F-2 Fundamentals of Fabric Collectors and Glossary of Terms

e. ICAC F-3 Operation and Maintenance of Fabric Collectors

f. ICAC F-5 Types of Fabric Filters

g. ICAC FGD-1 Flue Gas Desulfurization Terminology

h. ICAC G-1 Gaseous Emissions Equipment: Product Definitions and

Illustrations

i. ICAC WS-1 Wet Scrubber Terminology

j. ICAC WS-3 Basic Types of Wet Scrubbers

k. ICAC WS-4 Wet Scrubber System-Major Auxiliaries

1.1.1.10 MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

a. MSS SP-25 Standard Marking System for Valves, Fittings, Flanges and

Unions

b. MSS SP-70 Standard for Cast Iron Gate Valves, Flanged and Threaded Ends

c. MSS SP-80 Bronze Gate, Globe, Angle and Check Valves

1.1.1.11 NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

a. NEMA ICS 1 Standard for Industrial Control and Systems General

Requirements

b. NEMA ICS 6 Standard for Industrial Controls and Systems Enclosures

c. NEMA MG 1 Standard for Motors and Generators

d. NEMA SM 23 Steam Turbines for Mechanical Drive Service

1.1.1.12 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

a. NFPA 496 Purged and Pressurized Enclosures for Electrical Equipment

b. NFPA 70 National Electrical Code

c. NFPA 91 Exhaust Systems for Air Conveying of Vapors, Gases, Mists and

Noncombustible Particulate Solids

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

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a. 29 CFR 1910 Occupational Safety and Health Standards

b. 40 CFR 50 National Primary and Secondary Ambient Air Quality Standards

c. 40 CFR 60 Standards of Performance for New Stationary Sources

1.1.1.14 UNDERWRITERS LABORATORIES (UL)

a. UL 1002 Electrically Operated Valves For Use in Hazardous (Classified)

Locations

b. UL 5 Surface Metal Raceways and Fittings

c. UL 674 Standard for Electric Motors and Generators for Use in Division

1 Hazardous (Classified) Locations

d. UL 698 Industrial Control Equipment for Hazardous (Classified)

e. UL 823 Electric Heaters for Use in Hazardous (Classified) Locations

f. UL 886 Outlet Boxes and Fittings for Use in Hazardous (Classified)

g. UL 894 Switches for Use in Hazardous (Classified) Locations

h. UL 900 Standard for Air Filter Units

1.2 SUBMITTALS

1.2.1 Government approval may be required on any of the following items. Items requiring submittals shall be listed on the Submittal Register. Copies of all submittals shall be provided per the requirements in Section 01 33 00, Submittal Procedures, or as listed on the Submittal Register.

1.2.1.1 SD-02 Shop Drawings

a. Approved Detail Drawings

(1) Detail drawings containing complete wiring and schematic diagrams and any other details required to demonstrate that the system has been coordinated and shall properly function as a unit. Drawings shall show proposed layout and anchorage of equipment and appurtenances, and equipment relationship to other parts of the work including clearances for maintenance and operation.

1.2.1.2 SD-03 Product Data

a. Emission Monitoring System

b. Reports for emissions permit compliance.

c. Air Pollution Control Equipment

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(1) A complete list of equipment and material, including manufacturer's descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions. Spare parts data for each different item of material and equipment specified, after approval of detail drawings and not later than 2 months prior to the date of beneficial occupancy. The data shall include a complete list of parts and supplies, with current unit prices and source of supply.

(2) Proposed diagrams, instructions, and other sheets, prior to posting. Framed instructions under glass or in laminated plastic, including wiring and control diagrams showing the complete layout of the entire system, including equipment, piping, valves, and control sequence, shall be posted where directed. Condensed operating instructions explaining preventative maintenance procedures, methods of checking the system for normal, safe operation, and procedures for safely starting and stopping the system shall be prepared in typed form, framed as specified above for the wiring and control diagrams, and posted beside the diagrams. The framed instructions shall be posted before acceptance testing of the system.

(a) Instrumentation and Controls

(b) Detailed manufacturer's data on the overall controls, sensors, process controllers, control operators, ladder diagrams, timers, sequence of controls, valves, alarms, signals, interlocks and cut off systems. Data describing in detail the equipment used to monitor emissions, including the sampling probe, filters, sampling pump, moisture separator/drier, tubing, analyzer, analyzer calibration system, data recorder, and alarms.

Process and instrumentation diagrams (P&IDs).

(c) Training

(d) Training course curriculum and training instructions 14 days prior to the start of training.

(e) Testing and Inspections

(f) A proposed performance test procedure, 30 days prior to the proposed test date, containing a complete description of the proposed tests and sample locations, with calibration curves or test results by an independent testing laboratory of each instrument, meter, and gauge to be used in the tests. The test shall not commence until the procedure has been approved.

