MDOC Physical Plant Design Standardizations Manual.pdf

MICHIGAN DEPARTMENT OF CORRECTIONS

PHYSICAL PLANT

DESIGN STANDARDIZATIONS

Prepared by the

Physical Plant Division

BUDGET and OPERATIONS ADMINISTRATION

DECEMBER 2019

PREFACE

The purpose of MDOC Physical Plant Design Standardizations is for using design criteria already developed and improved on in many cases through several similar projects. Most of it has been approved by MDOC Leadership. Using these criteria will save time by not reinventing the wheel and avoid designing something other than what was already vetted and approved. It is a living document and will continue to be improved on. Please do not make changes without prior approval.

Edward S. Vallad, Administrator

Date

Physical Plant Division

PHYSICAL PLANT STANARDIZATIONS

TABLE OF CONTENTS

1. Bar Screens (Richard)

2. Boilers Domestic (Andrea)

3. Boilers Heat Including Power Plants and Building Boilers (Andrea)

4. Bubble Gate Replacements (Gene)

5. Building Management Systems (Andrea)

6. Cell Doors and Hardware (Richard)

7. Electrical, Ethernet, Fiber, & IP (Richard)

8. Exterior Doors (Andrea)

9. Fire Alarm Upgrades (Richard)

10. Glazing (Gene)

11. Gun Ranges (Richard)

12. PPD’s (Gene)

13. Razor Ribbon & Fence Enhancements (Gene)

14. Membrane Roofs (Gene)

15. Standing Seam Metal Roofs (Gene)

16. Sally Port Sliding Gate Replacements (Gene)

17. Scheduled Shutdowns of Security Systems (Richard)

18. Scheduled Shutdowns of Utilities (Andrea)

19. Security Detection Systems Interior and Exterior (Gene)

20. Smoke Purge Systems (Richard)

21. Stun Fence (Andrea)

22. Video Monitoring Systems (VMS) (Richard)

23. Wheelchair Lifts (Gene)

24. Wheelchair Ramps (Gene)

BAR SCREENS

SECTION 11330

AUGER MONSTER SYSTEM

SERIES AGE-480

SINGLE DRIVE-ELECTRIC 40002 GRINDER AND

ELECTRIC 480 MM AUGER

PART 1 GENERAL

1.1 SUMMARY

A. This section of the specification describes the screenings removal equipment consisting of a support system(s), grinder(s), auger(s), and motor controller(s). The equipment shall be installed as shown on the plans, as recommended by the supplier, and in compliance with all OSHA, local, state and federal codes and regulations.

B. The number of Auger Monster(s) systems shall be 1. Each system shall include the support system, grinder, auger, and motor controller.

C. The auger system shall be capable of processing 1 MGD (157.7 m³/h) with a maximum headloss of 16.65inches (422.9mm) at a downstream water level of

4.64inches (117.9mm).

1.2 REFERENCES

A. Support system(s), grinder(s), and auger(s) materials of construction shall, as applicable, meet the requirements of the following industry standards:

1. American Society for Testing and Materials (ASTM)

A36: Standard Specification for Carbon Steel Plate

2. American Society for Testing and Materials (ASTM)

A536-84: Standard Specification for Ferritic Ductile Iron Castings

3. American Iron and Steel Institute (AISI) 303 Stainless Steel

4. American Iron and Steel Institute (AISI) 304 Stainless Steel

5. American Iron and Steel Institute (AISI) 316 Stainless Steel

6. American Iron and Steel Institute (AISI) 4130 Heat Treated

Alloy Steel

7. American Iron and Steel Institute (AISI) 4140 Heat Treated

Hexagon Steel

8. Rockwell C

B. Motor controllers shall, as applicable, meet the requirements of the following Regulatory Agencies.

1. National Electrical Manufacturer's Association (NEMA)

Standards

2. National Electrical Code (NEC)

3. Underwriters Laboratory (UL and cUL)

PART 1 GENERAL

1.3 DOCUMENTS

A. Shop Drawing(s)

Supplier shall submit six (6) sets of shop drawings. Shop drawings shall include equipment descriptions, specifications, dimensional and assembly drawings, parts lists, and job specific drawings.

B. Operation and Maintenance Manuals

Supplier shall submit three (3) sets of Operation and Maintenance manuals prepared using best commercial practices. The manuals shall include equipment descriptions, operating instructions, drawings, troubleshooting techniques, a recommended maintenance schedule, and the recommended lubricants.

1.4 QUALITY ASSURANCE

Qualified suppliers shall have a minimum of five (5) years experience at manufacturing, support systems, two (2) shafted grinding equipment, inclined augers and motor controls with a minimum 500 installations of similar equipment. Supplier shall provide a list of names and dates of installations for verification by the Engineer or Owner's Representative.

Supplier shall provide the services of a factory-trained representative to check the installation and to start-up each grinder, auger and controller. The factory representative shall have complete knowledge of proper installation, operation, and maintenance of equipment supplied.

Representative shall inspect the final installation and supervise a start-up test of the equipment.

Each grinder, auger, and controller shall be factory tested to ensure satisfactory operation.

1.5 DELIVERY, STORAGE AND HANDLING

A. The equipment shall be packaged in containers constructed for normal shipping, handling and storage.

B. The containers shall provide adequate protection for the equipment in a dry indoor environment between +40F (+4.5C) and +100F (+37.8C) until time for installation.

1.6 IDENTIFICATION

Each unit of equipment shall be identified with a corrosion resistant nameplate, securely affixed in a conspicuous place. Nameplate information shall include equipment model number, serial number, supplier's name, and location.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Support system(s), grinder(s), auger(s), and motor controller(s) shall be in compliance with these specifications and plans and shall be supplied by one of the following manufacturers:

1. JWC Environmental®: Auger Monster® system Model No.

AGE1800-480-7500

2. Approved equal

B. Manufacturers requesting to be selected as an approved equal shall submit certified documentation showing compliance with these specifications a minimum of ten (10) days prior to bid opening. Selected equipment manufacturers shall be added to the list of approved manufacturers.

