A.07.24_Amendment_1_Specs_UPDATED_22_Aug_18.pdf

SECTION 40 05 13

PIPELINES, LIQUID PROCESS 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.

AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA C111/A21.11 (2017) Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings

(AM001)

AWWA C207 (2013) Standard for Steel Pipe Flanges for Waterworks Service-Sizes 100 mm through 3600 mm 4 in. through 144 in.

(AM001)

AWWA C208 (2007; Errata 2009) Standard for Dimensions for Fabricated Steel Water Pipe Fittings

AWWA C550 (2013) Protective Interior Coatings for Valves and Hydrants

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME A13.1 (2015) Scheme for the Identification of Piping Systems

ASME B16.1 (2015) Gray Iron Pipe Flanges and Flanged Fittings Classes 25, 125, and 250

ASME B16.11 (2016) Forged Fittings, Socket-Welding and Threaded

ASME B16.21 (2011) Nonmetallic Flat Gaskets for Pipe Flanges

ASME B16.5 (2017) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B16.9 (2012) Standard for Factory-Made Wrought Steel Buttwelding Fittings

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BAXTER COUNTY, ARKNASAS SOLICITATION NO. W9127S18R0016

AMENDMENT 001 TO SOLICTIATION NO. W9127S18R0016 ON 8/22/2018

ASME B31.1 (2016; Errata 2016) Power Piping

ASME B31.3 (2016) Process Piping

ASME B40.100 (2013) Pressure Gauges and Gauge Attachments

ASTM INTERNATIONAL (ASTM)

ASTM A105/A105M (2014) Standard Specification for Carbon Steel Forgings for Piping Applications

ASTM A153/A153M (2016) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A167 (2011) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A193/A193M (2016) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2017) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

ASTM A395/A395M (1999; R 2014) Standard Specification for Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures

ASTM A513/A513M (2015) Standard Specification for Electric-Resistance-Welded Carbon and Alloy Steel Mechanical Tubing

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A576 (1990b; R 2012) Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality

ASTM A780/A780M (2009; R 2015) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-25 (2013) Standard Marking System for Valves, SECTION 40 05 13 Page 2

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Fittings, Flanges and Unions

MSS SP-58 (1993; Reaffirmed 2010) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-70 (2011) Gray Iron Gate Valves, Flanged and Threaded Ends

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2014) Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 704 (2017) Standard System for the Identification of the Hazards of Materials for Emergency Response

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-310-04 (2013; with Change 1) Seismic Design for Buildings

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

29 CFR 1910 Occupational Safety and Health Standards

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Materials and Equipment

SD-03 Product Data

Qualifications

Welders

Waste Water Disposal

Manufacturer's Field Services

Delivery, Storage and Handling

Materials and Equipment

Installation

Valve Schedule

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SD-06 Test Reports

Pipe Leakage Tests; G

Hydrostatic Tests; G

Valve Testing

SD-10 Operation and Maintenance Data

Piping and Appurtenances; G

1.3 QUALIFICATIONS

1.3.1 Experience

Submit a statement certifying that the Contractor has the specified experience. Contractor shall have successfully completed at least three projects of the same scope and size or larger within the last six years.

Demonstrate specific experience in regard to the system installation to be performed.

1.3.2 Welders

Submit the names of all qualified welders, their identifying symbols, and the qualifying procedures for each welder including support data such as test procedures used, standards tested to, etc. The welding of pressure piping systems shall be in accordance with qualifying procedures using performance qualified welders and operators. Procedures and welders shall be qualified in accordance with Section 40 05 13.96 WELDING PROCESS PIPING.

1.4 DELIVERY, STORAGE, AND HANDLING

Materials delivered and placed in storage must be stored with protection from the weather, excessive humidity variation, excessive temperature variation, dirt, dust and/or other contaminants. Proper protection and care of material before, during and after installation is the Contractor's responsibility. Any material found to be damaged must be replaced at the Contractor's expense. During installation, piping must be capped to keep out dirt and other foreign matter. A Safety Data Sheet in conformance with 29 CFR 1910 Section 1200(g) must accompany each chemical delivered for use in pipe installation. At a minimum, this includes all solvents, solvent cements, glues and other materials that may contain hazardous compounds. Storage facilities must be classified and marked in accordance with NFPA 704 . Materials must be stored with protection from puncture, dirt, grease, moisture, mechanical abrasions, excessive heat, ultraviolet (UV) radiation damage, or other damage. Pipe and fittings must be handled and stored in accordance with the manufacturer's recommendation.

1.5 PROJECT/SITE CONDITIONS

1.5.1 Existing Conditions

Verify existing piping and penetrations. Prior to ordering materials, expose all existing pipes which are to be connected to new pipelines.

Verify the size, material, joint types, elevation, horizontal location, and pipe service of existing pipes, and inspect size and location of structure penetrations to verify adequacy of wall sleeves, and other

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openings before installing connecting pipes.

1.6 SEQUENCING AND SCHEDULING

For slab, floor, wall, and roof penetrations, keep on site pertinent wall pipes and sleeves before they are required for placement in concrete forms. Verify and coordinate the size and location of building and structure pipe penetrations before forming and placing concrete.