1.2.1.3 SD-06 Test Reports

a. Factory Tests

b. Printout of factory test results.

c. Testing and Inspections;

d. Test procedures, prior to starting test. Test reports in booklet form showing all field tests performed to adjust each component and all field tests performed to provide compliance with the specified performance criteria, upon completion and testing of the installed system. Each test report shall indicate the final position of controls.

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1.2.1.4 SD-07 Certificates

a. Manufacturer's Field Representative

b. Names and qualifications of each manufacturer's field representative and training engineer with written certification from the manufacturer that each representative and trainer is technically qualified.

1.2.1.5 SD-10 Operation and Maintenance Data

a. Air Pollution Control Equipment

b. Accessories

c. Six complete copies of operation manual outlining the step-by-step procedures required for system startup, operation, and shutdown. The manuals shall include the manufacturer's name, model number, service manual, parts list, and brief description of all equipment and its basic operating features. Six complete copies of maintenance manual listing routine maintenance procedures, possible breakdowns and repair, and troubleshooting guides. The manuals shall include piping layout, equipment layout, and simplified wiring and control diagrams of the system as installed. Operation and maintenance manuals shall be approved prior to training course.

1.3 QUALIFICATIONS

1.3.1 Welding

1.3.1.1 Piping shall be welded in accordance with qualified procedures using performance qualified welders and welding operators. Procedures and welders shall be qualified in accordance with

ASME BPVC SEC IX. Welding procedures qualified by others, and welders and welding operators qualified by another employer may be accepted as permitted by ASME B31.1. The

Contracting Officer shall be notified 24 hours in advance of tests and the tests shall be furnished at the work site if practicable. The Contracting Officer shall be furnished a copy of qualified procedures and a list of names and identification symbols of qualified welders and welding operators. The welder or welding operator shall apply his assigned symbol near his welds using a rubber stamp or felt-tipped marker with permanent weatherproof ink or other methods approved by the Contracting Officer that do not deform the metal. Structural members shall be welded in accordance with Section 05 05 23 WELDING, STRUCTURAL.

Nonpressure dust collection vessels shall be welded per provisions of 05 50 03.00 10

METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.

1.3.2 Contractor

1.3.2.1 Contractor’s key personnel shall meet the minimum requirements below:

SECTION 01030

ORGANIZATIONAL GUIDANCE

1.3.2.2 KEY PERSONNEL: Key contractor employees shall, as a minimum, meet the requirements listed below. All key personnel must be able to read, write, speak, and understand English.

a. PROGRAM MANAGER: The Contractor shall provide a Program Manager who shall be responsible for the performance of the work. The name of this person and alternates who shall

44 10 00 - 8 05/08/09 act for the Contractor when the primary is absent shall be designated in writing to the

Contracting Officer as a part of the management plan (see paragraph 3).

(1) The Program Manager shall have at least 5 years of experience in the management of government, commercial, or industrial construction and renovation projects, involving all of the following different disciplines: architectural, civil, mechanical, and electrical.

(2) The Program Manager and designated alternates shall have full authority to act for the

Contractor on all contract matters relating to daily operation of this contract with no dollar amount restrictions.

(3) The Program Manager shall be available by cellular telephone during normal duty hours.

(4) During normal duty hours, the Program Manager or designated alternate shall be available to meet on the installation with government personnel within one hour. After normal duty hours, the Program Manager shall be available to meet on the installation within two hours from the time of notification for emergency or urgent situations.

b. INSTALLATION CONSTRUCTION MANAGER: The Contractor shall provide an

Installation Construction Manager that will be knowledgeable on all projects on the installation(s) they are assigned. The name of this person and any alternates shall be designated in writing to the Contracting Officer as a part of the management plan (see paragraph 3).

(1) The Installation Construction Manager shall have at least 5 years of experience in construction superintendence for similar size/scope projects and be familiar with all aspects of general construction management, practices, methods, and materials.

(2) The Installation Construction Manager and designated alternates shall have full authority to act for the Contractor on all contract matters relating to daily operation of this contract that do not have cost impacts.

(3) The Installation Construction Manager shall be available by cellular telephone during normal duty hours.

(4) During normal duty hours, the Installation Construction Manager shall be available to meet on the installation with government personnel within one hour. After duty hours the

Installation Construction Manager or equivalent alternate shall be available to meet on the installation within two hours from the time of notification for emergency or urgent situations.

c. JOB FOREMEN: The Contractor shall maintain a Job Foreman on each project site with work being accomplished. This person shall be able to answer all questions pertaining to the work being accomplished. The name of this person shall be designated to the Contracting Officer. If the person changes, the Contracting Officer shall be notified.

(1) The Job Foreman shall possess at least 3 years of experience in an appropriate field for the job being supervised.

(2) The Job Foreman shall be available by cellular telephone during normal duty hours.

d. LEAD CRAFTSMEN/TRADESMEN: Lead Craftsmen/Tradesmen in standard trades must be certified or licensed at the journeyman level (or equivalent for non-standard trades).

