Specifications.pdf

SPECIFICATIONS

PUMPED PRETREATMENT WASTE PIPING

PART 1 GENERAL

1.1 REFERENCES

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

ASME INTERNATIONAL (ASME)

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

ASME B16.9 Factory-Made Wrought Steel Buttwelding Fittings

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A 105 Carbon Steel Forgings for Piping Applications

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

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

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

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

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

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

1.2 DESCRIPTION

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

DOUBLE WALL CONTAINMENT FOR PRETREATMENT WASTE.

PART 2 PRODUCTS

2.1 Fluid Description

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

2.2 Design Basis

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

2.3 Pipe

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

2.4 Joints

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

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

2.5 Fabrication and Erection

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

2.6 Testing

Testing (including welding and hydrostatic) shall follow Section 15216, WELDING PRESSURE PIPING per ASME B31.3 Process Piping Code. All (100%) socket weld joints for "PPW" piping shall be hydrostatically pressure tested at 90psi for one hour (by USDA staff). All (100%) buttweld joints for "PPW" piping shall be tested per radiography.

2.7 Flanges

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

2.8 Fittings

Fittings 2 inches and smaller shall be 3000-pound socket-weld in accordance with ASME B16.11. Material shall conform to ASTM A 105. 2” fittings shall be butt-welded A403-WP304L S/40s.

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

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

2.9 Bolting Materials

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

2.10 Unions

Unions 1-1/2 inches and smaller shall be 3000 pound, threaded, with steel-to-steel seats.

Material shall conform to ASTM A 105. Note that the use of unions shall be minimized as much as possible.

Unions 2 inches and larger shall be made with flanges.

2.11 Gaskets

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

2.12 Valves

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

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

2.13 Specialties

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

2.14 Supports

Support all piping with standard manufactured supports per MSS SP-58 and MSS SP-69.

Hardware shall be stainless steel.

PART 3 EXECUTION

3.1 INSTALLATION

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

3.1.1 Water Piping

ASME B31.3.

3.2 PIPING SYSTEMS

3.2.1 Flanged Joints

Faced true, square, tight, and provided as indicated and where necessary for normal maintenance.

Mate with valves and various equipment connections. Remove raised faces when used with flanges having a flat face.

3.2.2 Threaded Joints

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

3.2.3 Pipe Bends

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

3.2.4 Reducing Fittings

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

3.2.5 Insulation

Follow manufacturer’s installation instructions.

3.2.6 Pipe Hangers and Supports

Installation including spacing shall conform to ASME B31.3.

3.3 PPW PIPING AND ALL RELATED SYSTEMS IN PPW MANHOLES

Chilled Water, and Condenser Water Piping:

3.3.1 Fabrication and Assembly of Piping and Components

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

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

3.3.1.1 Valves

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

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

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

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

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

3.4 FIELD INSPECTIONS

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

3.5 FIELD TESTS

After completion of piping installation and prior to initial operation, conduct tests on piping system. Furnish materials and equipment required for tests. Correct defects disclosed by test.

Perform test after installation and prior to acceptance in presence of the Contracting Officer Representative and subject to his approval.

3.5.1 PPW Manhole Piping

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

-- End of Section --

WELDING PRESSURE PIPING

PART 1 GENERAL

1.1 REFERENCES

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

ASME INTERNATIONAL (ASME)

ASME B31.1 (2001) Power Piping

ASME B31.3 (2002) Process Piping

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

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

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

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

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

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

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

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

AMERICAN WELDING SOCIETY (AWS)

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

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

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

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

AWS QC1 (1996) AWS Certification of Welding Inspectors

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

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

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1926 Safety and Health Regulations for Construction

1.2 RELATED REQUIREMENTS

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

1.3 DEFINITIONS

AWS A3.0 and applicable ANSI piping documents.

1.4 SUBMITTALS

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

SD-02 Shop Drawings

Welding pressure piping; G

SD-07 Certificates

Welding procedures qualification; G

Nondestructive examination (NDE) procedures; G

NDE personnel certification procedures; G

Inspector certification; G

Submit inspector certification and NDE personnel certification for record.