1.7 MAINTENANCE

1.7.1 Service

Services for automatic valve systems shall be provided by a manufacturer's representative who is experienced in the installation, adjustment and operation of the equipment specified. The representative shall inspect the installation, and supervise the adjustment and testing of the equipment.

1.7.2 Extra Materials

Submit the manufacturer's installation recommendations or instructions for each material or procedure to be utilized, including materials preparation. Concurrent with delivery and installation of the specified piping systems and appurtenances, spare parts for each different item of material and equipment specified that is recommended by the manufacturer to be replaced any time up to 3 years of service shall be furnished. For each type and size of valve, the following extra materials shall be provided: lubricator, lubricant (with appropriate temperature rating), lubricator/isolating valve. Extra materials shall include 2 of the following spare parts for each type and size of valve: gaskets; O-ring seals; diaphragms (molded); all elastomer parts; stem packing; seat rings and seat ring pulling tool .

1. Extra materials shall include 2 of each size of gate and check valves, 1 spare valve actuator, and 1 spare heater. The 14 inch gate valve and 6 inch check valve shall only require 1 spare each.

2. Spare parts for each different item of material and equipment specified that is recommended by the manufacturer to be replaced any time up to 3 years of service shall be furnished.

This is a not inclusive list of spare parts.

PART 2 PRODUCTS

2.1 SYSTEM REQUIREMENTS

This specification covers the requirements for above and below grade liquid process pipe, pipe supports, fittings, equipment and accessories located both inside and outside of treatment plants.

2.1.1 Design Requirements

Support systems shall be selected and designed in accordance with MSS SP-58 within the specified spans and component requirements. The absence of pipe supports and details on the contract drawings does not relieve the Contractor of responsibility for sizing and providing supports throughout facility. The structural design, selection, fabrication and erection of

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piping support system components shall satisfy the seismic requirements in accordance with UFC 3-310-04 and Sections 13 48 00 SEISMIC PROTECTION FOR MISCELLANEOUS EQUIPMENT and 13 48 00.00 10 SEISMIC PROTECTION FOR

MECHANICAL EQUIPMENT.

2.1.2 Performance Requirements

The pressure ratings and materials specified represent minimum acceptable standards for piping systems. The piping systems shall be suitable for the services specified and intended. Each piping system shall be coordinated to function as a unit. Flanges, valves, fittings and appurtenances shall have a pressure rating no less than that required for the system in which they are installed.

2.1.2.1 Above Grade Piping Systems

Piping systems shall be suitable for design conditions, considering the piping both with and without internal pressure, and installation factors such as insulation, support spans, and ambient temperatures.

Consideration shall be given to all operating and service conditions both internal and external to the piping systems.

2.2 MATERIALS AND EQUIPMENT

Submit manufacturer's descriptive and technical literature for each piping system, including design recommendations; pressure and temperature ratings; dimensions, type, grade and strength of pipe and fittings;

thermal characteristics (coefficient of expansion and thermal conductivity); and chemical resistance to each chemical and chemical mixture in the liquid stream. Provide piping materials and appurtenances as specified and as shown on the drawings, and suitable for the service intended. Piping materials, appurtenances, and equipment supplied as part of this contract shall be of equal material and ratings as the connecting pipe, new and unused except for testing equipment. Components that serve the same function and are the same size shall be identical products of the same manufacturer. The general materials to be used for the piping systems shall be in accordance with TABLE I, (see 3.16 TABLES), and are indicated by service in the contract drawings. Submit a list of piping systems, pressure ratings and source of supply for each piping system broken out by material, size and application as indicated on the contract drawings. A list of any special tools necessary for each piping system and appurtenances furnished for adjustment, operation, maintenance and disassembly of the system. Pipe fittings shall be compatible with the applicable pipe materials.

2.2.1 Standard Products

Provide material and equipment which are the standard products of a manufacturer regularly engaged in the manufacturing of the products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Submit the following: Equipment shop drawings and support system detail drawings showing piping systems and appurtenances, such as mechanical joints, valves, local indicators and hangers, including a complete list of equipment and materials. As-built drawings showing pipe anchors and guides, and layout of piping systems relative to other parts of the work including clearances for maintenance and operation. As-built piping and instrumentation diagrams (P&IDs) identifying and labeling equipment, instrumentation, valves, vents, drains, and all other inline devices; if the contract drawings contained

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P&IDs, the P&IDs found in the contract drawings shall be revised to reflect the constructed process system, as directed by the Contracting Officer. Nominal sizes for standardized products shall be used. Pipe, valves, fittings and appurtenances shall be supported by a service organization that is, in the opinion of the Contracting Officer, reasonably convenient to the site.

2.2.2 Identification and Tagging

Each piece of pipe shall bear the ASTM designation and all other markings required for that designation. Valves shall be marked in accordance with MSS SP-25 and shall bear an identification tag securely attached using No. 12 AWG copper wire or stainless steel wire. Identification tags shall be 1.375 inch minimum diameter, made of stamped stainless steel.

Indentations shall be black for reading clarity. The service, valve identification number shown on the Valve Schedule in the contract drawings, the manufacturer's name, and the valve model number shall be displayed.

2.3 CARBON STEEL PIPING SYSTEM

2.3.1 Carbon Steel Pipe

2.3.1.1 General Service

Carbon steel pipe shall meet the requirements of ASTM A53/A53M seamless, Grade B, Schedule 40.