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e. QUALITY CONTROL OFFICER: The Quality Control Officer shall have at least 3 years of experience in the area of construction quality control. The Quality Control Officer shall manage the contractor’s quality control plan. This person shall have the authority to direct contractor personnel to correct construction deficiencies.

f. ENVIRONMENTAL OFFICER: The Environmental Officer shall have suitable training and at least 3 years of experience in environmental management for construction work. The

Environmental Officer shall manage all of the environmental concerns for each project. This function may be fulfilled by consulting firm.

1.3.2.3 PROFESSIONAL CERTIFICATION: The Contractor shall ensure that employees have current and valid professional certifications and licenses as stated in the accepted contractor’s management plan (see paragraph 3) before starting work.

1.3.2.4 MANAGEMENT PLAN: The Contractor shall create, maintain, and implement a Management

Plan within 30 days of contract award. This plan shall be available upon request. The

Management Plan shall include a position description for all personnel, required minimum qualifications, and specifies what positions are being accomplished by subcontractors. A complete organizational chart shall also be submitted, and kept current as part of the management plan.

a. The Contractor will provide personnel meeting the minimum requirements and qualifications specified in the position descriptions for Key Personnel in the contractor’s Management Plan.

b. The contractor’s organizational approach shall provide project management, project engineering, CAD support, project design, site superintendence, safe working environments, quality control, environmental management, subcontract purchasing and administration, and general office administration.

1.3.2.5 MEETINGS: The Contractor shall ensure key management personnel participate in and provide briefings to the Base Civil Engineer (BCE), or Director of Public Works (DPW), at each site, as required. The BCE or DPW will be represented by the SABER program manager, project manager, and project inspector. The Contractor’s Program Manager and Installation

Construction Manager, as a minimum, will interact, in the form of conferences, meetings, and reviews, on a weekly basis with government personnel at each installation regarding the performance and status of their respective task orders. The CO may decide to reduce the frequency of meeting if needed. The purpose of these meetings is to discuss the status of active projects, schedules, projections, problems, corrective actions, recommendations, etc., to help accomplish project and program goals. The Contractor shall be required to provide a written listing of all active projects for each installation containing, as a minimum: project name, project number, T.O. number, T.O. completion date, scheduled completion date, project status, and pertinent remarks. The listing shall be prepared by the Contractor in advance of the scheduled weekly meeting and copies of the listing shall be provided to all personnel in attendance. Contracting representatives and other government personnel may also attend these weekly meetings. The Contracting Officer at each site shall determine the most appropriate and mutually convenient date and time for the weekly meetings.

1.3.2.6 QUALITY CONTROL PLAN: See Section 01440.

END OF SECTION 01030

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1.3.2.7

PROJECT NUMBER PROJECT TITLE SOLICITATION/CONTRACT NUMBER

SCHEDULE OF MATERIAL SUBMITTALS

SABER

Solicitation

FA2517-08-

R-5002

TO BE COMPLETED BY PROJECT ENGINEER TO BE COMPLETED BY CONTRACT ADMINISTRATOR

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1.3.3 Manufacturer's Field Representative

1.3.3.1 Services of a manufacturer's field representative, who is experienced in the installation, adjustment, and operation of the equipment furnished, and who has complete knowledge of the proper operation and maintenance of the system, shall be provided. Field representative shall be onsite to supervise the installation, adjustment and compliance testing of the equipment.

Field representative shall provide supervision of the system for 90 days after startup of the system.

1.4 DELIVERY AND STORAGE

1.4.1 All equipment delivered and placed in storage shall be stored as recommended by the manufacturer, with protection from the weather, humidity and temperature variation, dirt and dust, or other contaminants.

1.5 FIELD MEASUREMENT

After becoming familiar with all details of the work, the Contractor shall verify all dimensions in the field, and shall advise the Contracting Officer of any discrepancy before performing the work.

1.6 CONSTRUCTION REQUIREMENTS

System shall be suitable for indoor or outdoor installation and shall be provided with or without a weather enclosure. Unit shall be provided with the specified thickness of insulation with a k value as indicated. Unit shall not be insulated. System shall be designed for a wind load as specified and an internal negative or positive static pressure as indicated of water gauge.

System shall be designed for a snow load as indicated. Seismic protection of equipment shall be in accordance with UFC 3-310-04 SEISMIC DESIGN FOR BUILDINGS, Section 13 48

00.00 10 SEISMIC PROTECTION FOR MECHANICAL EQUIPMENT, and Section 26 05

48.00 10 SEISMIC PROTECTION FOR ELECTRICAL EQUIPMENT.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Standard Products

2.1.1.1 Material and equipment shall be the standard products of a manufacturer regularly engaged in the manufacture of the products. Items of equipment shall essentially duplicate equipment that has been in satisfactory use at least 2 years prior to bid opening. Equipment shall be supported by in-service organization that is, in the opinion of the Contracting Officer, reasonably convenient to the site. In-service organization shall respond to a service call within 24 hours.

2.1.2 Nameplates

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2.1.2.1 Each major component of equipment shall have the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the equipment. Each piece of equipment shall bear the approval designation and the markings required for that designation.