SD-11 Closeout Submittals

Weld identifications; G

1.5 QUALITY ASSURANCE

1.5.1 Welding Pressure Piping

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

1.5.2 Procedures

Develop and qualify procedures for welding metals included in the work. Do not start welding until welding procedures, welders, and welding operators have been qualified. Perform qualification testing by an approved testing laboratory, or by the Contractor if approved by the Contracting Officer in accordance with the qualified procedures. Notify the Contracting Officer Representative at least 24 hours in advance of the time and place of the tests. When practicable, perform the qualification tests at or near the work site. Maintain current records of the test results obtained in welding procedure, welding operator/welder performance qualifications, and nondestructive examination (NDE) procedures. These records shall be readily available at the site for examination by the Contracting Officer Representative. Qualify the procedures for making transition welds between different materials or between plates or pipes of different wall thicknesses. ANSI Piping requirements for branch connections may be used in lieu of detailed designs. Unless otherwise specified, the choice of welding process shall be the responsibility of the Contractor.

1.5.2.1 Previous Qualifications

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

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

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

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

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

1.5.2.2 Performance

The Contractor shall be responsible for the quality of joint preparation, welding, and examination. Clearly identify and record materials used in the welding operations. The examination and testing defined in this specification are minimum requirements. Provide additional examination and testing as necessary to achieve the quality required.

1.5.3 Welding Procedures Qualification

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

1.5.4 Welder and Welding Operator Performance Qualification

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

1.5.5 Renewal of Qualification

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

a. When a welder or welding operator has not used the specific welding process for a period of 3 months. The period may be extended to 6 months if the welder has been employed on another welding process.

b. There is specific reason to question the welder's ability to make welds that will meet the requirements of the specifications.

c. The welder or welding operator was qualified by an employer other than those firms performing work under this contract and a qualification test has not been taken within the preceding 12 months. Renewal of qualification under this condition need be made on only a single test joint or pipe of any thickness, position, or material to reestablish qualification for any thickness, position, or material for which the welder or welding operator had qualified previously.

1.5.6 Qualification of Inspection and (NDE) Personnel

Qualification of Inspection and Nondestructive Examination (NDE) Personnel:

Qualify inspection and nondestructive examination personnel in accordance with the following requirements:

1.5.6.1 Inspector Certification

Qualify welding inspectors in accordance with AWS QC1.

1.5.6.2 NDE Personnel Certification Procedures

Certify NDE personnel and establish a written procedure for the control and administration of NDE personnel training, examination, and certification. Base procedures on appropriate specific and general guidelines of training and experience recommended by ASNT RP SNT-TC-1A, Supplement A-Radiographic Supplement B-Magnetic particle and Supplement D-Liquid Penetrant.

1.5.6.3 Welding Procedures and Qualifications

a. Specifications and Test Results: Submit copies of the welding procedure specifications and procedure qualification test results for each type of welding required.

Approval of any procedure does not relieve the Contractor of the responsibility for producing acceptable welds. Submit this information on the forms printed in ASME BPVC SEC IX or their equivalent.

b. Certification: Before assigning welders or welding operators to the work, submit their names, together with certification that each individual is performance qualified as specified. Do not start welding work prior to procedure qualification. The certification shall state the type of welding and positions for which each is qualified, the code and procedure under which each is qualified, date qualified, and the firm and individual certifying the qualification tests.

1.5.7 Symbols

Conform to AWS A2.4.

1.5.7.1 Weld Identifications

Submit a list of the welders' names and symbol for each welder. To identify welds, submit written records indicating the location of welds made by each welder or welding operator.

1.5.8 Safety

Conform to AWS Z49.1, 29 CFR 1910-SUBPART Q, "Welding, Cutting, and Brazing," 29 CFR 1926-SUBPART J, "Welding and Cutting."

1.6 ENVIRONMENTAL

Do not perform welding when the quality of the completed weld could be impaired by the prevailing working or weather conditions. The Contracting Officer Representative will determine when weather or working conditions are unsuitable for welding.

1.7 DELIVERY AND STORAGE

Deliver filler metals, electrodes, fluxes, and other welding materials to the site in manufacturers' original packages and store in a dry space until used. Label and design packages properly to give maximum protection from moisture and to assure safe handling.

PART 2 PRODUCTS

2.1 WELDING MATERIALS

Comply with ASME BPVC SEC II-C. Welding equipment, electrodes, welding wire, and fluxes shall be capable of producing satisfactory welds when used by a qualified welder or welding operator using qualified welding procedures.