2.3.2 Carbon Steel Joints

Carbon steel piping shall be joined by flanges. Dielectric fittings or isolation joints shall be provided between all dissimilar metals.

2.3.3 Carbon Steel Fittings

Fittings shall be carbon steel. Where cast fittings are not available, segmental welded steel fittings, ASTM A53/A53M, Grade B, meeting the requirements of manufacturer's recommended wall thicknesses shall be fabricated (AM001) according to AWWA C208.

2.3.3.1 Flanged Fittings

The internal diameter bores of flanges and flanged fittings shall be the same as that of the associated pipe. The flanges shall be welding neck, socket welding, or threaded type. Flanges and flanged fittings shall be forged steel, ASTM A105/A105M , faced and drilled to ASME B16.5 Class 150 (AM001) or drilled to AWWA C207Class D with a 0.06 inch raised face or flat face. For tie-in to existing flanges, field check existing flanges for non-standard bolt hole configurations and design as required to assure new pipe and flange mate properly. Bolting shall be alloy-steel ASTM A193/A193M Grade B7 hex head bolts and ASTM A194/A194M Grade 7 hex head nuts. When mating flange on valves or equipment is cast iron, ASTM A193/A193M Grade B8 Class 1 bolts and ASTM A194/A194M Grade 8 heavy hex head nuts shall be used. Bolts shall be provided with washers of the same material as the bolts. Gaskets shall meet the requirements of ASME B16.5 (AM001) or AWWA C207 . Nonmetallic gaskets shall conform to ASME B16.21 (AM001) or AWWA C207 and be a maximum 0.125 inch thick chloroprene rubber, durometer hardness No.80, 1,500 psi minimum tensile strength, 125 percent minimum elongation, flat ring type for use with

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raised face flanges and full face type for use with flat face flanges.

2.3.4 Carbon Steel Coatings

Carbon steel piping components shall be coated with corrosion resistant materials. Coatings and finishes shall be 100 percent holiday free.

2.3.4.1 Zinc Coating

Galvanizing shall be hot-dip applied and meet the requirements of ASTM A153/A153M ; electroplated zinc or cadmium plating is unacceptable.

2.4 ISOLATION JOINTS AND COUPLINGS

2.4.1 Dielectric Fittings

Dielectric fittings shall be provided between threaded ferrous and nonferrous metallic pipe, fittings and valves. Dielectric fittings shall prevent metal-to-metal contact of dissimilar metallic piping elements and shall be suitable for the required working pressure, temperature and corrosive application.

2.4.2 Isolation Joints

Isolation joints shall be provided between nonthreaded ferrous and nonferrous metallic pipe fittings and valves. Isolation joints shall consist of an isolation gasket of the dielectric type, isolation washers and isolation sleeves for flange bolts. Isolation gaskets shall be full faced with an outside diameter equal to the flange outside diameter. Bolt isolation sleeves shall be full length. Units shall be of a shape to prevent metal-to-metal contact of dissimilar metallic piping elements.

2.4.3 Metallic Piping Couplings

Thrust ties shall be provided where shown on the contract drawings and where required to restrain the force developed by 1.5 times the maximum allowable operating pressures specified. For metallic pipe other than ductile iron, thrust ties shall be attached with fabricated lugs. For ductile iron pipe, thrust ties shall be attached with socket clamps against a grooved joint coupling or flange. For exposed installations, zinc-plated nuts and bolts shall be used. However, high-strength, low-alloy steel, in accordance with AWWA C111/A21.11 , may be substituted for use on cast iron and ductile iron couplings. For buried and submerged installations, TP304 stainless steel bolts and nuts shall be provided.

2.4.3.1 Sleeve-Type Couplings

Sleeve-type couplings shall be used for joining plain end pipe sections in a flexible manner with a diameter to properly fit the pipe. A coupling shall consist of one steel middle ring, two steel followers, two elastomeric wedge section gaskets and elliptic-neck, track-head steel bolts designed to properly compress the gaskets. For pipe sizes 2 inch and larger, the followers shall be ASTM A395/A395M , and the middle ring shall be ASTM A513/A513M with AWWA C111/A21.11 bolting. Gaskets shall be natural rubber, butadiene acrylonitrile, isobutylene isoprene, ethylene propylene diene monomer (EPDM), ethylene propylene terpolymer (EPT), or fluoro-elastomeric.

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2.5 VALVES

2.5.1 General Requirements For Valves

Valves shall include operator, actuator, handwheel, chain wheel, extension stem, floor stand, worm and gear operator, operating nut, chain, wrench, and all other accessories required for a complete operation. The valves shall be suitable for the intended service. Renewable parts are not to be of a lower quality than those specified. Valves shall be the same size as adjoining pipe. Valve ends shall be compatible with adjacent piping system. An operator shall be sized to operate the associated valve for the full range of pressures and velocities. Valves will open by turning counterclockwise. Operators, actuators, and accessories shall be factory mounted.

2.5.2 Valve Schedule

Submit a list of valve materials, pressure ratings, valve operator's materials, air supply pressure, electrical service, location, source of supply, and reference identification as indicated in the contract drawings. Provide a list of any special tools necessary for each valve type and appurtenances furnished for adjustment, operation, maintenance and disassembly. Requirements relative to this paragraph are shown on the Valve Schedule located in the contract drawings.