Valves shall be marked in accordance with MSS SP-25 and shall bear a securely attached tag with the manufacturer's name, catalog number and valve identification permanently displayed.

2.1.3 General Requirements

2.1.3.1 Equipment and appurtenances shall be as specified and as shown on the approved detail drawings, and shall be suitable for the service intended. Materials and equipment shall be new and unused, to include testing equipment furnished under the contract. Components that serve the same function and are the same size shall be identical products of the same manufacturer.

2.1.4 Equipment Guards and Access

2.1.4.1 Belts, pulleys, chains, gears, couplings, projecting setscrews, keys, and other rotating parts so located that any person may come in close proximity thereto, shall be enclosed or guardedto prevent accidental personal injury, in accordance with 29 CFR 1910, Subpart O, Machinery and

Machine Guarding. Guards shall be removable and arranged to allow access to the equipment for maintenance. High-temperature equipment and piping so located as to endanger personnel or to create a fire hazard shall be guarded or covered with insulation of type specified for service. Items such as catwalk, stair, ladder, and guardrail shall be provided where shown and shall be in accordance with Section 05 50 13 METAL: MISCELLANEOUS FABRICATIONS.

2.2 GAUGE

2.2.1 Gauge shall conform to the following:

2.2.2 Draft Gauge

2.2.2.1 ASME B40.100. Tubing for gauges for service above 150 degrees F shall conform to ASTM B

68M( ASTM B 68); for service below 150 degrees F, plastic tubing conforming to ASTM D

1248 may be used.

2.2.3 Gauges, Pressure and Vacuum

2.2.3.1 ASME B40.100, range suitable for the related conditions.

2.3 LOW-WATER CUTOFF

2.3.1 Low-water cutoff shall be provided for all scrubber liquid sumps, holding tanks, reservoirs, and mixing tanks. Cut-off shall cause a safety shutdown of the scrubber and shall be provided with auxiliary contacts to be used to sound an alarm. Low-water shutdown shall require a manual reset before any equipment can recycle or operate.

2.4 PIPE, FITTINGS, AND TUBING

2.4.1 Pipe, fittings, and tubing shall conform to the following:

2.4.2 Pipe

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2.4.2.1 ASTM A 53/A 53M, Type S, Grade A, standard weight; or copper pipe, ASTM B 42.

2.4.3 Nipples

2.4.3.1 ASTM A 733, standard weight to match adjacent piping.

2.4.4 Pipe Fittings

2.4.4.1 Steel Pipe Fittings

a. ASME B16.9 for butt-welding fittings; ASME B16.11 for socket-welding fittings; and ASME

B16.5 for flanged fittings.

2.4.4.2 Brass or Bronze Pipe Fittings

a. ASME B16.15, Class A, 125 pound.

2.4.4.3 Malleable-Iron Pipe Fittings

a. ASME B16.3, type to match adjacent piping.

2.4.4.4 Unions

a. ASME B16.39, type to match adjacent piping.

2.4.4.5 Flanges, Cast-Iron and Bronze

a. ASME B16.1 and ASME B16.24.

2.4.4.6 Pipe Threads

a. ASME B1.20.1.

2.4.5 Tube, Copper

2.4.5.1 Tube for Air, Water, Gas, and Drains

a. ASTM B 68M( ASTM B 68) or ASTM B 88M ( ASTM B 88).

2.4.5.2 Tube for Refrigeration Systems

a. ASTM B 280.

2.5 STEEL SHEET

2.5.1 Steel sheets shall conform to the following:

2.5.2 Zinc Coated (Galvanized)

2.5.2.1 ASTM A 653/A 653M; ASTM A 924/A 924M for dust collector casings, housing, and components. Gauges specified are manufacturers' standard gauge.

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2.5.3 Low-Carbon

2.5.3.1 Gauges specified, for dust collector casings, housings, and components, refer to manufacturers' standard gauge.

2.5.4 Corrosion Resistant

2.5.4.1 ASTM A 167, Class 304 or 316. Gauges specified refer to U.S. Standard Gauge.

2.6 AIR TRAPS

2.6.1 Air traps for removal of moisture from plant compressed air supplied to air pollution control equipment shall conform to ASTM F 1139.

2.7 THERMOMETERS

2.7.1 Thermometers shall conform to ASME PTC 19.3 with wells and temperature range suitable for the use encountered.

2.8 VALVES

2.8.1 Valves shall conform to the following:

2.8.2 Angle Valves

2.8.2.1 MSS SP-80, Types 1, 2, or 3, Class 125, except that valves over 3 inch shall have iron bodies and brass or bronze standard trim with glands or followers in the stuffing boxes. Valves shall have nonmetallic renewable composition discs and raised flat seats designed for 125 psi steam.

Wheels shall be secured with hexagonal nuts.