PART 3 EXECUTION

3.1 WELDING

Do not deviate from applicable codes, approved procedures, and approved shop drawings without prior written approval from the Contracting Officer Representative. Materials or components with welds made off the site will not be accepted if the welding does not conform to the requirements of this specification unless otherwise specified. Assign each welder or welding operator an identifying number, letter, or symbol that shall be used to identify his welds. Each welder or welding operator shall apply his mark adjacent to his weld using an approved rubber stamp or felt-tipped marker with permanent, weatherproof ink or other approved methods that do not deform the metal. For seam welds, place identification marks adjacent to the welds at 3-foot intervals. Confine identification by die stamps or electric etchers to the weld reinforcing crown, preferably in the finished crater.

3.2 WELDING OPERATORS

Perform welding in accordance with qualified procedures using qualified welders and welding operators.

3.3 SUPPORTS

Welding of hangers, supports, and plates to structural members shall conform to AWS D1.1/D1.1M.

3.4 EXAMINATIONS AND TESTS

Visual and nondestructive examinations shall be performed by the Contractor to detect surface and internal discontinuities in completed welds. Visually examine welds Radiographic, Liquid penetrant, or Magnetic particle, examination shall be required as indicated in Tables IV and V attached to this section or in accordance with other sections where detailed requirements are specified. Random NDE testing applies to ASME B31.1 piping unless specified otherwise.

When examination and testing indicates defects in a weld joint, a qualified welder shall repair the weld in accordance with the paragraph entitled "Corrections and Repairs" of this section.

3.4.1 Random NDE Testing

When radiographic, liquid penetrant, or magnetic particle, examination is required, test a minimum of 10 percent of the total length or number of piping welds. Randomly select the welds examined but include an examination of welds made by each welding operator or welder.

If random testing reveals that a weld fails to meet minimum quality requirements, examine an additional 10 percent of the welds in that same group. If the additional welds examined meet the quality requirements, the entire group of welds represented shall be accepted and the defective welds shall be repaired. If any of the additional welds examined also fail to meet the quality requirements, that entire group of welds shall be rejected. Remove and reweld rejected welds or examine rejected welds 100 percent and remove and reweld defects.

3.4.2 Visual Examination

Visually examine welds as follows:

a. Before welding -- for compliance with requirements for joint preparation, placement of backing rings or consumable inserts, alinement and fit-up, and cleanliness.

b. During welding -- for conformance to the qualified welding procedure.

c. After welding -- for cracks, contour and finish, bead reinforcement, undercutting, overlap, and size of fillet welds.

3.4.3 Nondestructive Examination

NDE shall be in accordance with written procedures. Procedures for radiographic, liquid penetrant or magnetic particle, tests and methods shall conform to ASME BPVC SEC V. The approved procedure shall be demonstrated to the satisfaction of the Contracting Officer's QA personnel.

In addition to the information required in ASME BPVC SEC V, the written procedures shall include:

a. Timing of the nondestructive examination in relation to the welding operations.

b. Safety precautions.

3.4.4 Examinations and Tests by the Government

Examinations and tests will conform to paragraphs "Visual Examination" and "Nondestructive Examination" of this section, except that destructive tests may be required also. When destructive tests are made, qualified welders or welding operators shall make repairs using welding procedures which will develop the full strength of the members cut. Welding shall be subject to examination and tests in the mill, shop, and field.

3.5 ACCEPTANCE STANDARDS

3.5.1 Visual

The following indications are unacceptable:

a. Cracks--external surface.

b. Undercut on surface which is greater than 1/32 inch deep provided that the remaining wall thickness is not less than the minimum design thickness.

c. Weld reinforcement:

(1) ASME B31.1, conform to Table I.

TABLE I

REINFORCEMENT OF GIRTH AND LONGITUDINAL BUTT WELDS

Maximum Thickness of Reinforcement for Design Temperature

Greater than Less Than 750°F 350°F-750°F 350°F Thickness of Base Metal, _________ ___________ _______ inches inch inch inch

Up to 1/8, incl. 1/16 3/32 3/16 Over 1/8 to 3/16, incl. 1/16 1/8 3/16

TABLE I

REINFORCEMENT OF GIRTH AND LONGITUDINAL BUTT WELDS

Maximum Thickness of Reinforcement for Design Temperature

Greater than Less Than 750°F 350°F-750°F 350°F Thickness of Base Metal, _________ ___________ _______ inches inch inch inch Over 3/16 to 1/2, incl. 1/16 5/32 3/16 Over 1/2 to 1, incl. 3/32 3/16 3/16 Over 1 to 2, incl. 1/8 1/4 1/4 Over 2 5/32 The greater of ¼ in. or 1/8 times the width of the weld in inches.