2.5.3 Factory Finishing

Valves shall have an epoxy coating in accordance with AWWA C550 unless otherwise specified. The epoxy shall be either a two-part liquid material or a heat-activated (fusion) material except that only a heat-activated material shall apply if a valve coating is specified as "fusion" or "fusion bonded" epoxy. The epoxy coating shall have a minimum 7.0 mils dry film thickness except where it is limited by valve operating tolerances.

2.5.4 Check Valves

2.5.4.1 Swing Check Valves

Swing check valves shall conform to the following:

Swing check valves, 2.5 inches through 14 inch, shall have a cast iron or ductile iron body, in accordance with ASME B16.1 flanged ends.

Valves shall have a bronze-mounted swing type, bronze disc, solid bronze hinges, and stainless steel hinge shaft. Valves shall be rated for 200 psig service. Valves shall be fitted with an adjustable outside lever and spring or adjustable outside lever and weight.

2.5.5 Gate Valves

2.5.5.1 General Service Gate Valves

General service gate valves shall conform to the following:

Gate valves, 2.5 inch and larger, shall have cast-iron bodies with bronze trim. Valves shall meet the requirements of MSS SP-70 and have Class 125 flanged end connections. Bonnet shall be a NRS Bolted type. Discs shall be wedge type of iron or ductile iron construction, and have nonrising bronze stems. Valves shall be rated for 200 psig

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service. Valves shall be equipped with handwheel, extension stem and floor stand, or electrically actuated operators as indicated in the Valve Schedule.

2.5.6 Operators

2.5.6.1 Operator Schedule

Requirements relative to this paragraph are shown on the Valve Schedule located in the contract drawings.

2.5.6.2 Manual Operator

The rim pull force in a manual operator shall not exceed 39.3 pound under any operating condition, including initial breakaway. The operator shall be equipped with gear reduction when force exceeds 39.3 pound. The manual operator shall be a self-locking type or shall be equipped with a self-locking device. Worm and gear operators shall be a one-piece design with worm-gears of gear bronze material. Worm shall be hardened alloy steel with the thread ground and polished. Traveling nut type operators shall have threaded steel reach rods with an internally threaded bronze or ductile iron nut.

2.5.6.2.1 Exposed Operators

Exposed operators shall have galvanized and painted handwheels. Cranks shall be supplied on gear type operators. If located off of the operator floor, chain wheel operator with tiebacks, extension stem, floor stands, and other accessories shall be provided to permit operation from normal operation level. Valve handles shall be capable of padlocking, and wheels shall be lockable with a chain and padlock.

2.5.6.3 Electric Operator

Electric operators shall be provided complete with actuators, speed controls and accessories. The actuators shall operate on 125 VDC with a 75 percent duty cycle and shall be equipped with rotating equipment to full rotation. Gearing shall be a two-stage planetary, permanently lubricated self-locking gear train with self-lubricating bearings;

connections via male output staff. The actuator shall have a maximum torque capacity of 200 foot-pound or greater. Two travel stop limit switches with cams, internal, independent, adjustable, and actuated by cams shall be mounted on the drive shaft. A side mounted hand turn wheel shall be provided for a manual override. The actuators shall have a NEMA 250 Type 4 enclosure with a corrosion resistant, baked epoxy finish as standard. The actuator shall operate in a temperature range of -40 to plus 150 degrees F. Actuators shall fail in last position unless otherwise indicated. Electric operators shall be furnished with features noted on the Valve Schedule in the contract drawings. Limit switches shall be provided on all actuators.

2.5.6.3.1 Limit Switches

Limit switches shall be single-pole, double-throw (SPDT) type, rated 10 amps at 120 volts ac, housed in a NEMA 250 Type 4 enclosure, and adjustable for open and closed valve positions.

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2.5.6.3.2 Positioners

The positioners for modulating actuators shall control valve positions as a function of the input signals. The positioner shall operate on 125 VDC voltage. The mode of operation shall be direct acting. Modulating valve positioners shall operate on a 4 to 20 mA input signal unless otherwise indicated. Corrosion-resistant enclosures for positioners shall be splash-and moisture-proof with gasketed covers.

2.5.7 Valve Accessories

2.5.7.1 Extension Bonnet for Valve Operator

All extension bonnets shall be provided as necessary, complete with stem and accessories applicable to the specific valve and operator.

2.5.7.2 Floor Stand and Extension Stem

A floor stand and extension stem shall be the nonrising, indicating type;

complete with stem, coupling, handwheel, stem guide brackets, and yoke attachment. The stem guide shall be spaced such that stem L/R ratio does not exceed 200. In locations where stem guides cannot be used, the stem shall be designed such that the stem L/R ratio does not exceed 200 for the whole length of the stem. Extension stems shall not rely only on bolted connections of the coupled extension stem shafts. Bolts have been known to corrode and shear when operating valves. Extension stems shall have a splined coupling or other approved connection that is less prone to shear and more robust than a bolted configuration. Anchors shall be supplied as required.