2.8.3 Check Valves

2.8.3.1 MSS SP-80, Types 1, 2, 3, or 4, Class 125, as required. Valves over 3 inch shall have iron bodies and shall be the swing type designed for 125 psi steam. Check valves shall have renewable composition discs or shall have metallic discs of the regrinding type to permit regrinding without removing valve from the line.

2.8.4 Gate Valves

2.8.4.1 Sizes of 1-1/2 inch or less, MSS SP-80, Class 125, Type 1 and 2; 2 inch size and over, MSS

SP-70, Class 125 or 250, as specified; outside screw and yoke with threaded end (design OT), or flanged end (design OF), as required.

2.8.5 Globe Valves

2.8.5.1 MSS SP-80, Type 1. Valves over 3 inch shall have iron bodies and brass or bronze standard trim and shall have glands or followers in the stuffing boxes. Valves shall have nonmetallic renewable composition discs and raised flat seats designed for 150 psi steam. Wheels shall be secured to the stems with hexagonal nuts.

2.9 WATER METERS

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2.9.1 Water meters shall be the disc type with reinforced disc for hot water above 150 degrees F, and rubber or carbon disc for cold water, and shall be constructed of bronze composition or cast iron protected by noncorrosive coating. Moving parts subject to wear shall be easily replaceable.

Meters shall conform to the requirements of AWWA C700.

2.10 ELECTRICAL WORK

2.10.1 Electrical motor-driven equipment specified shall be provided complete with motors, motor starters, and controls. Electrical equipment and wiring shall be in accordance with Section 26 20

00 INTERIOR DISTRIBUTION SYSTEM and Section 33 70 02.00 10 ELECTRICAL

DISTRIBUTION SYSTEM, UNDERGROUND and Section 33 71 01 OVERHEAD

TRANSMISSION AND DISTRIBUTION. Electrical characteristics shall be as indicated or specified. Motor starters shall be provided complete with thermal overload protection and other appurtenances necessary for the motor control specified. Each motor shall be of sufficient size to drive the equipment at the specified capacity without exceeding the nameplate rating of the motor. Manual or automatic control and protective or signal devices required for the operation specified and any control wiring required for controls and devices specified but not shown, shall be provided. Motors shall conform to NEMA MG 1, with enclosures as indicated [except as specified for Petrol Vapor Recovery Unit]. Controls, interlocks, instruments, status indication lights, and other devices required for operation and observation of equipment status shall be assembled on an open face panel, enclosed panel with latched door, key locked door. Panel shall be factory-assembled, connected to equipment, and mounted on unit or factory assembled and boxed for field installation. Instrumentation and control system shall include local control panels and a central control panel located in the facility control room. The control system shall integrate local controls provided with equipment, as specified, so that complete system operation can be monitored and controlled from the control room. The air pollution control system shall be integrated with the emission generating equipment. The control system shall provide integrated control of all system processes and equipment, and shall contain all necessary instrumentation required for monitoring and operation of the air pollution control system. Control system panels shall graphically display the system. Local control panels shall be provided with selector switches so that equipment can be operated manually for test and maintenance purposes. Suitable safety interlocks shall be incorporated to assure that proper permissive conditions have been met prior to changing the operating status of major system components. Shutdown of the air pollution control equipment system, or portion thereof, shall be automatically initiated, with alarms should unsafe conditions arise during operation of the system. Visible and audible alarms shall be provided on critical functions locally and at central control room. Controls shall conform to

NEMA ICS 1. Enclosures for power and control panels shall conform to NEMA ICS 6.

2.11 DRAFT FANS

2.11.1 Centrifugal fans conforming to AMCA 801 Type I, Type II, forced draft and induced draft shall be furnished as an integral part of air pollution control equipment design. Fans shall be centrifugal with backward curved blades, radial tip blades or axial flow type. Each fan shall be sized for an output volume and static pressure rating sufficient for pressure losses, leakages, temperature, and elevation corrections for worst ambient conditions. In addition, fan sizing shall include margins of 10 percent volume and 21 percent static pressure, plus margins of 10 degrees

F for forced draft fans and 40 degrees F for induced draft fans. [Induced draft fans shall be provided with outlet dampers]. Noise levels for fans shall not exceed 85 decibels in any octave band at a 3 foot station. Fan bearings shall be air cooled or water cooled, and backward curved fan blade type with bearings not requiring water cooling may be of the self-aligning antifriction type. Scroll sheets and rotor blades shall have liners.

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2.11.2 Draft Fan Control

2.11.2.1 Forced draft centrifugal fans shall have inlet vane control or variable speed control where indicated. Induced draft centrifugal fans shall have inlet vane control, inlet damper control or variable speed control. Axial propeller fans shall have variable propeller pitch control and variable speed drive. Inlet vanes or dampers shall be suitable for use with air pollution control equipment.