NOTES:

1. For double welded butt joints, this limitation on reinforcement given above shall apply separately to both inside and outside surfaces of the joint.

2. For single welded butt joints, the reinforcement limits given above shall apply to the outside surface of the joint only.

3. The thickness of weld reinforcement shall be based on the thickness of the thinner of the materials being joined.

4. The weld reinforcement thicknesses shall be determined from the higher of the abutting surfaces involved.

5. Weld reinforcement may be removed if so desired.

(2) ASME B31.3, conform to Table II.

TABLE II

Wall Thickness, Inches Height, Inches Less than or equal to 1/4 Less than or equal to 1/16 Greater than 1/4, is less Less than or equal to 1/8 than or equal to 1/2 Greater than 1/2, is less Less than or equal to 5/32 than or equal to 1 Greater than 1 Less than or equal to 3/16

NOTES:

1. Wall thickness is the nominal wall thickness of the thinner of components joined by butt weld.

2. Height: For "Normal Service" and "Severe Cyclic" conditions, use the listed value. For "Category D Fluid Service," use twice the listed value. Measure from surfaces of adjacent components. The lesser of the two measurements, in any plane through the weld, shall not exceed the applicable value at right. Weld metal shall merge smoothly into component surfaces.

(3) ASME B31.4, conform to Table I for under 350 degrees F.

(4) ASME B31.5, conform to Table III.

TABLE III

Pipe Wall Thickness, inches Reinforcement Thickness, inches.

1/4 and under 1/16 Over 1/4 through 1/2 3/32 Over 1/2, through 1 1/8 Over 1 3/16

d. Lack of fusion on surface.

e. Incomplete penetration (applies only when inside surface is readily accessible).

f. Convexity of fillet weld surface greater than 10 percent of longest leg plus 0.03 inch.

g. Concavity in groove welds.

h. Concavity in fillet welds greater than 1/16 inch.

i. Fillet weld size less than indicated or greater than 1 1/4 times the minimum specified fillet leg length.

3.5.2 Magnetic Particle Examination

The following relevant indications are unacceptable:

a. Any cracks and linear indications.

b. Rounded indications with dimensions greater than 3/16 inch.

c. Four or more rounded indications in a line separated by 1/16 inch or less edge-to-edge.

d. Ten or more rounded indications in any 6 square inches of surface, with the major dimension of this area not to exceed 6 inches, with the area taken in the most unfavorable location relative to the indications being evaluated.

3.5.3 Liquid Penetrant Examination

Indications whose major dimensions are greater than 1/16 inch shall be considered relevant. The following relevant indications are unacceptable:

a. Any cracks or linear indications.

b. Rounded indications with dimensions greater than 3/16 inch.

c. Four or more rounded indications in a line separated by 1/16 inch or less edge-to-edge.

d. Ten or more rounded indications in any 6 square inches of surface, with the major dimension of this area not to exceed 6 inches, with the area taken in the most unfavorable location relative to the indications being evaluated.

3.5.4 Radiography

Welds that are shown by radiography to have any of the following discontinuities are unacceptable:

a. Any type of crack or zone of incomplete fusion or penetration.

b. Any other elongated indication which has a length greater than:

(1) 1/4 inch for t up to 3/4 inch, inclusive;

(2) 1/3 t for t from 3/4 inch to 2 1/4 inches, inclusive;

(3) 3/4 inch for t over 2 1/4 inches where t is the thickness of the thinner portion of the weld.

("t" pertains to the thickness of the weld being examined. If a weld joins two members having different thickness at the weld, "t" is the thinner of these two thicknesses.)

c. Any group of indications in line that have an aggregate length greater than t in a length of 12t, except where the distance between the successive indications exceeds 6L where L is the longest indication in the group.

d. Porosity in excess of that shown acceptable in Appendix A-250, Acceptance Standard for Radiographically Determined Rounded Indications in Welds, ASME

BPVC SEC I.

3.6 CORRECTIONS AND REPAIRS

Remove defects and replace welds as specified in ASME B31.1, unless otherwise specified.

