Am0002 - Specifications - FR Zebra Mussel.pdf

Zebra Mussel Mitigation System, Fort Randall Dam, SD FRH2

SECTION TABLE OF CONTENTS

DIVISION 43 - PROCESS GAS AND LIQUID HANDLING, PURIFICATION, AND STORAGE

EQUIPMENT

SECTION 43 32 69

LIQUID COPPER BASED PESTICIDE (CBP) DISTRIBUTION SYSTEM FOR ZEBRA MUSSEL

MITIGATION

PART 1 SCOPE OF WORK

1.1 REFERENCES

1.2 SUBMITTALS

1.3 DELIVERY, STORAGE, AND HANDLING

1.4 EXTRA MATERIALS (CLIN 0004-Option)

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Liquid Copper Based Pesticide (CBP) Distribution System

2.1.2 Copper Analyzer

2.1.3 Control

2.1.3.1 Automatic/Manual Control

2.1.4 Performance Requirements

2.1.5 Submittal Data

2.2 MATERIALS AND EQUIPMENT

2.2.1 Standard Products

2.2.2 Nameplates

2.2.3 Identification of Piping/Tubing Systems

2.3 ELECTRICAL

2.3.1 Conduits

2.3.1.1 Rigid Metallic Conduit

2.3.1.2 Liquidtight Flexible Metallic Conduit (LFMC)

2.3.2 Outlet Boxes, Pull Boxes and Junction Boxes

2.3.3 Motor Starters

2.3.4 Control and Protective Devices

2.4 EQUIPMENT APPURTENANCES

2.4.1 Ball Valve

2.4.2 Pipe Hangers, Inserts, and Supports

2.4.3 Building Structure Attachments

PART 3 EXECUTION

3.1 FIELD MEASUREMENTS

3.2 INSTALLATION

3.2.1 Dielectric Connections

3.2.2 Welding

3.2.2.1 Employer's Record Documents (For Welding)

3.2.2.2 Welding Procedures and Qualifications

3.2.2.3 Examination of Piping Welds

3.2.2.4 Welding Safety

3.3 FACTORY PAINTING

3.4 FIELD PAINTING

3.5 FIELD TESTING

3.5.1 Pressure Tests

SECTION 43 32 69 Page 1 Am0002

3.5.2 Liquid CBP Distribution System

3.6 FIELD TRAINING

3.7 CLOSEOUT ACTIVITIES

3.7.1 Operating Instructions

3.7.2 Maintenance Instructions

-- End of Section Table of Contents --

SECTION 43 32 69 Page 2

SECTION 43 32 69

LIQUID COPPER BASED PESTICIDE (CBP) DISTRIBUTION SYSTEM FOR ZEBRA MUSSEL

MITIGATION

PART 1 SCOPE OF WORK

Provide four (4) complete sets of the LIQUID COPPER BASED PESTICIDE (CBP) [Am#0002]DISTRIBUTION SYSTEM (pesticide chemical totes are not included in this contract) to control / prevent zebra mussel infestation in four (4) of the 14" raw water intake piping serving various cooling systems in the powerhouse. At a minimum, each chemical distribution system must include but not limited to following;

[Am#0002]

1. Packaged wall skid (including factory wired junction box for control cables and power supply) with metering pump, ancillary piping, tubing, by-pass, gauges, check valves, air vents, pressure relief valves, and all other piping specialties that are necessary and recommended by metering pump and skid manufacturer.

2. Programmable Logic Controller(PLC) and Human Machine Interface (HMI) with local display screen for the metering pump control.

3. Insertion type magnetic flow meter (0~7,000 GPM) with 316L Stainless Steel full port isolation valve assembly.

4. Chemical distribution tubing (316L Stainless Steel) including all necessary compression type fittings, hangers, clamps, anchors, and hardware.

5. Chemical injection quill with 316L stainless steel full port isolation valve assembly.

It must be noted that the scope of work specified herein requires the contractor to perform on-site hot work (see paragraph 3.2.2 Welding for detailed requirements) associated with hot-taps and/or other small (2" diameter or less) welded branch piping connections to install insertion type flow meters and chemical injection ports in the existing 14" raw water piping. When such work requires the subject raw water piping to be de-watered, the contractor must notify the COR at least 2 weeks prior to performing work.