2.11.3 Draft Fan Drives

2.11.3.1 Fan shall be driven by an electric motor or a steam turbine. Electric motor shall be drip-proof, totally enclosed nonventilated, totally enclosed fan-cooled or totally enclosed fan-cooled, suitable for installation in a Class II, Division 1, Group F, hazardous location conforming to

NFPA 70. Motor starter shall be magnetic across-the-line or reduced voltage start type with general-purpose, weather-resistant, water tight, dust-tight or explosion-proof enclosure and shall be furnished with four auxiliary interlock contacts. Steam turbines shall operate properly with a steam inlet pressure as indicated and with steam back pressure as specified. Turbines shall have horizontally-split, centerline support casings, water-cooled bearing housings with ring-oiled, babbitt-lined, bronze packed sleeve bearings. Turbines shall also be equipped with a mechanical shaft speed governor and valve, and independent emergency overspeed governor and trip valve, reed tachometer, constant pressure type governor, insulation with removable metal jacket, oil-sight glasses with guards, removable stainless steel steam strainer without disconnecting piping, any special wrenches and tools required for servicing turbine, and a sentinel warning on the exhaust casings. Turbines shall conform to NEMA SM 23.

2.12 DUCTWORK

2.12.1 Ductwork shall be galvanized sheet metal conforming to ASTM A 653/A 653M with a minimum gauge thickness as indicated. Ductwork shall be designed to convey air with a minimum of pressure loss due to friction. Ducts shall be straight and smooth on the inside with laps made in the direction of airflow. Ducts shall be externally braced and shall be so installed and anchored as to be free of vibration. Access and inspection doors shall be provided as indicated, with a minimum of one in each section between dampers or items of equipment. Ducts shall be constructed with long radius elbows having a centerline radius of 1.5 times the duct width, or where the space does not permit the use of long radius elbows, short radius or square elbows with factory-fabricated turning vanes may be used. Duct joints shall be substantially air-tight and shall have adequate strength for the service.

2.13 AIR POLLUTION CONTROL EQUIPMENT

2.13.1 Performance of equipment shall be as indicated in Paragraph "Schedules". Paint spray and wet process gas ductwork shall comply with AIHA Z9.3 and NFPA 91. Air and water piping shall comply with ASME B31.1. Particulate emission control equipment shall conform to ASME PTC

21, ASME PTC 28, and ASME PTC 38. Equipment shall be provided with steel walkways, safety rails and stairs, or ladders as indicated. Access shall be by means of caged ladders or step stairs with handrails.

2.13.2 Dry Dynamic Precipitator

2.13.2.1 Unit shall be a mechanical collector consisting of a motor-driven fan, a fan casing, a hopper or dust bin, fan motor, fan motor starter with overload protection, fan drive coupling belt drive with fan and motor pulleys and adjustable motor base, fan and motor mounting base on hopper, 44 10 00 - 17 05/08/09 and a ceiling mounting or floor mounting stand for the entire assembly. The fan shall comply with AMCA 99, Section 99-0401, Classification for Spark Resistant Construction, AMCA 210, and AMCA 300.

2.13.2.2 Fan Impeller

a. Fan Impellers shall be steel and shall be designed to provide the static head required for pumping the dirty and cleaned gas streams through the duct systems and related components.

Impeller shall be keyed and locked on a cold drawn, turned and polished steel shaft mounted on heavy duty grease or oil lubrication ball or roller bearings. Shaft shall have a diameter and stiffness that shall limit deflection at the maximum shaft loading, within the operating range of the fan, to not more than 0.002 inch/foot of shaft. Shaft shall be provided with a locked key slot for mounting a pulley, a direct drive, or coupling. The entire rotating assembly shall be dynamically balanced at operating speeds. Shop balancing of the fan impeller assembly shall be to acceptable standard as defined in ANSI S2.19 quality, Grade G6.3 or equivalent.

Installed vibration levels shall not exceed the levels specified in AMCA 801.

2.13.2.3 Fan Casing

a. Fan casing shall be abrasion resistant cast iron conforming to ASTM A 48/A 48M or abrasion resistant steel consisting of a fan support base with back-housing, involute fan discharge scroll with inlet and discharge duct connections, and a dirt discharge port. Scroll shall be provided with readily replaceable wear plates and shall be constructed to permit field positioning the direction of discharge in at least eight different directions. Scroll shall provide means for accumulating and diverting the bulk of the particulate enriched gas stream into the hopper before the gas stream is returned to the inlet to the scroll.

2.13.2.4 Hopper Storage

a. Hopper storage capacity shall be as indicated. Unit shall be constructed of not less than 10 gauge welded, low carbon, corrosion resistant, steel plate for the vertical sides and bottom which shall be sloped steeper than the slump angle of the material being collected to minimize bridging over at the outlet. Top shall be constructed to support the fan, motor, and drive without buckling or being resonated by the fan and shall be not less than 1/4 inch thick.

Hopper shall be provided with an access door and shall have a manually-operated rotary lock, a motor-driven rotary lock or a guillotine-type slide gate.

2.13.2.5 Test Connections

a. Pressure test connections shall be provided at the suction and discharge ducts connecting to the precipitator.