2.6 MISCELLANEOUS PIPING COMPONENTS

2.6.1 Indicating Devices

2.6.1.1 Pressure and Vacuum Gauges

Pressure and vacuum gauges shall be stem mounted, with stainless steel or brass cases and dry dials. The gauge sensors shall be C-Type Bourdon tube actuated and constructed of stainless steel. The gauges shall be equipped with brass threaded 0.25 inch male connections. The dials of the gauges shall be 4.5 inch in diameter with scale readings in psig ranging from zero to approximately twice the anticipated process operating or equipment pressure. A slotted adjustable pointer shall be provided with accuracy to conform to ASME B40.100 , Grade A.

2.7 PIPE SUPPORTS AND PENETRATIONS

Provide auxiliary steel where the support of piping systems and equipment is required between building structural elements. Light gauge and structural steel shapes shall conform to the requirements of ASTM A36/A36M.

The Contractor has the option to use pre-engineered support systems of electrogalvanized steel products. However, a mixture of support system manufacturers products is not permitted. Where auxiliary steel is indicated as stainless steel, provide TP304 stainless steel conforming to ASTM A167, No. 1 Finish.

2.7.1 Pipe Supports

Pipe supports shall conform to the requirements of MSS SP-58 . Where pipe

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supports contact bare piping or in-line devices, provide supports of compatible material so that neither shall have a deteriorating action on the other. Threaded connections of pipe supports shall have a graphite-based anti-seize applied to the threads.

2.7.1.1 Beam Clamps

For upper attachments on structural steel, provide beam clamps of ASTM A36/A36M carbon steel and MSS SP-58 Types 19 through 23, 25 or 27 through 30. Holes drilled in structural steel for hanger support rods will not be permitted. Clamps shall be provided with hardened steel cup-point set screws and lock-nuts for anchoring in place. Clamp size selection shall only be based on the support of the required load.

2.7.1.2 Riser Clamps

Vertical runs of piping shall be supported at each floor, or closer where required, with ASTM A36/A36M carbon steel clamps bolted around pipes and attached to the building construction.

2.7.1.3 Brackets

Where piping is run adjacent to walls or steel columns, provide welded ASTM A36/A36M steel brackets, pre-punched with a minimum of two fastener holes.

2.7.1.4 Offset Pipe Clamp

Where pipes are indicated as offset from wall surfaces, supply a double-leg design two-piece pipe clamp.

2.7.1.5 Racks

Multiple pipe racks or trapeze hangers shall be fabricated from ASTM A36/A36M steel, and designed to suit the conditions at the points of installation. Pipes shall be kept in their relative positions to each other by the use of clamps or clips. Pipelines subject to thermal expansion must be free to slide or roll.

2.7.1.6 Hangers

Hangers shall be fabricated of ASTM A36/A36M carbon steel. All hangers shall be of a uniform type and material for a given pipe run and application. Coated or plated hangers shall be used to isolate steel hangers from dissimilar metal tube or pipe. Hangers for pipe sizes 2.5 inch or larger shall incorporate a means of vertical adjustment after erection while supporting the load. For piping systems with liquid temperatures up to 122 degrees F the following shall be used: MSS SP-58 Types 1,3 through 12, Types 24 and 26 with overhead support, or Types 35 through 38 with support from below.

2.7.1.7 Hanger Rods

Hanger rods shall be carbon steel conforming to ASTM A576. The diameter of the rods for piping system support shall conform to ASME B31.1 .

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2.7.2 Pipe Guides

2.7.2.1 Intermediate Guides

For piping 6 inch and smaller, a pipe clamp with an oversize pipe sleeve shall be provided for a minimum 0.16 inch clearance. For piping 8 inch and larger, U-bolts with double nuts that are manufactured for the purpose shall be used to provide a minimum 0.28 inch clearance around pipe. The stock sizes for the U-bolts are as follows: for a 8 inch pipe use a 0.625 inch U-bolt; for a 10 inch pipe, use a 3/4 inch U-bolt for a 12 inch to 16 inch pipe, use a 0.875 inch U-bolt.

2.7.2.2 Alignment Guides

For piping, 8 inch and smaller, alignment guides shall be galvanized steel, spider or sleeve type. For piping, 10 inch and larger, alignment guides shall be galvanized steel, roller type guides.

2.8 Television Inspection

2.8.1 General

The Television camera used for the inspection shall be one specifically designed and constructed for such inspection. Lighting for the camera shall be suitable to allow a clear picture of the entire periphery of the pipe. The camera shall be operative in 100% humidity conditions. The camera, television monitor, and other components of the video system shall be capable of producing picture quality to the satisfaction of the Owner's Representative; and if unsatisfactory, equipment shall be removed and no payment will be made for an unsatisfactory inspection.

The camera shall be moved through the line in either direction at a moderate rate, stopping when necessary to permit proper documentation of the pipe's condition. In no case will the television camera be pulled at a speed greater than 30 feet per minute. Manual winches, power winches, TV cable, and powered rewinds or other devices that do not obstruct the camera view or interfere with proper documentation of the pipe conditions shall be used to move the camera through the pipe line. If, during the inspection operation, the television camera will not pass through the entire pipe section, the Contractor shall set up his equipment so that the inspection can be performed from the opposite end of the pipe. If, again, the camera fails to pass through the entire manhole section, the inspection shall be considered complete noted as Survey Abandoned and no additional inspection will be required.