C. The manufacturer must certify that the unit can be returned for maintenance to the factory or a local repair facility. The certification shall include a statement that there will be no charge for repair labor.

2.2 SUPPORT SYSTEM(S)

A. GENERAL

1. A grinder and auger system support frame with adjustable mounting brackets shall be provided for a 24 inch (609.6 mm) wide and a 183.5 inch (4660.9 mm) deep channel.

2. An auger drive-end support shall be provided as required by the application. The drive end shall provide a method for pivoting the auger from the channel to perform simple maintenance. Installations with transport lengths of the auger greater than 4000 mm (157 in) shall require additional supports.

3. A horizontal support shall be provided for mounting an ultrasonic sensor upstream from the system support frame.

B. COMPONENTS

The support frame, tube and additional supports shall be of welded square tube, angle, and plate construction. The construction material shall be 304 stainless steel unless noted.l.

2.3 GRINDER(S)

1. Each grinder shall include cutters, spacers, shafts, bearings and seals, side rails, end housings, covers, reducer, and motor.

2. The grinder shall be of two (2) shaft design and be capable of continuous operation, processing wet or dry. Bar screens or single shaft devices utilizing a single rotating cutter bar with stationary cutters shall not be acceptable. Grinders designed with cutter and spacer cartridges rather than individual cutters and spacers shall not be acceptable.

PART 2 PRODUCTS (Cont'd)

2.3 GRINDER(S) (Cont'd)

A. GENERAL (Cont'd)

3. Two (2) shaft design shall consist of two (2) parallel shafts alternately stacked with individual intermeshing cutters and spacers positioned on the shaft to form a helical pattern. The two (2) shafts shall counter-rotate with the driven shaft operating at approximately two-thirds (2/3) the speed of the drive shaft. Cutter diameters on the drive and driven shafts shall be of equal diameter to ensure proper clean-out of the spacers.

1. Individual Cutters and Spacers

a. The cutting chamber shall be a nominal height of 18 inch ( 457.2 mm).

b. Individual cutters and spacers shall be AR500 abrasion resistant alloy steel, surface ground for uniformity with a hardness of 50-52 HRc.

c. The inside configuration of both the individual cutters and the individual spacers shall be hexagonal so as to fit the shafts with a total clearance not to exceed 0.015 inch (0.38 mm) across the flats to assure positive drive, minimize wear on the cutters.

d. Cutter configuration shall consist of individual eleven (11) tooth cam cutters on both shafts. To maintain particle size, the height of the tooth does not exceed 1/2 inch (13) mm) above the root diameter. Cutter root diameter overlap is not less than 1/16 inch or greater than 1/4 inch to maintain the best possible cutting efficiency while incurring the least amount of frictional losses. Clearance between overlapping cutters of opposing shaft shall be no greater than 0.011 inches

(0.28 mm).

e. The cutters shall exert a minimum force at the tooth tip of 1,624 lbs/hp (9,685 N/kW) during momentary load peaks.

2. Shafts

a. Grinder drive and driven shafts shall be made of

4140 heat treated hexagon steel with a tensile strength rating of not less than 149,000 psi (1,027 MPa).

b. Each hexagonal shaft shall measure a nominal two and one half (2 1/2) inch (64 mm) across parallel surfaces.

3. Shaft Bearings and Seals

a. The radial and axial loads of the cutter shafts shall be borne by sealed, oversized, deep-groove ball bearings at each end.

b. The bearings shall be protected by a combination of a replaceable and independent tortuous path device and mechanical seals.

c. Face materials shall be of tungsten carbide to tungsten carbide.

B. COMPONENTS (Cont'd)

3. Shaft Bearings and Seals (Cont'd)

d. O-rings shall be made of Buna-N elastomers.

e. Products requiring continuous or occasional lubrication or flushing shall not be accepted.

f. The mechanical seal shall be rated at 90 psi (620 kPa) continuous duty by the seal supplier.

g. The bearings shall be housed in a replaceable cartridge that supports and aligns the bearings and seals, as well as protects the shafts and end housings. The seal elements shall be independent of the stack height; therefore cutter stack tightness shall not affect seal performance. The seal elements shall maintain their factory set preload independent of the cutter stack tightness.

h. Seals shall meet required pressure rating regardless of cutter stack fit. The seal cartridge shall provide seal protection against axial loading on shafts and bearings during shaft deflection.

i. Each seal element shall be positively locked to its corresponding rotating or static cartridge element. This positive lock on the seal elements is critical to long seal life in applications where grit or other abrasive materials are present.

4. Side Rails

a. The inside profile of the side rails shall be concave to follow the radial arc of the cutters.

b. Clearance between the major diameter of the cutter and the concave arc of the side rails shall not exceed 5/16 inch (7.9 mm).

c. The side rails shall have evenly spaced slots that increase flow and decrease head loss.

d. The side rails shall be cast of A536-84 ductile iron.

5. End Housings and Covers

a. Grinder end housings shall be of cast A536-84 ductile iron with a cast-in-place flow deflector, designed to protect the bushings while guiding particles directly into the cutting chamber.

b. Top covers shall be A536-84 ductile iron and bottom covers shall be A36 hot rolled plates.

6. Reducer

a. The speed reducer shall be a grease-filled planetary-type reducer with a 500% shock load capability. The reduction ratio shall be 43:1.

b. The input shaft of the reducer shall be directly coupled to the motor using a three-(3) piece coupling, and the output shaft of the reducer shall be directly coupled with the grinder using a two (2)-piece coupling.

7. Motor

a. The motor shall be 10 hp (7.5 kW), Immersible, 1725 rpm, 460 volt, 3 phase, 60 Hz.

b. Motor service factor shall be 1.15, the efficiency factor not less than 85% at full load and the power factor not less than 80% at full load.

c. Required Running Torque per Horsepower (kW):

At Momentary Load Peaks: 6,088 in-lbs/hp (922 Nm/kW)

2.4 AUGER(S)

1. The auger(s) shall be comprised of a perforated screen segment, transport segment, discharge segment, and drive segment with an internal rotating spiral.