Repair defects discovered between weld passes before additional weld material is deposited.

Wherever a defect is removed, and repair by welding is not required, the affected area shall be blended into the surrounding surface eliminating sharp notches, crevices, or corners. After defect removal is complete and before rewelding, reexamine the area by the same test methods which first revealed the defect to ensure that the defect has been eliminated. After rewelding, reexamine the repaired area by the same test methods originally used for that area. For repairs to base material, the minimum examination shall be the same as required for butt welds. Indication of a defect shall be regarded as a defect unless reevaluation by NDE or by surface conditioning shows that no unacceptable indications are present. The use of foreign material to mask, fill in, seal, or disguise welding defects will not be permitted.

TABLE IV

EXAMINATIONS AND TESTS FOR VARIOUS MATERIALS AND SERVICES

Examinations or Tests Required

Magnetic Particle Material or or Liquid Application Visual Radiographic Penetrant

High-alloy austenitic or nickel steels or nickel alloys for cryogenic service and vacuum service

a. Tack welds Yes No No No

b. Root passes Yes No Yes No

c. Intermediate passes Yes No No No

d. Completed weld Yes 100 percent Yes(PT only) Yes for for NPS over wall thickness 1 1/4 inches 1/2 inch and over 60 percent for NPS 1 1/4 inches and less

High-alloy austenitic or nickel steels or nickel alloys for other than cryogenic or vacuum service

a. Tack welds Yes No No No

b. Root passes Yes No No

c. Intermediate passes Yes No No

d. Completed weld Yes Random Yes (PT only)

Stainless steel to carbon steel

a. Completed weld Yes Yes Yes(PT only)

Carbon steel piping systems

a. Tack welds Yes No No

b. Root passes Yes No No

c. Intermediate passes Yes No No

d. Completed weld Yes Random No

TABLE V

MANDATORY MINIMUM NONDESTRUCTIVE EXAMINATIONS FOR ASME B31.1

PIPING

Temperatures over Temperatures between All others 750 degrees F and 350 degrees F and at all pressures. 750 degrees F inclusive and at all pressures over 1052 psig gage

Buttwelds RT for NPS over RT for over 2 inch Visual for (Girth and 2 inches MT or PT NPS with thickness all sizes Longitudinal) for NPS 2 inches over 3/4 inch. and and less. Visual for all thicknesses.

sizes with thickness 3/4 inch or less.

Welded Branch RT for NPS over RT for branch over Visual for Connections 2-inch MT or PT 4-inch NPS and all sizes (Size indicated for NPS 2-inch thickness of branch and is Branch Size) and less. over 3/4 inch. thicknesses.

Visual for all sizes with branch thickness 3/4 inch.

or less.

Fillet, Socket PT or MT for Visual for all sizes Visual for Welds all sizes and and thicknesses. all sizes and thicknesses. thicknesses.

NOTES:

1. Thickness refers to pressure boundary wall thickness (such as pipe wall, fitting wall, or nozzle wall thickness).

2. All welds must be given a visual examination in addition to type of specific nondestructive examination specified.

3. NPS-Nominal Pipe Size.

4. RT-Radiographic examination; MT-magnetic particle examination; PT-liquid penetrant examination.

5. RT of branch welds shall be performed before any nonintegral reinforcing material is applied.

6. The thickness of buttwelds is defined as the thicker of the two abutting ends after end preparation.

7. Temperatures and pressures shown are design.

8. In lieu of radiography of welded branch connections when required above, liquid penetrant or magnetic particle examination is acceptable and, when used, shall be performed at the lesser of one-half of the weld thickness or each 1/2 inch of weld thickness and all accessible final weld surfaces.

9. For nondestructive examination of the pressure retaining component, refer to the standards listed in applicable code or the manufacturing specifications.

-- End of Section --

Rehabilitation and Lining for Concrete Wastewater Structures with Ultra-high Build Structural Epoxy

PART 1 - GENERAL

1.1 DESCRIPTION

A. SCOPE:

A manufacturer certified Applicator shall provide all labor, materials, equipment, incidentals, and quality requirements for concrete for surface preparation, repair or resurfacing, and ultra-high build, Structural Epoxy lining work to the entire interior surfaces of the structures as shown on drawings and specified herein.