When manually operated winches are used to pull the television camera through the line, telephones or other suitable means of communication shall be set up between the two ends of the section being inspected to insure good communications between members of the crew.

The importance of accurate distance measurements is emphasized.

Measurement for location of defects shall be above ground by means of a meter device. Marking on the cable, or the like, which would require interpolation for depth of manhole, will not be allowed. Accuracy of the distance meter shall be checked by use of a walking meter, roll-a-tape or other suitable device, and the accuracy shall be satisfactory to the Owner's Representative.

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2.8.2 Television Results

Television Inspection Logs: Electronic media location records shall be kept by the Contractor and will clearly show the location, by distance in 1/10 of a foot, from the end of the pipe, in relation to an adjacent end of each infiltration point observed during inspection. In addition, other points of significance such as locations of building raw water pipes, unusual conditions, cracks, fractures, broken pipe, presence of scale and corrosion, and other discernible features will be recorded on electronic media and a copy of such records will be supplied to the Owner.

Digital Photographs of the pipe condition and all defects shall be taken by the Contractor. Photographs shall be located by distance in 1/10 of a foot, from the end of pipe, in relation to an adjacent end.

Electronic media recordings: The purpose of electronic media recording shall be to supply a visual and audio record of problem areas of the lines that may be replayed by the Owner. Each original electronic media recording of conditions and defects will be delivered to the Customer upon completion of a specific line section.

2.9 Hydrocleaning

The intent of line cleaning is to remove foreign materials from the lines and restore the line to a minimum of 95% of the original carrying capacity or as required for proper seating of internal pipe joint sealing packers.

Since the success of the other phases of work depends a great deal on the cleanliness of the lines, the importance of this phase of the operation is emphasized. It is recognized that there are some conditions such as broken pipe and major blockages that prevent cleaning from being accomplished or where additional damage would result if cleaning were attempted or continued. Should such conditions be encountered, the Contractor will not be required to clean those specific lines. If in the course of normal cleaning operations, damage does result from preexisting and unforeseen conditions such as broken pipe, the Contractor will not be held responsible.

2.9.1 Cleaning Equipment

Hydraulically Propelled Equipment: The equipment used shall be of a movable type and be constructed in such a way that a portion of the dam may be collapsed at any time during the cleaning operation to protect against flooding of the plant. The movable dam shall be equal in diameter to the pipe being cleaned and shall provide a flexible scraper around the outer periphery to insure removal of grease. If pipe cleaning balls or other equipment which cannot be collapsed is used, special precautions to prevent flooding of the plant and public or private property shall be taken.

High-Velocity Jet (Hydrocleaning) Equipment: All high-velocity pipe cleaning equipment shall be constructed for ease and safety of operation.

The equipment shall have a selection of two or more high-velocity nozzles. The nozzles shall be capable of producing a scouring action from 15 to 45 degrees in all size lines designated to be cleaned. Equipment shall also include a high-velocity gun for washing and scouring fittings.

The gun shall be capable of producing flows from a fine spray to a solid stream. The equipment shall carry its own water tank, auxiliary engines, pumps, and hydraulically driven hose reel.

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BULL SHOALS POWERHOUSE

Mechanically Powered Equipment: Bucket machines shall be in pairs with sufficient power to perform the work in an efficient manner. Machines shall be belt operated or have an overload device. Machines with direct drive that could cause damage to the pipe will not be allowed. A power rodding machine shall be either a sectional or continuous rod type capable of holding a minimum of 750 feet of rod. The rod shall be specifically heat treated steel. To insure safe operation, the machine shall be fully enclosed and have an automatic safety clutch or relief valve.

PART 3 EXECUTION

3.1 EXAMINATION

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

3.2 PREPARATION

3.2.1 Protection

Pipe and equipment openings shall be closed with caps or plugs during installation. Equipment shall be protected from dirt, water, and chemical or mechanical damage.

3.2.2 System Preparation

3.2.2.1 Pipe and Fittings

Pipe and fittings shall be inspected before exposed piping is installed.

Clean the ends of pipes thoroughly, remove foreign matter and dirt from inside of pipes, and keep piping clean during installation.

3.2.2.2 Damaged Coatings

Repair damaged coating areas in the field with material equal to the original coating. Do not install damaged piping materials. Field repair of damaged and uncoated areas of galvanized piping shall conform to

ASTM A780/A780M .

3.2.2.3 Field Fabrication

Notify the Contracting Officer at least 2 weeks prior to the field fabrication of pipe or fittings and at least 3 days prior to the start of any surface preparation or coating application work. Field welding shall be performed in accordance with Section 40 05 13.96 WELDING PROCESS PIPING. Welding electrodes shall be provided in accordance with Table 3.1 of AWS D1.1/D1.1M as required for the applicable base metals and welding process. Fabrication of fittings shall be performed in accordance with the manufacturer's instructions.

3.3 EXPOSED PIPING INSTALLATION

Exposed piping shall be run as straight as practical along the alignment shown on the contract drawings and with a minimum of joints. Piping and appurtenances shall be installed in conformance with reviewed shop drawings, manufacturer's instructions and ASME B31.3 . Piping shall be installed without springing or forcing the pipe.