2. Each auger shall be installed at an inclination of 35 degrees from horizontal immediately downstream of the grinder.

3. The auger screen segment trough with a rotating spiral shall provide particle capture and transport to the discharge segment outlet.

4. A wiper/brush shall be affixed to the outer edge of the spiral in the screen segment trough to provide trough cleaning and particle transport. The wastewater shall be permitted to pass through the screen segment and flow downstream.

5. Particles shall be washed both by the highly-agitated passing wastewater and by the discharge of a spray wash system. Dewatering shall occur as the rotating spiral conveys the washed screenings.

2.4 AUGER(S) (Cont'd)

A. GENERAL (Cont'd)

6. A spray wash assembly shall be provided to rinse the organic material from the processed solids back into the waste stream. The spray wash system shall consist of a set of nozzles proving a covering spray of water for cleaning the captured solids along with a set of nozzles providing an impact spray to hold the solids against the screen trough for transportability. A spray wash solenoid valve shall be automatically energized by the system controller allowing wash water to spray into the screen segment whenever the auger spiral is in operation. The spray wash solenoid shall be automatically de-energized, stopping the flow of wash water whenever the auger spiral is stopped.

7. Starting of auger run cycles shall be initiated by signals from an ultrasonic level sensor.

1. Spiral

a. The 480 mm (18.89 in) spiral shall be made of high wear-resistant, alloy carbon steel.

b. The spiral shall have a groove designed into the outside diameter of the spiral for the mounting of the brush. The groove shall securely position the brush so that constant contact is maintained with the screen segment for the purpose of cleaning the perforations and the free passage of soft organics and liquids. Spirals that mount the brush to the face of the spiral shall not be acceptable.

c. The spiral shall have a welded drive plate for connection to the drive shaft.

d. The spiral tip speed shall not be more than 54 feet/minute (0.27 m/s).

e. The spiral transport speed shall not be more than

6.25 feet/minute (0.03 m/s).

2. Screen Segment

a. The screen segment trough shall be a replaceable, perforated stainless steel assembly. The perforated area of the segment shall be constructed of 14 ga. Sheet.

b. The screen trough perforations shall be 6 mm for separation of the liquids from the solids. The sharp edges of the perforations shall be removed.

3. Transport Segment

a. The transport segment shall be a stainless steel assembly with inspection port(s). The segments shall be constructed of 10

ga. sheet

b. The transport segment shall have stainless steel wear bars to support the rotating spiral.

2.4 AUGER(S) (Cont'd)

4. Discharge Segment

a. The discharge segment shall be a stainless steel assembly with an inspection port and a full-width bottom discharge flange.

The segment shall be constructed of 10 ga. Sheet.

b. The discharge segment shall have a stainless steel endplate for mounting the drive segment.

5. Drive Segment

a. The drive segment shall be comprised of a drive shaft with welded drive plate, shaft seal, drive adapter spool, speed reducer and electric motor.

b. The shaft seal shall consist of a packing housing;

four (4) PTFE impregnated packing cords, and adjustable packing ring.

c. The drive adapter spool shall be cast A536-84 ductile iron coated to inhibit corrosion.

d. The speed reducer shall have a reduction ratio of 160:1.

e. The electric motor shall be of 2 hp (1.5 kW), Immersible, 1725 rpm, 460 volt, 3-phase, 60-Hz.

6. Spray Wash Assembly

a. Spray Wash Assembly shall consist of a one (1) inch spray wash manifold, solenoid operated valve, manually operated ball-valve, and a remotely installed basket strainer.

b. The spray wash manifold shall be of stainless steel pipes and fittings. The spray nozzle shall consist of 40° “V” spray nozzles rated for 1.5 GPM @ 40 PSI and high impact 50° spray nozzles rated for 1.0 GPM @ 40 PSI.

c. The solenoid valve shall be of bronze construction, fitted with an explosion proof enclosure, housing a 120 volt, ac coil.

d. The manually operated ball valve shall be of 316 stainless steel and shall provide adjustment for the spray wash water flow.

e. A one (1) inch NPT strainer shall be of SST material, with an 80 mesh 304 stainless steel screen and a threaded drain.

f. A one (1) inch NPT double back-flow preventer

(not supplied by equipment manufacturer) is recommended when using potable water for spray wash.

PART 2 PRODUCTS (Cont’d)

2.5 LEVEL SENSORS

1. The Auger Monster system shall be provided with upstream and downstream ultrasonic level sensors.

2. The level sensors will initiate auger run cycles based on channel head differential and the parameters set in the operator interface.

3. The PLC logic shall determine differential levels using signals from two (2) separately-mounted ultrasonic level sensors.

a. One (1) level sensor shall be installed upstream of the system and measure the system’s upstream water level.

b. One (1) level sensor shall be installed downstream of the system and measure the channel’s downstream water level.

c. The head in front (upstream) of the system shall be compared to the head behind (downstream) of the system to determine the water level differential.

2.6 MOTOR CONTROLLER(S)

1. The controller shall provide independent control of the grinder, auger and spray wash assembly.

2. Controller shall be the supplier's standard UL/cUL listed Model

PC-2251D.

3. The controller shall be rated for 10 hp (7.5 kW) and 2 hp

(1.5 kW), 460 volts, 3-phase, 60-Hz.

B. OPERATION

1. The controller shall be equipped with a GRINDER

ON/OFF/RESET-REMOTE three (3) position selector switch.

a. In the OFF/RESET position the grinder shall not run.

b. In the ON position the grinder will run.

c. In the REMOTE position the grinder shall start and stop as controlled by a remotely-located contact.

d. The grinder shall only be reset by switching the

GRINDER ON-OFF/RESET-REMOTE switch to the OFF/RESET position.