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 SOCIETY OF MECHANICAL ENGINEERS (ASME)

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

ASME B16.9 (2018) Factory-Made Wrought Buttwelding

SECTION 43 32 69 Page 3

Fittings

ASME B31.1 (2018) Power Piping

AMERICAN WELDING SOCIETY (AWS)

AWS Z49.1 (2012) Safety in Welding and Cutting and Allied Processes

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

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

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

ASTM INTERNATIONAL (ASTM)

ASTM A269/A269M (2015; R 2019) Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service

ASTM F593 (2017) Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

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

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 1 (2015) Solvent Cleaning

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

CID A-A-1923 (Rev A; Notice 3) Shield, Expansion (Lag, Machine and Externally Threaded Wedge Bolt Anchors)

UNDERWRITERS LABORATORIES (UL)

UL 50 (2015) UL Standard for Safety Enclosures for Electrical Equipment, Non-Environmental Considerations

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

SECTION 43 32 69 Page 4 that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Manufacturer's Shop Drawings; G, DO

SD-03 Product Data

Magnetic Flow Meters; G, DO

Metering Pump; G, DO

Auxiliary Equipment and Spare Parts; G, DO

[Am#0002]

[Am#0002]

SD-06 Test Reports

Piping Welds NDE report; G, DO

Report must be provided electronically as pdf file. In the report, document all phases of the tests performed including photos of welds. Include initial test summaries, all repairs/adjustments made, and the final test results.

Field Test Plan; G, PO

[Am#0002] Final Test Reports; G, PO

Training Plan; G, PO

Pressure Test Reports ; G, PO

SD-07 Certificates

Employer's Record Documents (For Welding); G, DO

Welding Procedures and Qualifications; G, DO

Certificates must be submitted showing conformance with the referenced standards contained in this section.

Certificate Of Calibration; G, PO

[Am#0002]

[Am#0002]

[Am#0002] SD-10 Operation and Maintenance Data

Operating Instructions; G, PO

Maintenance Instructions; G, PO

SECTION 43 32 69 Page 5

SD-11 Closeout Submittals

As-Built Drawings; G, PO

1.3 DELIVERY, STORAGE, AND HANDLING

Protect material and equipment delivered and placed in storage from the weather, excessive humidity and excessive temperature variation, dirt, dust, or other contaminants.

1.4 EXTRA MATERIALS (CLIN 0004-Option)

Include items needed for normal operation, future maintenance, and repair, items that might be difficult to obtain because of color or pattern match, or spare parts needed to ensure continued operation of critical equipment.

Concurrent with delivery and installation of the specified equipment, furnish auxiliary equipment and spare parts as follows:

a. Auxiliary equipment must include;

1.Portable copper analyzer and reagents in equipment manufacturer's hard storage case. See paragraph 2.1.3 for additional requirements.

b. Spare parts must include;

1.Two(2) metering pumps with pre-programmed PLCs, and HMIs.

2.Two(2) insertion type magnetic flow meter assemblies.

3.Two(2) chemical injection quill assemblies.

[Am#0002] 4.Four(4) additional secondary spill containments.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

[Am#0002]

2.1.1 Liquid Copper Based Pesticide (CBP) Distribution System

Provide Liquid Copper Based Pesticide (CBP) Distribution System as described below;

a. The liquid CBP distribution system and accessories must be suitable for 24/7 continuous operation.

b. Provide four (4) sets of completely packaged wall skid with integral metering pump system including but not limited to; all components required such as suction / discharge tubing, fittings, calibration column, valves, pressure gauge, etc.. Provide each skid with wall mountable brackets, concrete wall anchoring systems (wedge anchors only), and vibration isolators if required or recommended by the pump and skid manufacturer. Provide each metering pump skid with spray shield and drip pan with drain plugs to allow containing chemical leak, to protect operating personnel, and other government properties near and below the system.

c. Provide a positive displacement type, self-priming (including by-pass piping to chemical container when required), controlled volume metering pumps. Each metering pump must be capable of dosing chemical at any

SECTION 43 32 69 Page 6 rate from [Am#0002]the minimum flow rate (0.02 liter/hr) to the maximum flow rate(12 liter/hr), and be capable of continuous operation at rated capacity. Accuracy must be plus or minus 2 percent over a 1 to 100 range from the required minimum to maximum dosing rate [Am#0002].