This Section’s intent is to provide minimum requirements of an installation of an ultra-high build, high strength, structural epoxy system; and the lining of newly installed, existing, and/or defective specified concrete/masonry structures and surfaces exposed to domestic wastewater and/or municipal sanitary sewage by an applied and bonded application of high performance, 100% solids, ultra-high build, structural grade, applied fiber-reinforced-polymer (FRP) epoxy coating/lining system (Structural Epoxy).

This Section’s intent is for concrete and/or other masonry structures which are exposed to or in contact with domestic wastewater service; constituting domestic municipal wastewater and plant treatment and municipal sanitary sewage from collection systems (sanitary sewer and/or stormwater), where sewage contact and exposure to hydrogen sulfide are present. Not intended for non-sewage applications or industrial waste.

Structural Epoxy minimum film thickness specified herein is designed and intended for applied and bonded coating/lining, delivering barrier protection with high mechanical strength with a reinforced film to bridge and seal against low pressure forces of effective lateral earth pressure, moisture vapor transmission (MVT), hydrostatic head pressure, and inflow and infiltration (I&I) once cured; while protecting from effluent and H2S. Design thickness herein also accounts for long term performance; as unintentionally there may be circumstances that may prevent bonding in certain areas that an engineered Structural Epoxy is designed to bridge (with limitations), whereas non-structural coatings may not. Not intended: excessive or high-pressure forces and loading, or other force considerations for full structural reinstatement without a qualified assessment with calculated, verified and adjusted structural thickness calculations performed and certified by a registered Professional Engineer (film or system thicknesses may change depending on types of forces, force values and other variables, engineering assessments and calculations).

Types of Structural Epoxy lining for concrete Work required include but are not necessarily limited to the following:

1. Hydraulic water plug

2. Cementitious repair mortar

3. Epoxy cementitious resurfacer

4. Structural epoxy lining

5. Miscellaneous materials

B. Coordination:

1. Coordinate surface preparation of substrates to avoid later difficulty or delay in performing the Work of this Section.

2. Review installation procedures under other Sections and coordinate the installation of items that must be installed prior to application of the Structural Epoxy lining.

3. The Contractor shall coordinate with Engineer regarding the availability of work areas, completion times, safety, access, and other factors which can impact plant operations.

1.2 REFERENCES

A. This Section contains references to the governing standards and documents listed below. They are a part of this Section as specified and modified; the current version shall apply unless otherwise noted. In case of conflict between the requirements of this section and those of the listed documents, the more stringent of the requirements shall prevail.

American Concrete Institute, (ACI)

1. ACI 301 – Specifications for Structural Concrete ASTM International, (ASTM)

2. ASTM C 868 – Standard Test Method for Chemical Resistance of

Protective Linings

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

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

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

5. ASTM D 4285 – Standard Test Method for Indicating Water or Oil in Compressed Air

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

7. ASTM D 7682 – Standard Test Method for Replication and Measurement of Concrete Surface Profiles Using Replica Putty

International Concrete Repair Institute, (ICRI)

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

Deteriorated Concrete Resulting from Reinforcing Steel Corrosion

9. Guideline No. 310.2 – Selecting and Specifying Concrete Surface

Preparation for Sealer, Linings, and Polymer Overlays NACE International, (NACE)

10. NACE SP0188 – Standard Practice for Discontinuity (Holiday) Testing of

Protective Linings

11. NACE No. 6/SSPC-SP13 – Surface Preparation of Concrete Occupational Safety and health Administration, (OSHA)

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

SSPC: The Society for Protective Coatings, (SSPC)

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

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

B. Unless otherwise specified, references to documents shall mean the documents in effect at the time of receipt of Bids. If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents, the last version of the document before it was discontinued.

1.3 SUBMITTALS

A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300 entitled “Submittals”, the Contractor shall submit all required information as specified herein.

B. Shop Drawings: Submit for approval prior to commencing any Work:

1. Manufacturer’s project reference lists with coating systems specified herein, stating project location, Owner contact information, Engineer contact information, Installer contact information, containing a minimum of 10 projects of similar capacity with a minimum of 5 years of satisfactory service.

2. Product Data Sheets: Copies of current technical data for each component specified and applied as outlined in this Section.

3. Safety Data Sheets: Copies of current SDS for any materials brought on-site including all clean-up solvents, repair or resurfacing mortars and lining materials.