2.6 MOTOR CONTROLLER(S) (Cont'd)

B. OPERATION (Cont'd)

2. The controller shall be equipped with an AUGER

ON/OFF/RESET-LEVEL three (3) position selector switch.

a. In the OFF/RESET position the auger shall not run.

b. In the ON position the auger shall continuously initiate

Auger Run Cycles.

c. In the LEVEL position, auger run cycles shall be initiated by the ultrasonic level sensors or the Level Sensor Backup Timer.

Auger Run Cycles in the LEVEL position shall only be enabled when the grinder is running.

d. The auger shall only be reset by switching the

AUGER ON/OFF/RESET-LEVEL switch to the OFF/RESET position.

3. The controller shall be equipped with a digital operator interface.

a. The operator interface shall display grinder and auger run times, elapsed times, reversals, jams, motor overloads and over-temperature occurrences.

b. The operator interface shall display Fail, Service

Reminder, and Operational Messages.

c. Operator interface function keys shall select the following displays: Date and Time, Auger Run Cycle, Auger Start Time

Interval, and System Monitor.

d. The Auger Cycle Run times, and Level Sensor

Backup Timer shall be programmable. Settings shall be entered at the operator interface using panel keys to initiate a desired run sequence.

4. The controller shall be equipped with a programmable Level

Sensor Backup Timer.

a. The Level Sensor Backup Timer shall initiate an auger run cycle if the ultrasonic sensor fails to start an auger cycle within a preset interval of 0 to 999 minutes.

b. The Level Sensor Backup Timer shall run the system continually when the timer is set to 0.

C. COMPONENTS

1. Enclosure

a. Enclosures shall be NEMA 4X, 304 stainless steel construction and shall be suitable for wall mounting. Doors shall have corrosion-resistant hinges and latches.

b. Enclosure shall house the control devices, relays, terminal blocks and reversing motor starters.

C. COMPONENTS (Cont'd)

2. Control Devices

a. Operator interface and pilot devices shall be mounted on the enclosure front panel door.

b. The controller shall have indicator lights for

GRINDER RUN, AUGER RUN, and common FAIL.

c. POWER ON, GRINDER JAMMED, AUGER

JAMMED,GRINDER MOTOR OVERLOAD, AUGER MOTOR

OVERLOAD, GRINDER MOTOR OVERTEMP, and AUGER MOTOR

OVERTEMP, LEVEL SENSOR 1 FAILED, LEVEL SENSOR 2 FAILED

and HIGH LEVEL ALARM shall be displayed by the operator interface.

d. Control devices are mounted in the front panel of the enclosure. Indicator lights shall be LED type pilot lights. Lights and the selector switches shall be heavy duty NEMA 4X type.

e. Control transformer shall be protected by two (2) primary fuses and one (1) secondary fuse. The 120 volt secondary shall have one (1) leg grounded.

f. Relay contacts shall be included for GRINDER

RUN, AUGER RUN, and common FAIL signal outputs. The contacts shall be rated 10 ampere, 240 VAC, resistive load.

3. Motor Starters

a. Starters shall be a full-voltage reversing type with 120 volt operating coils.

b. Forward and reverse contactors on the starters shall have both mechanical and electrical interlocks.

c. Overload relays (OL) shall be adjustable so that the range selected includes the full load amperes (FLA) rating and service factor.

D. SAFETY FEATURES

1. When a grinder jam condition occurs in the grinder ON or REMOTE mode the controller shall stop the grinder and reverse grinder rotation to clear the obstruction. If the jam is cleared, the controller shall return the grinder to normal operation. Up to two (2) additional reversing cycles (3 times total) may occur within 30 seconds before the controller de-energizes the grinder motor and activates the grinder fail indicator and relay.

The auger shall continue operating during a grinder fail condition.

D. SAFETY FEATURES (Cont'd)

2. When an auger jam condition occurs in the auger ON or

LEVEL modes the controller shall stop the auger, and reverses auger rotation to clear the obstruction. If the jam is cleared, the controller shall return the auger to normal operation. One (1) additional auger reversal (2 times total) may occur within 30 seconds before the controller de-energizes the auger motor and activates the auger fail indicator and common fail relay. The grinder shall continue operating during an auger fail condition.

3. If a power failure occurs while a grinder or auger is running, operation will resume running when power is restored.

4. If a power failure occurs while the grinder or auger is in a fail condition the fail indicator shall be reactivated when power is restored.

5. The controller shall provide overload protection for the motor through an overload relay mounted directly on the grinder and auger starters.

6. The controller shall be equipped with a main power disconnect switch. Motor branch circuits shall be short circuit protected.

7. Controller reset shall be from the local panel controls only.

PART 3 EXECUTION

3.1 INSTALLATION

Support system(s), grinder(s), auger(s), and motor controller(s) shall be installed in accordance with the supplier’s installation instructions, and in compliance with all OSHA, local, state, and federal codes and regulations.

END OF SECTION

BOILERS DOMESTIC

SECTION 223500 - DOMESTIC-WATER HEAT EXCHANGERS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary

Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section Includes:

1. Circulating, storage, domestic-water heat exchangers.

1.3 ACTION SUBMITTALS

A. Product Data: For each type and size of domestic-water heat exchanger indicated. Include rated capacities, operating characteristics, electrical characteristics, and furnished specialties and accessories.

B. Shop Drawings:

1. Wiring Diagrams: For power, signal, and control wiring.

1.4 INFORMATIONAL SUBMITTALS

A. Product Certificates: For each type of circulating, domestic-water heat exchanger, from manufacturer.

B. Domestic-Water, Heat-Exchanger Labeling: Certified and labeled by testing agency acceptable to authorities having jurisdiction.

C. Source quality-control reports.

D. Field quality-control reports.

E. Warranty: Sample of special warranty.

1.5 CLOSEOUT SUBMITTALS

A. Operation and Maintenance Data: For domestic-water heat exchangers to include in emergency, operation, and maintenance manuals.

1.6 QUALITY ASSURANCE

A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.