d. Provide Human Machine Interface (HMI)for each metering pump to allow manual calibration, change of setting, varying injection rate, manual input of raw water flow rate, etc. at the local pump controller. HMI local display screens must be supplied to provide an interface to the PLC. The HMI screens must be compatible with the specific PLC being provided. HMI and PLC may be integral to the metering pump.

e. Four (4) insertion type magnetic flow meters must be installed in 14" raw water supply piping (generator unit #2, #4, #6, #8). All parts must meet or exceed the pressure classification of the pipe system it is installed in (typical raw water system pressure is between 60 psig - 70 psig, occasionally up to 100 psig). Each flow meter must be a combined meter/transmitter unit that is capable to be loop powered from respective metering pump PLC. The flow meters must be equipped with 316L stainless steel electrodes which can provide flow reading accuracy of +/- 1% of full scale when installed per manufacturer's recommendations. Flow meters must be provided with integral display (flow range 0-7,000 GPM)-capable of indicating flow rate in gpm and flow velocity in ft/sec. 4-20mA analog output wiring from each flow meter to associated liquid CBP metering pump control system must be provided. Additional 4-20 mA output contact must be available for the future connection into the powerplant supervisory system. Each flow meter must be installed with a full port isolation valve, adapter, and ample clearance from the wall or other obstructions to allow removal /replacement of the flow meter without system shutdown.

f. No materials containing lead may be used in chemical distribution tubing, fittings, and accessories. All wetted components on the distribution system including all piping, tubing, other components of packaged pump skid that are in contact with the liquid CBP must be corrosion resistant, 316L stainless steel to the extent possible.

g. Liquid CBP distribution tubing must be Type 316L stainless steel (min-1/2" O.D. with 0.05" wall thickness)in accordance with ASTM A269/A269M . Provide flexible tubing (convoluted 316L stainless steel core and braid)as necessary to isolate the vibration and to allow removal and replacement of the components. At a minimum, flexible tubing must be provided between injection quill assemblies and rigid tubing, metering pump suction and discharge connections, and pumping skid connections to the chemical totes. Pump suction tubing inlet must be provided with meshed screen if recommended by the pump manufacturer.

h. Each liquid CBP injection port in the 14" raw water piping must be provided with chemical injection quill(316L SS and integral backflow preventer component, extended to centerline of the 14" pipe) to minimize localized corrosion that may occur on the inner surface of the piping. The The injection quill, port, and flexible tubing must be provided with full port isolation valves and unions to allow replacement in the future while the 14" pipe remains in service.

i. All fittings for the 316L stainless steel chemical carrying tubing must be compression type, and sufficient unions and flexible tubing must be provided to allow repair and replacement of components such as pumps, quills, and flow meters.

SECTION 43 32 69 Page 7

2.1.2 Copper Analyzer

Contractor must supply a portable (hand held- battery operated) multi-parameter colorimeter-style copper analyzer for measuring the concentration of copper in the chemically treated raw water. Analyzer must have a data logger function capable of logging up to 500 measured values (Result, Date, Time, Sample ID, User ID). New copper analyzer must be supplied with following sets of reagents and each set of reagent must be sufficient to conduct a total of 100 tests;

1. One (1) set of reagents for low range copper test(1 ppb-240 ppb).

2. One (1) set of reagents for High range copper test(40 ppb -5 ppm) and instruments required for adjustment, calibration, disassembly, operation, and maintenance of the equipment. Provide with manufacturer's standard hard case for storage.

2.1.3 Control

2.1.3.1 Automatic/Manual Control

Liquid CBP distribution system control must be programmable and capable to automatically modulate the chemical feed rate based on raw water flow rate sensed by each flow meter, and provide manual override functions. Provide with all software, rights, and programming information required to interface/update/program the HMI, PLC, flow meter, and other electronic equipment. The control panel must have front panel mounted ON/OFF switch, Power ON LED indicator light, two system indicator lights (one turns red when a fault or alarm condition is detected and one that turns green only if no fault/alarm condition is detected). Provide each control system with additional set of visual alarm lights (similar to stacklights-Green / Red, steady type, compatible with metering pump PLCs provided) installed (potentially under the cable tray) such that the lights indicating the system conditions can be clearly seen from the either end of the corridor where the systems are to be installed.