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BULL SHOALS POWERHOUSE

3.3.1 Anchors and Fasteners

Impact expansion (hammer and explosive charge drive-type) anchors and fastener systems are not acceptable. Lead shields, plastic or fiber inserts, and drilled-in plastic sleeve/nail drive systems are also not acceptable.

3.3.1.1 Drilled-In Expansion Anchors and Fasteners

Anchors shall be designed to accept both machine bolts and/or threaded rods. Such anchors shall consist of an expansion shield and expander nut contained inside the shield. The expander nut shall be fabricated and designed to climb the bolt or rod thread and simultaneously expand the shield as soon as the threaded item, while being tightened, reaches, and bears against the shield bottom. The shield body shall consist of four legs, the inside of each shall be tapered toward shield bottom (or nut end). The end of one leg shall be elongated and turned across shield bottom. The outer surface of shield body shall be ribbed for grip-action. The expander nut shall be of square design with sides tapered inward from bottom to top. The anchor materials of construction shall be TP304 stainless steel of 43,541 psi minimum tensile strength.

Fasteners shall be machine bolts for use with above anchors; nuts and washers shall conform to ASTM A194/A194M . The anchor length, diameter, and embedment depth shall meet the manufacturer's requirements for the maximum allowable working load of the application. Overhead applications shall use flare type anchors.

3.3.1.2 Drilled-In Adhesive Anchors

Drilled-in adhesive anchors shall not be used for overhead applications.

The anchors shall be composed of an anchor rod assembly and an anchor rod adhesive cartridge. The anchor rod assembly shall be a chamfered and threaded stud rod of TP304 stainless steel with a nut and washer of TP316 stainless steel. The anchor length, diameter, and embedment depth shall meet the manufacturer's requirements for the maximum allowable working load of the application. The adhesive cartridge shall be a sealed capsule containing premeasured amounts of resin, quartz sand aggregate, and a hardener contained in a separate vial within the capsule. The capsule ingredients shall be activated by the insertion procedure of the anchor rod assembly.

3.3.2 Piping Flexibility Provisions

Thrust protection shall be provided as required. Flexible couplings and expansion joints shall be installed at connections to sump pumps at the discharge tee, and where shown on the contract drawings. Additional pipe anchors and flexible couplings beyond those shown on the contract drawings, shall be provided to facilitate piping installation, in accordance with reviewed shop drawings.

3.3.3 Couplings, Adapters and Service Saddles

Pipes shall be thoroughly cleaned of oil, scale, rust, and dirt in order to provide a clean seat for gaskets. Gaskets shall be wiped clean prior to installation. Flexible couplings and flanged coupling adapter gaskets shall be lubricated with soapy water or the manufacturer's standard lubricant before installation on the pipe ends. Couplings, service saddles, and anchor studs shall be installed in accordance with manufacturer's instructions. Bolts shall be tightened progressively, SECTION 40 05 13 Page 16

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BULL SHOALS POWERHOUSE

drawing up bolts on opposite sides a little at a time until all bolts have a uniform tightness. Torque-limiting wrenches shall be used to tighten bolts.

3.3.4 Piping Equipment/Component Installation

Piping components and indicators shall be installed in accordance with manufacturer's instructions. Required upstream and downstream clearances, isolation valves, and miscellaneous devices shall be provided for an operable installation.

3.3.4.1 Local Indicators

All direct-reading indicator devices, thermometers, and pressure gauges shall be installed so that they can be easily read from floor level, and are readily accessible for maintenance and service. Pressure gauges and thermometers shall be installed where indicated in the contract drawings or specifications. Field calibration of all indicators shall be performed at time of installation to ensure measuring and reading accuracy.

3.3.5 Pipe Flanges

Pipe flanges shall be set level, plumb, and aligned. Flanged fittings shall be installed true and perpendicular to the axis of the pipe. The bolt holes shall be concentric to the centerline of the pipe.

3.3.6 Valve Locations

Valves shall be located in accordance with the contract drawings where actuators are shown. Where actuators are not shown, valves shall be located and oriented to permit easy access to the valve operator, and to avoid interferences.

3.3.7 Pipe Tap Connections

Taps to pipe barrels are unacceptable. Taps to ductile iron piping shall be made only with a service saddle or at a tapping boss of a fitting, valve body, or equipment casting. Taps to steel piping shall be made only with a welded threadolet connection.

3.4 CONNECTING DISSIMILAR PIPE

Flexible transition couplings, dielectric fittings and isolation joints shall be installed in accordance with the manufacturer's instructions.

3.5 EXTERNAL CORROSION PROTECTION

Protect all pipe and piping accessories from corrosion and adverse environmental conditions.

3.5.1 Above Grade Metallic Piping

Nonferrous and stainless steel piping shall not be painted except for aluminum alloy piping. Where dissimilar metals are joined, isolation joints shall be used.

3.5.1.1 Ferrous Piping

Shop primed surfaces shall be touched up with ferrous metal primer.

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BULL SHOALS POWERHOUSE

Surfaces that have not been shop primed shall be solvent cleaned.

Surfaces that contain loose rust, mill scale or other foreign substances shall be mechanically cleaned by power wire brushing and primed with a ferrous metal primer. Primed surfaces shall be finished with two coats of paint in accordance with Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES.