B. ASHRAE/IESNA 90.1 Compliance: Applicable requirements in ASHRAE/IESNA 90.1.

C. ASME Compliance: Where ASME-code construction is indicated, fabricate and label heat-exchanger storage tanks to comply with ASME Boiler and Pressure Vessel Code: Section VIII, Division 1.

D. NSF Compliance: Fabricate and label equipment components that will be in contact with potable water to comply with NSF 61, "Drinking Water System Components - Health Effects."

1.7 COORDINATION

A. Coordinate sizes and locations of concrete bases with actual equipment provided.

1.8 WARRANTY

A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace components of domestic-water heat exchangers that fail in materials or workmanship within specified warranty period.

1. Failures include, but are not limited to, the following:

a. Structural failures including heat exchanger, storage tank, and supports.

b. Faulty operation of controls.

c. Deterioration of metals, metal finishes, and other materials beyond normal use.

2. Warranty Periods: From date of Substantial Completion.

a. Circulating, Storage, Domestic-Water Heat Exchangers:

1) Storage Tank: Five years.

2) Tube Coil: Five years.

3) Controls and Other Components: Three years.

PART 2 - PRODUCTS

2.1 CIRCULATING, DOMESTIC-WATER HEAT EXCHANGERS

A. Circulating, Storage, Domestic-Water Heat Exchangers:

1. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

a. Cemline Corporation.

b. PVI Industries, LLC.

2. Description: Packaged, large-capacity, hot-water storage tank with heat-exchanger coil;

circulator; controls; and specialties for heating domestic water with heating hot water in coil.

3. Flow Pattern: Standard-flow arrangement, with water from bottom of storage tank circulated across heat-exchanger coil and returned to tank. Include hot-water outlet located at top of tank and temperature sensor in tank.

4. Storage-Tank Construction: ASME-code steel with 125-psig working-pressure rating.

Include nozzle and head for heat-exchanger tube coil.

a. Configuration: Vertical.

b. Manhole: 11 by 15 inches in sidewall of vertical storage-tank shell.

c. Tappings: Factory fabricated of materials compatible with tank. Attach tappings to tank before testing and labeling.

1) NPS 2 and Smaller: Threaded ends according to ASME B1.20.1.

2) NPS 2-1/2 and Larger: Flanged ends according to ASME B16.5 for steel and stainless-steel flanges and according to ASME B16.24 for copper and copper-alloy flanges.

d. Lining: Cement complying with NSF 61 barrier materials for potable-water tank linings, including extending lining into and through tank fittings and outlets.

e. Insulation: Heater shall be insulated with 3” fiberglass protected by an enameled metal jacket, 20 gauge minimum thickness, with access panel to the manhole.

f. Anode Rods: Factory installed, magnesium.

5. Heat-Exchanger Coil: 836DW. Double wall copper inner / copper outer tubes, copper lined tube sheet on tank side, steel tube sheet on coil head side, copper baffles, 8” - 150#

4 pass carbon steel coil head.

6. Temperature Control: Solid state control module with two temperature sensors (1000 ohm) that includes the following functions:

a. LED touch screen display with built in on/off switch, remote start/stop, alarm horn, 24 VAC relay for primary and secondary high temperature limits.

b. PID control signal. 0 - 10 VDC output signal for modulation of control valve.

c. Built in LED display of set point, operating temperature, and output voltage.

d. Built in LCD display of functions and alarms: Power on, primary high limit, and secondary high limit.

http://www.specagent.com/LookUp/?uid=123456809970&mf=&src=wd http://www.specagent.com/LookUp/?uid=123456809974&mf=&src=wd

e. Built in contacts to notify BAS of functions and alarms: Power on, primary high limit, secondary temperature limit, call for heat (contact open when control valve is closed), any alarm, and operating temperature (4 - 20 mA).

f. Built in: Input for remote temperature control (4 - 20 mA input signal).

g. Built in MODBUS RTU.

7. Safety Control: Automatic, high-temperature-limit cutoff device or system. Include automatic low-water cutoff device or system.

8. Relief Valves: ASME rated and stamped for combination temperature-and-pressure relief valves. Include one or more relief valves with total relieving capacity at least as great as heat input, and include pressure setting less than working-pressure rating of heat exchanger. Select one relief valve with sensing element that extends into storage tank.

9. Gages:

a. Digital readout on controller.

b. Heating supply thermometer.

c. Vessel pressure gauge.

10. Circulating Pump: UL 778, all-bronze, centrifugal, overhung-impeller, separately coupled in-line pump as defined in HI 1.1-1.2 and HI 1.3. Include mechanical seals, 125-psig minimum working-pressure rating, and 225 deg F continuous-water-temperature rating.

a. Pump Control: Sensor for operating pump and control valve.

11. Support: Factory mounted on skids.

12. Energy Management System Interface: Normally closed dry contacts for enabling and disabling heat exchanger.

13. Component Piping: Refer to schedule on prints.

14. Water heater shall comply with lead free laws.

15. Single point wiring.

2.2 DOMESTIC-WATER, HEAT-EXCHANGER ACCESSORIES

A. Domestic-Water Compression Tanks:

1. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

a. AMTROL Inc.

b. Bell & Gossett.

c. Smith, A. O. Water Products Co.; a division of A. O. Smith Corporation.

d. State Industries.

e. Taco, Inc.

2. Description: Steel pressure-rated tank constructed with welded joints and factory-installed butyl-rubber diaphragm. Include air precharge to minimum system-operating pressure at tank.

3. Construction:

http://www.specagent.com/LookUp/?uid=123456810019&mf=&src=wd http://www.specagent.com/LookUp/?uid=123456824510&mf=&src=wd http://www.specagent.com/LookUp/?uid=123456810022&mf=&src=wd http://www.specagent.com/LookUp/?uid=123456810023&mf=&src=wd

a. Tappings: Factory-fabricated steel, welded to tank before testing and labeling.