The control must be capable of automatically shutting the system down if it detects an out of range chemical injection rate(the upper threshold of the dosing rate must be calculated and programmed not to exceed 900 ppb of copper concentration in the treated water) due to control failure, and/or factory set fault/alarm conditions. Control panel must have an integrated local display indicating the operational status including the following:

1. Identifying fault / no fault / alarm conditions.

2. Raw water flow rate (GPM).

3. Liquid CBP chemical injection rate [Am#0002](ml/min).

4. Control must be capable to provide following operator-selectable modes;

a. Automatic Proportional Control Mode: Controller must provide automated proportional chemical dosing rate based on raw water flow rate from each respective flow meter. Copper concentration setpoint in the treated water must be operator adjustable from 10-900 ppb (or adjustable equivalent chemical dosing rate).

SECTION 43 32 69 Page 8

b. Manual Mode: Operator must have the ability to directly input raw water flow rate to be treated and/or desired chemical dosing rate into the controller. The controller then must maintain the manual settings until further adjustments from the operator.

5. Control must be capable of collecting, storing, and transmitting process data and alarm information. It must be able to transmit data to and/or communicate with powerplant supervisory system via Modbus or Ethernet. Provide all communication instrumentations required for this function.

2.1.4 Performance Requirements

The liquid CBP distribution system must be designed to modulate the chemical feed rate to maintain concentration of copper in the treated raw water flow at 20 ppb under normal operating condition (up to 900 ppb per user override) to protect four (4) -14" raw water supply lines from zebra mussel biofouling. Each 14" raw water supply line has flow rate of 0-3,300 GPM (intermittently up to 7,000 GPM).

[Am#0002]

The individual liquid CBP distribution system must operate independently of each other and be capable of operating at various raw water flow rates. The pumping equipment provided for each distribution must be controlled and monitored directly by PLC controller or similar to maintain a suitable liquid CBP injection feed rate to treat the raw water. The injection feed rate must be modulated based on analog input from insertion type flow meter in each 14" raw water supply line.

2.1.5 Submittal Data

Submit manufacturer's equipment product literature, Manufacturer's Shop Drawings, performance charts, electrical and distribution tubing schematics, and pump curves. List of materials, list of equipment, including a complete list of parts and supplies with current unit prices and source of supply. List of special tools for each type of equipment furnished including special tools necessary for adjustment, operation, maintenance, and disassembly. Refer to Section 1.2 for a complete list of submittals.

2.2 MATERIALS AND EQUIPMENT

2.2.1 Standard Products

Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture of the products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening.

2.2.2 Nameplates

Each piece of equipment provided must have the manufacturer's name, type or style, model or serial number, on a plate secured to the item of equipment. Plates must be durable and legible throughout equipment life and made of stainless steel. Plates must be fixed in prominent locations with nonferrous screws or bolts. Nameplates for valves, and metering pumps must be constructed of stamped metal tags (see below for examples). Minimum size of nameplates is be 1 inch by 2.5 inches. Lettering must be a minimum

SECTION 43 32 69 Page 9 of 0.125 inch high, normal block style. Nameplate examples as follows;

1. Isolation valves to be labeled as ZMX-Y convention.

where ZM denotes the Zebra Mussel mitigation system, X denotes the associated generator unit # (2, 4, 6, or 8), Y denotes the sequential valve number (1, 2, 3, etc), (Ex. A valve nameplate associated with generator unit #6 and 13th valve, ZM6-13)

2. Metering Pumps to be labeled as ZMP-X convention.

where ZM denotes the Zebra Mussel mitigation system, P denotes a pump, X denotes the sequential number and align with the associated generator unit # (2, 4, 6, or 8) (Ex. A metering pump nameplate associated with generator unit #2, ZMP-2)

2.2.3 Identification of Piping/Tubing Systems

Provide color coded piping /tubing identification label wraps on the chemical distribution tubing and piping. All identifications on the label must conform to ASME A13.1 and at a minimum, include; pipe or tubing OD with material, type of chemical in the piping or tubing, flow direction with an arrow, and designated hazard classifications with a specific color.

Provide identification label wraps every 10 ft on piping or tubing unless otherwise recommended per applicable standard.