2.13.3 Wet Dynamic Precipitator

2.13.3.1 Unit shall be a mechanical collector consisting of a motor-driven fan, a fan casing with water sprayhead, a hopper or slurry bin, fan motor, fan motor starter with overload protection, fan drive coupling, belt drive with fan and motor pulleys and adjustable motor base, fan and motor support on the hopper or a rigid structural steel base arranged for floor mounting. Fan shall comply with AMCA 99, Section 99-0401, Classification for Spark Resistant Construction, AMCA 210, and AMCA 300.

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2.13.3.2 Collector

a. Collector shall consist of a heavy steel plate fan housing constructed of low carbon steel. Fan shall have ASTM A 240/A 240M stainless steel blades and rivets. Blades shall be fastened to a heavy forged steel hub mounted on a forged, ground, and polished ASTM A 302/A 302M stainless steel shaft supported on ball or roller bearings. Shaft shall have a diameter and stiffness that shall limit deflection at the maximum shaft loading to not more than 0.002 inch/foot of shaft. Impeller and driven units shall be lock-keyed to the shaft with the entire assembly dynamically balanced at all operating speeds. Shop balancing of the fan impeller shall be to acceptable standards as defined in ANSI S2.19 quality, Grade G6.3 or equivalent.

Housing and impeller shall be provided with components that shall provide for uniformly covering rotating and stationary parts with a film of moving water to provide for wetting and capturing of centrifugally impinged particulates. Means shall be provided for separation from the air stream and drainage of the water and particulate slurry from the collector. Installed vibration levels shall not exceed the levels specified in AMCA 801.

2.13.3.3 Hopper Storage

a. Hopper storage capacity shall be as indicated. Unit shall be constructed of not less than 10 gauge welded, black or welded, corrosion resistant, steel plate for the vertical sides and sloped bottom. Top shall be constructed to support the fan, motor, and drive without buckling or being resonated by the fan and shall be not less than 1/4 inch thick. Hopper bottom shall be sloped for complete drainage of slurry of collected material; shall be free of ledges and pockets; and shall provide for full free flushing of particulate when operating wet. Hopper shall be provided with an inspection window, cleanout, and access door. Hopper shall be provided with electric heating coils, modules, or blankets to keep collected material dry and free flowing with the unit installed outdoors and out of service in a local winter outdoor design temperature of as specified.

2.13.3.4 Nonstainless Components

a. Water wetted, nonstainless components shall be coated with a permanently bonded, abrasion and corrosion resistant rubber facing suitable for the operating temperature of the gas stream.

2.13.3.5 Water Supply Components

a. Precipitator shall be provided with water supply components sized to meet equipment capacity requirements and shall include:

(1) A stainless steel water supply strainer with removable screen, flow control valve with rate adjustment, pressure gauge, low pressure alarm switch or water meter.

(2) Analog solenoid water flow control valve.

(3) Adjustable water pressure control switch with contacts to open on low pressure, to stop or prevent operation of the fan motor if water pressure is below the minimum required for efficient operation of the collector. An additional set of contacts to close on low pressure to permit operation of an annunciator alarm. The adjustable range of the switch trip shall be as indicated.

(4) Water pressure gauges with 0-100 psig range.

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(5) Adjustable automatic water pressure or water flow rate regulator to provide a steady controlled rate of water flow as required for optimum collector performance.

(6) Water flow meter sized for rate required by the collector.

2.13.3.6 Test Connections

a. Pressure test connections shall be provided at the suction and discharge ducts connecting to the precipitator.

2.13.3.7 Drain Connections

a. Slurry drain connections shall be screwed or flanged pipe connections sized as recommended by the manufacturer.

2.13.4 Conical Dry Dust Collector

2.13.4.1 Unit shall be a mechanical collector consisting of a top horizontal involute scroll gas inlet and outlet mounted over a vertical cylindrical shell or cone which shall have a narrow angle cone below. Unit shall be specifically designed to impart a high velocity vortex spin to the incoming downflowing gas stream to throw particulates to the wall of the cylinder and cone before turning upward in an internal vortex to the outlet. Replaceable wear plates are or are not required.

2.13.4.2 Scrolls, Cylinder, and Cone

a. Scrolls, cylinder, and cone shall all be not less than the size/gauge indicated of welded black or corrosion resistant steel. Inlet and outlet scrolls shall be connected for clockwise or counterclockwise connection and rotation of the vortex when looking down on the collector.

Four equally spaced, welded steel support brackets shall be provided on the bottom of the inlet scroll or on the vertical walls of the cylindrical section of the collector. The collector cone shall not be used for storage. Particulate shall be removed and collected, and cone bottom shall be provided with an air-tight seal. A guillotine-type slide gauge. A manually-operated rotary lock. A motor-driven rotary lock shall be provided on the bottom of cone, bottom of surge tank or bottom of storage receptacle.

2.13.4.3 Test Connections

a. Pressure test connections shall be provided at the inlet and outlet ducts connecting to the collector.