Include ASME B1.20.1 pipe thread.

b. Interior Finish: Comply with NSF 61 barrier materials for potable-water tank linings, including extending finish into and through tank fittings and outlets.

c. Air-Charging Valve: Factory installed.

4. Capacity and Characteristics:

a. Working-Pressure Rating: 100 psig.

b. Capacity Acceptable: 2 gal. minimum.

c. Air Precharge Pressure: 50 psi.

2.3 SOURCE QUALITY CONTROL

A. Factory Tests: Test and inspect domestic-water heat exchangers specified to be ASME-code construction, according to ASME Boiler and Pressure Vessel Code.

B. Hydrostatically test domestic-water heat exchangers to minimum of one and one-half times pressure rating before shipment.

C. Domestic-water heat exchangers will be considered defective if they do not pass tests and inspections. Comply with requirements in Section 014000 "Quality Requirements" for retesting and reinspecting requirements and Section 017300 "Execution" for requirements for correcting the Work.

D. Prepare test and inspection reports.

PART 3 - EXECUTION

3.1 DOMESTIC-WATER, HEAT-EXCHANGER INSTALLATION

A. Domestic-Water, Heat-Exchanger Mounting: Install domestic-water heat exchangers on concrete base.

1. Install dowel rods to connect concrete base to concrete floor. Unless otherwise indicated, install dowel rods on 18-inch centers around the full perimeter of concrete base.

2. For supported equipment, install epoxy-coated anchor bolts that extend through concrete base and anchor into structural concrete floor.

3. Place and secure anchorage devices. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded.

4. Install anchor bolts to elevations required for proper attachment to supported equipment.

5. Anchor heat exchangers to substrate.

B. Install domestic-water heat exchangers level and plumb, according to layout drawings, original design, and referenced standards. Maintain manufacturer's recommended clearances. Arrange units so controls and devices needing service are accessible.

1. Install shutoff valves on domestic-water-supply piping to heat exchangers and on domestic-hot-water outlet piping. Comply with requirements for shutoff valves specified in Section 220523.12 "Ball Valves for Plumbing Piping," Section 220523.13

"Butterfly Valves for Plumbing Piping," and Section 220523.15 "Gate Valves for

Plumbing Piping."

2. Install shutoff valves on heating hot-water piping to heat exchangers. Comply with requirements for shutoff valves specified in Section 230523 "General-Duty Valves for

HVAC Piping."

C. Install temperature and pressure relief valves in top portion of storage-tank shells of domestic-water heat exchangers with domestic-water storage. Use relief valves with sensing elements that extend into shells. Extend relief-valve outlet, with drain piping same as domestic-water piping in continuous downward pitch, and discharge by positive air gap onto closest floor drain.

D. Install heat-exchanger drain piping as indirect waste to spill by positive air gap into open drains or over floor drains. Install hose-end drain valves at low points in water piping for domestic-water heat exchangers that do not have tank drains. Comply with requirements for hose-end drain valves specified in Section 221119 "Domestic Water Piping Specialties."

E. Install thermometer on each domestic-water, heat-exchanger, inlet and outlet piping, and install thermometer on each domestic-water, heat-exchanger, heating-fluid inlet and outlet piping.

Comply with requirements for thermometers specified in Section 220519 "Meters and Gages for

Plumbing Piping."

F. Fill domestic-water heat exchangers with water.

G. Charge domestic-water compression tanks with air.

3.2 CONNECTIONS

A. Comply with requirements for piping specified in Section 221116 "Domestic Water Piping."

B. Comply with requirements for heating hot-water piping specified in Section 232113 "Hydronic

Piping" and Section 232116 Hydronic Piping Specialties."

C. Drawings indicate general arrangement of piping, fittings, and specialties.

D. Where installing piping adjacent to domestic-water heat exchangers, allow space for service and maintenance of heat exchangers. Arrange piping for easy removal of domestic-water heat exchangers.

3.3 IDENTIFICATION

A. Identify system components. Comply with requirements for identification specified in

Section 220553 "Identification for Plumbing Piping and Equipment."

3.4 FIELD QUALITY CONTROL

A. Perform tests and inspections.

1. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installations, including connections, and to assist in testing.

2. Leak Test: After installation, charge system and test for leaks. Repair leaks and retest until no leaks exist.

3. Operational Test: After electrical circuitry has been energized, start units to confirm proper operation.

4. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.

B. Domestic-water heat exchangers will be considered defective if they do not pass tests and inspections. Comply with requirements in Section 014000 "Quality Requirements" for retesting and reinspecting requirements and Section 017300 "Execution" for requirements for correcting the Work.

C. Prepare test and inspection reports.

3.5 DEMONSTRATION

A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain circulating and domestic-water heat exchangers.

END OF SECTION 223500

BOILERS HEAT

DIVISION 23 – Heating, Ventilating, and Air Conditioning

GENERAL STANDARDS

1. All new equipment to be on-site before removing existing equipment.

2. All room sensors in prisoner occupied areas shall be a flat metal plate wall sensor not controlled by room occupants only from the BAS. (Trane

Aspiration box or equal).

3. BAS systems to be locally controlled on the campus through the black network, not accessible remotely off campus.

4. Provide a minimum of one weeks’ notice before all shutdowns.

5. When replacing boilers contractor shall sequence the work to allow for a backup boiler throughout the project or have a temporary boiler on standby.

6. If replacing a chiller in critical areas, contractor to provide a temporary chiller during construction.

7. Exposed piping on roof to have a Painted Aluminum, Stucco Embossed, 0.020 inch thick field applied jacket.

8. All fasteners used in areas exposed to inmates shall use tamperproof screws.

9. Contractor to maintain heat in the building during construction if work is being completed during the heating season.

10. Contractor to provide a detailed construction schedule and update the schedule weekly. Contractor to submit the updated schedule to the project team (Facility, PTC, DTMB, and MDOC) weekly to coordinate escort requirements.

11. When conducting roof work the contractor shall maintain any existing warranties on the roof.

12. Contractor to notify the facility at least 1 day in advance for any hot work to allow the owner to disable the fire alarm.