4. Qualification Data: Approved Installer Certification from manufacturer.

5. Performance Testing Reports: Copies of test data for the entire physical, chemical, and permeation properties listed herein and as outlined within this Section.

6. Installation Instructions: Manufacturer’s written installation instructions for the materials specified in this Section.

C. Product Substitution: The specified corrosion protection system is the minimum standard of quality for this project. Equivalent materials of other manufacturers may be substituted only by approval of Engineer. Requests for material substitutions shall be in accordance with requirements of the project specification.

1. All Contractors must provide pricing based on the compliant system of Epoxytec Company in the Base Bid. Other approved coating manufacturer system, if provided, will be shown in the Bid Schedule as Additive Bid Item as an ADD or DEDUCT to overall Base Bid.

2. Manufacturers of “or equal” products shall provide direct property comparison with the materials specified in addition to complying with all other requirements of these Specifications. “Or equal” products shall employ the same generic materials and system components as the Structural Epoxy lining specified and shall provide same intent by description and equivalent performance as the specified Structural Epoxy lining to protect against H2S corrosion and seal from I&I.

3. “Or equal” products’ manufacturer must provide documentation supporting product’s success and history in severe wastewater environments for at least ten (10) years; must also provide samples of cured material covering at least one (1) square foot of surface, at the specified thickness; and must provide written repair instruction and a list of materials should a repair be needed in the future.

4. Bidders desiring to use linings other than those specified shall submit proposed system with their proposal at the time of bid, together with the information required herein, and indicate the sum which will be deducted from the base bid should alternate materials be accepted.

D. Jobsite Reports: Submit at the completion of Work

1. Daily Reports: Include surface preparation, substrate conditions, ambient conditions application procedures, lining materials applied, material quantities, material batch number(s), description of work completed and location thereof.

2. Quality Control Reports: Include all quality control testing and physical specimens.

3. Contractor shall maintain a copy of records until the expiration of the specified warranty period.

1.4 QUALITY ASSURANCE

A. Applicator Qualifications:

1. Contractor shall be a certified Applicator by the Structural Epoxy manufacturer prior to bid date. Submit proof of Applicator certification by manufacturer to Engineer.

2. Installation equipment shall be acceptable to the Structural Epoxy manufacturer. If spraying Structural Epoxy, Applicator must utilize equipment approved by Structural Epoxy manufacturer.

3. Applicator shall establish quality control procedures and practices to monitor phases of surface preparation, storage, mixing, application, and inspection throughout the duration of the project. Contractor to provide a fulltime, on-site person whose dedicated responsibilities will include quality control of the Structural Epoxy linings and completed manufacturing certification training.

4. Applicator’s quality control procedures and practices must include the following items:

a. Training of personnel in the proper surface preparation requirements.

b. Training of personnel in the proper storing, mixing, and application and quality control testing of the Structural Epoxy linings.

c. If spraying, training of personnel with the spray equipment to ensure proper film build, film quality, and ratio control.

B. Mock-Ups:

1. Prior to the installation of the Structural Epoxy lining and auxiliary system components, but after Engineer’s approval of the Samples and Shop Drawings, install 150 square foot (14 square meters) stepped-back mock-ups of the systems showing surface preparation and each system component in an area selected by Engineer to show representative installation of the Work.

2. Engineer shall approve the mock-up before the start of Work.

3. Retain and protect mock-ups during construction as one standard for judging completed corrosion protection lining Work. Do not alter mock-ups after approval by Engineer.

4. Contractor shall build as many mock-ups as required to achieve Engineer’s acceptance of the corrosion protection lining.

5. The approved mock-up shall be considered the acceptable minimum standard of quality.

6. Any corrosion protection lining Work that proceeds without approved mock-ups will not be accepted by the Engineer and removed at no cost to the Owner.

C. Pre-Installation Conference:

1. Before erecting mock-ups Contractor, Installer and technical representative of the corrosion protection lining manufacturer shall meet on-site with Engineer to discuss approved products and workmanship to ensure proper application of the corrosion protection lining components and substrate preparation requirements.