2.3 ELECTRICAL

Government will provide 120/240 VAC disconnect at each metering pump skid location as shown on the contract drawings. Contractor must complete the final connections between disconnects and metering pumps, pump controls, and flow meters. Cabling not routed in the existing cable tray must run in Rigid Metallic Conduits(RMCs). Liquidtight flexible metallic conduit (LFMCs) may be allowed between 2 and 6 feet(including necessary slacks) in length for final connections to the equipment subject to vibration, noise transmission, or movement and for motors. Provide separate ground conductor across flexible connections if used. The contractor must provide all necessary transformers, rectifiers, and pre-wired junction boxes, conduits, cables, and wiring to complete final connections between the disconnects and all equipment provided under this contract. Provide electric motor-driven equipment complete with motor, motor starter, and controls.

Provide electrical equipment and wiring in accordance with manufacturer's recommendations. Equipment, materials, installation, and workmanship shall be in accordance with the mandatory and advisory provisions of NFPA 70 unless more stringent requirements are specified or indicated.

2.3.1 Conduits

2.3.1.1 Rigid Metallic Conduit

Provide hot dipped galvanized rigid steel conduit complying with UL 6.

Except where installed underground, or in corrosive areas, provide polyvinylchloride (PVC), or painted with bitumastic coated rigid steel conduit in accordance with NEMA RN 1.

Use threaded fittings for rigid steel conduit.

Use solid gaskets. Ensure conduit fittings with blank covers have gaskets, SECTION 43 32 69 Page 10 except in clean, dry areas or at the lowest point of a conduit run where drainage is required.

Provide covers with captive screws and are accessible after the work has been completed.

2.3.1.2 Liquidtight Flexible Metallic Conduit (LFMC)

Provide liquidtight flexible metallic conduit with a protective jacket of PVC extruded over a flexible interlocked galvanized steel core to protect wiring against moisture, oil, chemicals, and corrosive fumes.

Ensure liquidtight flexible metallic conduit is galvanized steel and complies with UL 1.

Ensure fittings for liquidtight flexible metallic conduit are specifically designed for such conduit.

2.3.2 Outlet Boxes, Pull Boxes and Junction Boxes

Ensure outlet boxes for use with conduit systems are in accordance with NEMA FB 1 and are not less than 1-1/2 inches deep. Furnish all pull and junction boxes with screw-fastened covers.

2.3.3 Motor Starters

Provide motor starters complete with thermal overload protection and other appurtenances necessary for the motor control specified.

2.3.4 Control and Protective Devices

Provide manual/automatic control and protective or signal devices required for the operation and any control wiring required for controls and devices. Pre-wire equipment to the maximum practicable extent. Control cabinets at a minimum must conform to the requirements of UL 50, NEMA 250, Type 12.

2.4 EQUIPMENT APPURTENANCES

Bolts, nuts, anchors, washers and all other types of supports necessary for the installation of the equipment must be galvanized steel, cadmium plated, ASTM A153/ASTM A153M, or Type 316 stainless steel depending on the material being fastened. Stainless steel materials must conform to ASTM F593.

2.4.1 Ball Valve

Full port design. Ball valves 1/2 inch and larger shall conform to MSS SP-72 or MSS SP-110 and shall be of stainless steel. Valves must have lockable handles.

2.4.2 Pipe Hangers, Inserts, and Supports

Pipe hangers, inserts, guides, and supports must conform to MSS SP-58 and MSS SP-69. Stainless steel chemical distribution tubing supports shall be stainless steel clevis style hangers, Behringer/Stauff style clamps, or other approved equivalent hardware. Use only circular cross-section rod hangers to connect building structure attachments to pipe (tubing) support devices. Provide turnbuckles, swing eyes, and clevises as required by support system to accommodate pipe (tubing) accessibility and adjustment

SECTION 43 32 69 Page 11 for load and pitch. Suspend tubing by the existing pipe rack to the extent possible.

2.4.3 Building Structure Attachments

Attachment to building structure concrete must be by wedge type expansive concrete anchors. The anchors shall be applied with a safety factor not less than 5. Secure wall mounted and suspended equipment with undercut anchors if the equipment weighs 50 lbs and above. Wall mounted systems may be secured with expansive anchors capable of resisting dynamic loading in cracked and un-cracked concrete. All structural steel brackets, clamps, bolts, nuts, washers, required to support piping, tubing, pump skid, and equipment, but not shown, must be provided under this contract. Use concrete and masonry anchor devices that conform to requirements of

CID A-A-1923.