3.6 FLEXIBLE JOINTS AT CONCRETE STRUCTURES

Flexible joints shall be provided at the face of all structures, whether or not shown on the contract drawings. Rubber ring joints, mechanical joints, flexible couplings, and proprietary restrained ductile iron pipe joints shall be considered flexible joints; welded pipe joints shall not.

3.7 CLOSURES

Closure pieces shall be installed as necessary to end pipe runs and shall conform to ASME B16.9 or ASME B16.11 . Elastomer sleeves bonded to pipe ends are not acceptable. Pressure piping shall have closures of blind flanges or threaded plugs, unless otherwise shown on contract drawings or approved by the Contracting Officer. Pipes with restrained joints shall have pipe closures installed with thrust tie-rod assemblies.

3.8 PENETRATIONS

Steel pipe sleeves shall be hot-dipped galvanized after fabrication for applications in nonsubmerged areas. Joints shall be sealed with a wall penetration seal. For existing concrete walls, rotary drilled holes may be provided in lieu of sleeves.

3.8.1 Filling Penetrations

For concrete penetrations, clean the concrete face and apply a bonding agent to ensure full bonding. Place a backing material and fill the penetration with a non-shrink grout or concrete. For a sleeved penetration, the bonding agent used will have to be specific to the material used as a sleeve and a non-shrink grout shall be used.

3.9 VALVE INSTALLATION

Flanged valve bolt holes shall be installed so as to straddle the vertical centerline of pipe. Flanged faces shall be cleaned prior to inserting the gasket and bolts, and then the nuts shall be tightened progressively and uniformly. Threaded ends shall have the threads cleaned by wire brushing or swabbing prior to installation.

3.9.1 Valve Orientation

The operating stem of a manual valve shall be installed in a vertical position when the valve is installed in horizontal runs of pipe having centerline elevations 4.5 feet or less above finished floor, unless otherwise shown on contract drawings. The operating stem of a manual valve shall be installed in a horizontal position in horizontal runs of pipe having centerline elevations between 4.5 feet and 6.75 feet above finish floor, unless otherwise shown on contract drawings. Automatic valves shall be installed in accordance with the manufacturer's instructions.

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BULL SHOALS POWERHOUSE

3.10 AIR RELEASE, DRAINS AND SAMPLE PORTS

Sample ports shall be provided where indicated on the contract drawings.

Install specified vents at piping high points for entrapped air release and install drains in the low points of pipelines regardless of whether shown on contract drawings.

3.11 PIPING SUPPORT SYSTEMS INSTALLATION

The absence of pipe supports and details on the contract drawings shall not relieve the Contractor of responsibility for sizing and providing supports throughout plant.

3.11.1 General Support Requirements

Pipe support systems shall meet the requirements of MSS SP-58 .

Contractor-designed and selected support systems shall be installed in accordance with MSS SP-58 , and as specified herein. Piping connections to equipment shall be supported by pipe supports and not off the equipment.

Large or heavy valves, fittings, and/or equipment shall be supported independently of associated piping. Pipes shall not be supported off other pipes. Supports shall be provided at piping changes in direction or in elevation, adjacent to flexible joints and couplings, and where otherwise shown on the contract drawings. Pipe supports and hangers shall not be installed in equipment access areas or bridge crane runs. Hanging pipes shall be braced against horizontal movement by both longitudinal and lateral sway bracing. At each channel type support, every pipe shall be provided with an intermediate pipe guide, except where pipe anchors are required. Existing support systems may be used to support additional new piping only if the Contractor can demonstrate that the existing support systems are adequate for the additional loads, or if the existing systems are strengthened to support the additional loads. Pedestal type pipe supports shall be provided under base flanges adjacent to rotating equipment and where required to isolate vibration. Piping 2.5 inch in diameter and larger shall be braced for seismic forces. Lateral supports for seismic loads shall be installed at all changes in direction.

3.11.2 Dielectric Barriers

Dielectric barriers shall be installed between supports and copper or stainless steel piping, and between stainless steel supports and non-stainless steel ferrous piping.

3.11.3 Support Methods

Piping support shall be provided as specified and as shown in the contract drawings. Single horizontal suspended piping shall be supported by adjustable swivel-ring, split-ring, or clevis hangers. Multiple horizontal suspended piping shall be supported by trapeze hangers with channel type supports. Horizontal pedestal mounted piping shall have saddle type supports. Horizontal wall mounted piping shall have wall brackets. Vertical piping shall be supported by wall brackets, base elbows, or riser clamps on floor penetrations.

3.12 PIPE IDENTIFICATION, PAINTING AND COLOR CODING

Color and coating requirements for exposed piping shall be in accordance with Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES. A single individual band, of plastic adhesive tape or paint, designating pipe contents shall

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BULL SHOALS POWERHOUSE

be provided with sufficient length to permit the stenciling of pipe contents in letters. Identification shall be provided at branch connections, inlets and outlets of equipment, every 19.7 feet of straight run, upstream of valves, and within 3.3 feet of entrance to or exit from wall curtains, or other similar type barrier. Provide piping identification in accordance with ASME A13.1 . Place stenciling in clearly visible locations.