13. Access panels to be high security 10 gage with a knockout for a lock. Owner will provide their own lock for the access panel.

MECHANICAL PIPING STANDARDS

3.1 LOW PRESSURE STEAM PIPING APPLICATIONS

A. LP Steam Piping, NPS 2 and Smaller: Schedule 80, Type S, Grade B, steel pipe;

Class 150 cast-iron fittings; and threaded joints.

B. LP Steam Piping, NPS 2-1/2 through NPS 12: Schedule 80, Type E, Grade B, steel pipe; Class 150 wrought-steel fittings, flanges, and flange fittings; and welded and flanged joints.

C. Steam Condensate piping above grade, NPS 2 and smaller, shall be the following:

1. Schedule 80, Type S, Grade B, steel pipe; Class 150 cast-iron fittings;

and threaded joints.

D. Steam Condensate piping above grade, NPS 2-1/2 and larger, shall be the following:

1. Schedule 80, Type E, Grade B, steel pipe; Class 150 wrought-steel fittings, flanges, and flange fittings; and welded and flanged joints.

3.2 HIGH PRESSURE STEAM PIPING APPLICATIONS

A. All boiler room piping must be A106 seamless, all blowdown piping must be A106 seamless and have 3000# couplings, schedule 80, this can be welded or threaded and the 3000# couplings are the only ones that can be backwelded.

B. HP Steam Piping, NPS 2 and Smaller: Schedule 80, Type S, Grade B, steel pipe; Class 150 cast-iron fittings; and threaded joints.

C. HP Steam Piping, NPS 2-1/2 through NPS 12: Schedule 80, Type E, Grade B, steel pipe; Class 150 wrought-steel fittings, flanges, and flange fittings; and welded and flanged joints.

D. Condensate piping above grade, NPS 2 and smaller, shall be the following:

1. Schedule 80, Type S, Grade B, steel pipe; Class 125 cast-iron fittings;

and threaded joints.

E. Condensate piping above grade, NPS 2-1/2 and larger, shall be the following:

1. Schedule 80, Type E, Grade B, steel pipe; Class 150 wrought-steel fittings, flanges, and flange fittings; and welded and flanged joints.

3.3 INDOOR NATURAL GAS PIPING SCHEDULE FOR SYSTEM PRESSURES

LESS THAN 0.5 PSIG

A. Aboveground, branch piping NPS 1and smaller shall be one of the following:

1. Steel pipe with malleable-iron fittings and threaded joints.

B. Aboveground, distribution piping shall be one of the following:

1. Steel pipe with malleable-iron fittings and threaded joints.

2. Steel pipe with wrought-steel fittings and welded joints.

3.4 INDOOR NATURAL GAS PIPING SCHEDULE FOR SYSTEM PRESSURES

MORE THAN 0.5 PSIG AND LESS THAN 5 PSIG

A. Aboveground, branch piping NPS 1 and smaller shall be one of the following:

1. Steel pipe with malleable-iron fittings and threaded joints.

B. Aboveground, distribution piping shall be one of the following:

1. Steel pipe with malleable-iron fittings and threaded joints.

2. Steel pipe with steel welding fittings and welded joints.

3.5 INDOOR NATURAL GAS PIPING SCHEDULE FOR SYSTEM PRESSURES

MORE THAN 5 PSIG

A. Aboveground Piping: Maximum operating pressure more than 5 psig.

B. Aboveground, Branch Piping: Steel pipe with steel welding fittings and welded joints.

C. Aboveground, distribution piping shall be the following:

1. Steel pipe with steel welding fittings and welded joints.

3.6 HOT AND CHILLED WATER PIPING APPLICATIONS

A. Hot and Chilled Water, NPS 2 and Smaller: Aboveground, use Type L drawn-temper copper tubing with soldered joints or Schedule 40 steel pipe with threaded joints.

B. Hot and Chilled Water, NPS 2-1/2 and Larger: Schedule 40 steel pipe with welded, flanged, or grooved mechanical-joints.

C. Condensate Drain Lines: Type L drawn-temper copper tubing with soldered joints.

3.7 AIR CONDITIONING UNITS

A. Data Rooms

1. Liebert

a. Data Mate – Split System

b. Mini Mate – Roof-top Unit

BUBBLE GATE REPLACEMENTS

SECTION 083463 - DETENTION DOORS AND FRAMES

PART 4 - GENERAL

4.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

4.2 SUMMARY

A. Section Includes:

1. Sliding detention doors.

2. Detention panels.

3. Detention frames.

B. Related Requirements:

1. Section 013513.16 “Special Project Procedures for Detention Facilities.” for coordination of detention work.

2. Section 087100 “Door Hardware" for door hardware for detention doors, panels and frames.

3. Section 088853 “Security Glazing” for security glazing in detention doors, panels and frames.

4.3 DEFINITIONS

A. Minimum-Thickness Steel: Indicated as the specified minimum thicknesses for base metal without coatings, according to NAAMM-HMMA 803.

4.4 COORDINATION

A. Detention Specialist: Coordinate with Section 013513.16 "Special Project Procedures for Detention Facilities" for requirements of this Section that are to be performed by a Detention Contractor or other entity.

B. Coordinate installation of anchorages for detention frames. Furnish setting drawings, templates, and directions for installing anchorages, including sleeves, concrete inserts, anchor bolts, and items with integral anchors that are to be embedded in adjacent construction. Deliver such items to Project site in time for installation.

4.5 PREINSTALLATION MEETINGS

A. Preinstallation Conference: Conduct conference at Project site.

4.6 ACTION SUBMITTALS

A. Product Data: For each type of product.

1. Include construction details, material descriptions, core descriptions, label compliance, and finishes for each detention door and frame type specified.