2.13.5 Multitube, Centrifugal Dry Dust Collector

2.13.5.1 Unit shall be a mechanical collector utilizing a number of parallel vertical or horizontal tubes of small diameter in an enclosure having a single gas inlet and single gas outlet.

2.13.5.2 Inlet Tube Assemblies, Casing and Hopper

a. Inlet tube assemblies shall be replaceable cast iron, wear resistant steel with replaceable cast iron spinner vanes and cones or [wear resistant steel with replaceable spinner vanes and cones.

Casing shall be the size/gauge indicated of low carbon, corrosion resistant steel with the dust released into a 10 gauge, 3/16 inch, 1/4 inch black or corrosion resistant steel sloped bottom

44 10 00 - 20 05/08/09 dust hopper. Hopper valley angle shall be 60 degrees from the horizontal. The hopper shall be provided with a poke hole and access door. Hopper bottom outlet shall be provided with a guillotine-type slide gate, a gravity-type trip gate opened by the weight of the collected material, a manually-operated rotary lock or a motor-driven rotary lock. Unit shall be provided with a welded steel support assembly for field erection with no additional work other than setting and bolting the unit in place.

2.13.5.3 Test Connections

2.13.6 Electrostatic Precipitator (ESP)

2.13.6.1 Unit shall comply with requirements of ICAC EP-1, ICAC EP-7, and ICAC EP-8, and shall remove aerosols and particulates from processed gas stream by impressing a polarized electrostatic charge to the contaminants causing them to be drawn to and deposited upon opposite polarity charged plates. Unit shall contain multiple chambers and be of gas-tight construction. Unit shall be provided with insulator compartments or penthouse. Unit shall be provided with anti-sneak baffles to force all gas flow through ionizing gas passages and to prevent gas bypassing the precipitator sections. Assembly shall consist of discharging electrodes and opposite charged plates, high voltage power pack and controls, a rapping system for knocking dust from the discharge electrodes and collector plates, perforated gas distribution plates, sheet steel enclosure with dust collecting hopper bottom, dirty gas inlet, clean gas outlet, and structural steel frame. Precipitator systems shall include microprocessor based controls flue gas conditioning systems, pulse energization or intermittent energization.

2.13.6.2 Discharge Electrodes

a. Discharge electrodes shall be wires and weights, rigid electrodes or rigid frame. Discharge electrodes shall be top supported with the bottom free to expand and contract with gas stream temperature changes. Electrodes shall be laterally restrained to maintain optimum spacing from the plates. Electrodes shall have a stiffness, length, or restraints required to prevent vibration or flutter when the unit is in service.

2.13.6.3 Collecting Plates

a. Collecting plates shall consist of vertical panels of multiple steel strips hanging edgewise in the horizontal air stream so as to form the equivalent of many vertical splits of the gas stream into many gas passages. The strips shall be convoluted, stiffened or constructed with raised ribs, to provide sufficient stiffness to prevent distortion of the plates and also present vertical ridges to support boundary layer edges to increase plate dust retention. Plates shall be top supported with the bottom free to expand and contract with changes of gas stream temperature. Plate configuration and support system design shall be coordinated with the plate rapping system design and operation to shed collected material from the plates and to retain a consistent and optimum spacing from the discharge electrodes.

2.13.6.4 Power Supply and Control System

a. Power supply and control system shall be solid state microprocessor type. Control system shall provide for continuous monitoring and regulating of applied voltage for effective maximum performance of precipitation over the range of plate loadings with minimum sparking and

44 10 00 - 21 05/08/09 arcing to the plates. Entire system shall be provided with a system of safety interlocks and grounding devices to prevent personnel physical contact with high voltage components.

Voltage insulators shall be provided with heaters.

2.13.6.5 Rapping Systems

a. The rapping systems shall consist of multiple hammers or other impact devices to cause particulate shedding from the collecting plate. Rapping shall automatically be programmed so that a minimum number of collecting plates and discharge electrodes are rapped simultaneously. The unit shall be designed to limit reentrainment of collected material falling from the collecting plates and discharge electrodes during the rapping operation without exceeding the design cleaning efficiency.

2.13.6.6 Inlet and Discharge Ducts

a. Inlet and discharge ducts shall be provided with turning vanes, deflectors, and baffle plates to provide for uniform distribution of gas flow through all gas passages and in each gas passage per ICAC EP-7. Pressure test connections shall be provided at the inlet and discharge ducts connecting to the precipitator.

2.13.6.7 Dust Storage Hopper

a. The unit shall be provided with a 3/16 inch, 1/4 inch, low carbon or corrosion resistant sloped steel bottom dust storage hopper having the dust holding capacity indicated. The hopper shall be arranged to prevent reentrainment of collected material into the gas stream. The hopper bottom shall be provided with rappers or fluidizing pads and a hopper valley angle of 60 degrees and shall be free of pockets, ribs, fins, or any other obstruction to hold or interfere with free release of collected material to the outlet. The outlet shall be provided with a guillotine-type slide gate, a manually-operated rotary lock or a motor-driven rotary lock.