PART 3 EXECUTION

3.1 FIELD MEASUREMENTS

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

3.2 INSTALLATION

Install system components and appurtenances in accordance with the manufacturer's instructions and provide necessary interconnections, services, and adjustments required for a complete and operable system.

Adjust or replace devices not conforming to the required accuracies.

Replace factory sealed devices, rather than adjusting. Installation, adjustment, and operation of the equipment specified must be supervised by a manufacturer's representative experienced in the installing, adjusting, and testing of the equipment. Submit detail drawings containing complete tubing, wiring schematic, flow diagrams, and any other details required to demonstrate that the system has been coordinated and will properly function as a unit. Drawings must show proposed layout and anchorage of equipment and appurtenances, and equipment relationship to other parts of the work including clearances for installation, maintenance and operation.

3.2.1 Dielectric Connections

Electrically insulate dissimilar metals including bolts, nuts and washers from each other by couplings, unions, or flanges commercially manufactured for that purpose and rated for the service pressure and temperature. The isolation must prevent electrical current flow between adjacent parts.

3.2.2 Welding

Provide welding work specified this section for piping systems in conformance with ASME B31.1, as modified and supplemented by this specification section and the accompanying drawings. For welded branch connections, the connections must be made with welding tees, forged welding branch outlets, or other suitable weldolets required for the components or equipment to be connected. Butt-welded fittings shall conform to ASME B16.9.

Socket-welded fittings shall conform to ASME B16.11. Welded fittings shall be identified with the appropriate grade and marking symbol. Pipe must be thoroughly cleaned of all scale and foreign matter before the piping is assembled. During welding, the pipe and fittings must be filled with an

SECTION 43 32 69 Page 12 inert gas, such as nitrogen, to prevent the formation of scale. Beveling, alignment, heat treatment, and inspection of weld must conform to ASME B31.1.

Weld defects must be removed and rewelded at the Contractor's expense.

Electrodes must be stored and dried in accordance with AWS D1.1/D1.1M or as recommended by the manufacturer. Electrodes that have been wetted or that have lost any of their coating must not be used. The welding work includes:

qualification of welding procedures, welders, welding operators, brazers, brazing operators, and nondestructive examination personnel; maintenance of welding records, and examination methods for welds. Welding inspection must be performed by an independent firm, hired by the Contractor.

3.2.2.1 Employer's Record Documents (For Welding)

Submit for review and approval the following documentation. This documentation and the subject qualifications must be in compliance with

ASME B31.1

a. List of qualified welding procedures that are proposed to be used to provide the work specified in this specification section.

b. List of qualified welders, brazers, welding operators, and brazing operators that are proposed to be used to provide the work specified in this specification section.

c. List of qualified weld examination personnel that are proposed to be used to provide the work specified in this specification section.

3.2.2.2 Welding Procedures and Qualifications

a. Specifications and Test Results: Submit copies of the welding procedures 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 a list of qualified welders, together with data and certification that each individual is performance qualified as specified. Do not start welding work prior to submitting welder, and welding operator qualifications. The certification must 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.

3.2.2.3 Examination of Piping Welds

Conduct Non-Destructive Examinations (NDE) on piping welds and verify the work meets the acceptance criteria specified in ASME B31.1. Submit a piping welds NDE report meeting the requirements specified in ASME B31.1.

3.2.2.4 Welding Safety

Welding and cutting safety requirements must be in accordance with AWS Z49.1.

SECTION 43 32 69 Page 13

3.3 FACTORY PAINTING

Factory painting must conform to manufacturer's standard factory finish, provided it does not discolor /deteriorate in the presence of high water vapor atmosphere, alkaline water vapor, and/or contact with liquid CBP product used.

3.4 FIELD PAINTING

Hot worked piping surfaces must be field painted using system No. 23-A-Z moisture cure urethane (primer-a zinc-rich coating conforming to SSPC Paint 40, intermediate coat - a single component aromatic moisture cure urethane conforming to SSPC Paint 41, top coat-a single component aliphatic moisture cure urethane conforming to SSPC Paint 38 The coating system must be applied according to the manufacturer's written instructions and be 3-coat system. All materials shall be procured from the same coating manufacturer.

Clean surfaces to be painted before applying paint or surface treatments.