B. Shop Drawings: In addition to requirements below, provide a schedule using same reference numbers for details and openings as those on Drawings:

1. Elevations of each door type.

2. Direction of slide.

3. Inmate and non-inmate sides.

4. Details of doors, including vertical and horizontal edge details, and metal thicknesses.

5. Details of frames, including dimensioned profiles, and metal thicknesses.

6. Locations of reinforcement and preparations for hardware.

7. Details of each different wall opening condition.

8. Details of anchorages, joints, field splices, and connections.

9. Details of speaking apertures/intercoms.

10. Details of moldings, removable stops, and glazing.

11. Details of conduits, junction boxes, and preparations for electrically operated door hardware.

C. Samples for Verification:

1. For each type of exposed finish required, prepare Samples not less than 3 by 5 inches.

2. For "Detention Doors" and "Detention Frames" subparagraphs below, prepare Samples approximately 12 by 12 inches to demonstrate compliance with requirements for quality of materials and construction:

a. Detention Doors: Show vertical-edge, top, and bottom construction; insulation; face stiffeners; and hinge and other applied hardware reinforcement. Include separate section showing glazing if applicable.

b. Detention Frames: Show profile, welded corner joint, welded hinge reinforcement, grout-cover boxes, floor and wall anchors, and silencers. Include separate section showing fixed steel panels and glazing if applicable.

4.7 INFORMATIONAL SUBMITTALS

A. Qualification Data: For Installer.

B. Welding certificates.

C. Product Test Reports: For each type of detention hollow-metal door and frame assembly including vision and side lights, for tests performed by a qualified testing agency.

D. Examination reports, documenting inspection of substrates, areas, and conditions.

E. Anchor inspection reports, documenting inspections of built-in and cast-in anchors.

F. Field quality-control reports, documenting inspections of installed products.

1. Field quality-control certification, signed by Contractor.

G. Oversize Construction Certification: For assemblies required to be fire rated and exceeding limitations of labeled assemblies.

4.8 MAINTENANCE MATERIAL SUBMITTALS

A. Furnish extra materials that match products installed and that are packaged with protective covering for storage and identified with labels describing contents.

1. Security Fasteners: Furnish not less than one box for every 50 boxes or fraction thereof, of each type and size of security fastener installed.

2. Tools: Provide two sets of tools for installing and removing security fasteners.

4.9 QUALITY ASSURANCE

A. Installer Qualifications: An entity that employs installers and supervisors who are trained and approved by manufacturer.

B. Welding Qualifications: Qualify procedures and personnel according to the following:

1. AWS D1.3/D1.3M, "Structural Welding Code - Sheet Steel."

4.10 DELIVERY, STORAGE, AND HANDLING

A. Deliver detention hollow-metal work palletized, packaged, or crated to provide protection during transit and Project-site storage. Do not use nonvented plastic.

B. Deliver detention frames with two removable spreader bars across bottom of frames, tack welded to jambs and mullions.

C. Store detention hollow-metal work vertically under cover at Project site with head up. Place on minimum 4-inch high wood blocking. Provide minimum 1/4-inch space between each stacked door to permit air circulation.

PART 5 - PRODUCTS

5.1 MANUFACTURERS

A. Trussbilt, Inc., St. Paul, MN

B. American Steel, Swainsboro, GA

C. Other approved manufacturer, capable of meeting product specifications.

D. Source Limitations: Obtain detention doors and frames from single source from single manufacturer.

5.2 DETENTION DOOR AND FRAME ASSEMBLIES

A. Detention Door and Frame Assemblies: Provide detention door and frame assemblies that comply with the following, based on testing manufacturer's standard units in assemblies similar to those indicated for this Project:

1. Security Grade: Assemblies pass testing requirements in ASTM F 1450 for security grades specified.

2. Bullet Resistance: Level 2 rated when tested according to UL 752.

a) Manufacturer shall provide a letter of compliance for all sliding door and frame assemblies that materials, methods of construction and fabrication of sliding door assemblies use the same materials and methods as manufacturer’s bullet resistant swing Door/Frame assembly meeting UL 752 Level 2 rating.

3. Tool-Attack Resistance: Small-tool-attack-resistance rated when tested according to UL 437 and

UL 1034.

B. Detention Frames: Provide sidelight and borrowed-light detention frames that comply with ASTM F 1592 and removable stop test according to NAAMM-HMMA 863, based on testing manufacturer's standard units in assemblies similar to those indicated for this Project.

5.3 DETENTION DOORS

A. General: Provide flush-design detention doors of seamless hollow construction, 2 inches thick unless otherwise indicated. Construct detention doors with smooth, flush surfaces without visible joints or seams on exposed faces or stile edges.

1. For sliding detention doors, square both vertical edges.

B. Core Construction: Provide the following core construction of same material as detention door face sheets, welded to both detention door faces:

1. Steel-Stiffened Core: 0.042-inch thick, steel vertical stiffeners extending full-door height, with vertical webs spaced not more than 4 inches apart, spot welded to face sheets a maximum of 3 inches o.c. Fill spaces between stiffeners with insulation.

C. Vertical Edge Channels: 0.123-inch thick, continuous channel of same material as detention door face sheets, extending full-door height at each vertical edge; welded to top and bottom channels to create a fully welded perimeter channel. Noncontiguous channel is permitted to accommodate lock-edge hardware only if lock reinforcement is welded to and made integral with channel.

D. Top and Bottom Channels: 0.123-inch thick metal channel of same material as detention door face sheets, spot welded, not more than 4 inches o.c., to face sheets.

1. Reinforce top edge of detention door with 0.053-inch thick closing channel, welded so channel web is flush with top door edges.

E. Hardware Reinforcement: Fabricate reinforcing plates from same material as detention door face sheets to comply with the following minimum thicknesses:

1. Full-Mortise Hinges and Pivots: 0.187 inch thick.

2. Maximum-Security Surface Hinges: 0.250 inch thick.

3. Strike Reinforcements: 0.187 inch thick.

4. Slide-Device Hanger Attachments: As recommended by device manufacturer.

5. Lock Fronts, Concealed Holders, and Surface-Mounted Closers: 0.093 inch thick.

6. All Other Surface-Mounted…