2. Review foreseeable methods and procedures related to the Structural Epoxy lining of coating Work including but not necessarily limited to the following:

a. Review Project requirements and the Contract Documents.

b. Review required submittals, both completed and yet to be completed.

c. Review status of substrate Work, including approval of surface preparations and similar considerations.

d. Review requirements of on-Site quality control testing and requirements for preparing Site Quality Control Report as specified herein.

e. Review availability of materials, tradesmen, equipment and facilities needed to make progress and avoid delays.

f. Review required inspection and testing.

g. Review environmental conditions, other Project conditions, and procedures for coping with unfavorable conditions.

h. Review regulations concerning code compliance, environmental protection, health, safety, fire and similar considerations.

i. Review procedures required for the protection of the Structural Epoxy lining during the remainder of the construction period.

3. Record the discussions of the Pre-Installation Conference and the decisions and agreements or disagreements reached and furnish a copy of the minutes to each party attending. Record any revision or changes agreed upon, reasons therefore, and parties agreeing or disagreeing with them.

4. Reconvene the conference at the earliest opportunity if additional information must be developed in order to conclude the subjects under consideration.

D. Performance Criteria: Structural Epoxy lining shall be capable of withstanding under constant exposure to raw wastewater, permeation from hydrogen sulfide and other sewer gases, and attack from organic acids generated by microbial sources with no adverse effects; cured film at specified thickness must withstand negative side film forces from inflow and infiltration. Products must have sufficient field history and accelerated laboratory testing to substantiate product viability for these exposures.

E. Source Quality Control: Provide each component of Structural Epoxy lining produced by a single manufacturer, including recommended repair mortar, repair overlay (resurfacer), base coat and topcoat materials.

F. Reference Standards: Comply with applicable provisions and recommendations of all standards listed in Section 1.2 except as otherwise shown or specified.

1.5 PRODUCT DELIVERY, STORAGE, AND HANDLING

A. Delivery of Materials:

1. Deliver material in manufacturer’s original, unopened and undamaged packages.

2. Clearly identify manufacturer’s, brand name, contents, color, batch number, and any personal safety hazards associated with the use of or exposure to the materials on each package.

3. Packages showing indications of damage that may affect condition of contents are not acceptable.

B. Storage of Materials:

1. Materials shall be stored in accordance with manufacturer's recommendations in enclosed structures and shall be protected from weather and adverse temperature conditions. Flammable materials shall be stored in accordance with state and local codes. Materials exceeding storage life as defined by the manufacturer shall be removed promptly from the site. Store all materials only in area or areas designated by the Engineer solely for this purpose.

2. Store in original packaging under protective cover and protect from damage.

3. Stack containers in accordance with manufacturer’s recommendations.

C. Handling of Materials: Handle materials in such a manner as to prevent damage to products or finishes.

1.6 JOB CONDITIONS

A. Environmental Requirements:

1. Proceed with Work only when temperature and moisture conditions of substrates, air temperature, relative humidity, dew point and other conditions comply with the Structural Epoxy lining manufacturer’s written recommendations and when no damaging environmental conditions are forecasted for the time when the material will be vulnerable to such environmental damage. Record all such conditions and include in final Site Quality Control Report.

2. Maintain substrate temperature and ambient temperature before, during and after installation above 45°F (8°C) and rising in accordance with Structural Epoxy lining material manufacturer’s instructions.

3. Provide adequate ventilation during instillation and full curing periods of the Structural Epoxy lining.

4. Structural Epoxy lining shall not be applied when ambient air temperature is within 5°F (3°C) of the dew point.

5. Structural Epoxy lining shall not be applied when relative humidity is outside of material manufacturer’s recommendations. Do not prepare surfaces or apply materials in rain, snow, fog, mist, or otherwise inclement weather as per material manufacturer’s instructions.

B. Dust and Contaminants: Protect work and adjacent areas from excessive dust and airborne contaminates during Structural Epoxy lining application and curing.

Schedule Work to avoid excessive dust and airborne contaminants.

1.7 WARRANTY

A. Structural Epoxy lining Manufacturer shall warranty its products as free from material defects for a minimum period of three (3) years. Provide associated Warranty Certificate.

B. Contractor shall warranty the installed Structural Epoxy lining system as free from workmanship defects for a minimum period of three (3) years.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Products and Manufacturer:

1. Materials specified are those that have been evaluated for the specific service.

Products of Epoxytec LLC (a Tnemec company, www.tnemec.com, +1-800- 863-6321) www.epoxytec.com are specified as a standard of quality and basis of design. The specified basis of design is intended to provide the longest service life possible, lowest life cycle cost, and most sustainable solution.