Remove deposits of grease or oil in accordance with SSPC SP 1, prior to mechanical cleaning. Use clean cloths and clean fluids to avoid leaving a thin film of greasy residue on the surfaces being cleaned. Protect items not to be prepared or coated from damage by the surface preparation methods. Wire brush weld beads, and remove weld spatters. Remove heavy rust or mill scale with wire brush.

3.5 FIELD TESTING

Provide personnel, equipment, instrumentation, and supplies necessary to perform site testing. The Government will witness the testing, and written permission must be obtained from the Government before proceeding with the testing. Submit a complete field test plan no less than 30 days prior to field testing of the system for review and approval by the government. Test plan must include at a minimum; chemical distribution system tubing and piping pressure test, start up and operating the chemical distribution system under normal raw water flow condition, automatic and manual mode of operation[Am#0002]. The test procedure must describe all tests to be performed and other pertinent information such as specialized test equipment required and the length of the test. The test procedures must explain, in detail, step-by-step actions and the expected results, to demonstrate compliance with all the requirements of the drawings and this specification.

3.5.1 Pressure Tests

Each liquid CBP distribution system including injection tubing, tubing and piping integral to the metering pump skid must be hydrostatically tested at a pressure not less than 120 psig for period of time sufficient to inspect every joint in the system and in no case less than 2 hours. Test pressure must be monitored by a currently calibrated test pressure gauge with no more than one (1) psig gradations. Leaks must be repaired and piping retested until test requirements are met. No leakage or reduction in gage pressure must be allowed.

Leaks must be repaired by rewelding or replacing pipe, tubing, or fittings. Caulking of joints will not be permitted. Concealed and insulated piping must be tested in place before concealing.

Submit pressure test reports for approval covering the above specified piping pressure tests; describe the systems tested, test results, defects found and repaired, and signature of the pressure tests' director. Obtain

SECTION 43 32 69 Page 14 approval from the COR before concealing piping or applying insulation to tested and accepted piping.

3.5.2 Liquid CBP Distribution System

After successful completion of the system pressure test, conduct operational tests including but not limited to; metering pump functional test (automatic and manual modes), [Am#0002] all other instrumentation devices installed and connected to the process control system. The test must be performed minimum of four (4) hours while all four (4) systems operate simultaneously. During the field test, verify and assure the equipment installation for leak, vibration, or any other unusual conditions, and the functionality of all control systems provided. If any deficiencies are revealed during any tests, correct such deficiencies and reconduct the tests. Submit final test reports of all tests in booklet form prior to final acceptance of the installation. Show all field tests performed to adjust each component and all field tests performed to prove compliance with the specified performance criteria, upon completion and testing of the installed system. Indicate in each test report the final position of controls. Submit valid Certificate of Calibration for the copper concentration test analyzer.

[Am#0002]3.6 FIELD TRAINING

Conduct a field training course for designated operating, maintenance and supervisory staff members. Contractor must submit a training plan at least 30 days prior to training date. Provide training for a total period of 8 hours of normal working time and start after the system is functionally complete but prior to final acceptance tests. At a minimum, the training must include: physical layout of each piece of hardware, calibration procedures, preventive maintenance procedures, troubleshooting, diagnostic procedures and repair instructions. In addition, followings must be thoroughly covered during the training;

1. Provide and review the preventative maintenance program requirements and O&M manual.

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2. PLC logic and HMI interfacing.

3. PLC & HMI troubleshooting and software update/interfacing requirements.

4. Flow meter & Injection Quill troubleshooting and replacement procedure.

3.7 CLOSEOUT ACTIVITIES

3.7.1 Operating Instructions

Submit complete copies of operating instructions outlining the step-by-step procedures required for system startup, operation and shutdown. Include in the instructions the manufacturer's name, model number, service manual, parts list, and brief description of all equipment and their basic operating features. Also include in the instructions as-built drawings of the tubing layout, equipment layout, simplified wiring and control diagrams of the system as installed.

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3.7.2 Maintenance Instructions

Submit complete copies of maintenance instructions listing routine maintenance procedures and frequencies, manufacturer information, troubleshooting guides, and ordering information for all equipment & materials provided including; metering pumps, flow meters, injection quills, [Am#0002] spill containments, valves, HMI, PLC, and other equipment/materials provided. Include in the instructions, layout, wiring and control diagrams of the system as installed, the manufacturer's name, model number, service manual, parts list and a brief description of all equipment and their basic operating features.

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