CITY OF PETALUMA ELLIS CREEK WATER RECYCLING FACILITY

Kennedy/Jenks Consultants

CITY OF PETALUMA ELLIS CREEK WATER RECYCLING FACILITY

BIOMASS TO BIOFUEL (B2B) PROJECT CNG FUELING STATION PROJECT NO. C66501518

100% DESIGN SUBMITTAL VOLUME 5

TECHNICAL SPECIFICATIONS – DIVISIONS 2-17

September 2017

KENNEDY JENKS PROJECT NO. 1668020*00

Kennedy/Jenks Consultants

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City of Petaluma Biomass to Biofuel Project 1668020*00 © 2015 Kennedy/Jenks Consultants

1 Table of Contents CNG Fueling Station

VOLUME 5 – CNG FUELING PROJECT TECHNICAL SPECIFICATIONS

TABLE OF CONTENTS

DIVISION 00 – PROCUREMENT AND CONTRACTING REQUIREMENTS (SEE VOLUME 1)

DIVISION 01 – GENERAL REQUIREMENTS (SEE VOLUME 1)

DIVISION 02 – SITEWORK

Section 02050 Demolition Section 02301 Earthwork Section 02705 Asphalt Paving Section 02820 Fences DIVISION 03 – CONCRETE

Section 03200 Concrete Reinforcing Section 03300 Cast-in-Place Concrete Section 03350 Concrete Finishing DIVISION 05 – METALS

Section 05090 Metal Fastenings Section 05500 Metal Fabrications (Miscellaneous Metals)

DIVISION 07 – THERMAL AND MOISTURE PROTECTION

Section 07900 Joint Sealants DIVISION 09 – FINISHES

Section 09960 High Performance Coatings DIVISION 10 - SPECIALITIES

Section 10400 Signage DIVISION 11 – EQUIPMENT

Section 11001 General Equipment and Mechanical Requirements Section 11002 Electric Motor Drives Section 11209 Rotary Actuators Section 11300 Gas Treatment System Section 11381 Digester Gas Processing Equipment Section 11700 Waste Gas Burner Section 11750 Vehicle Fuel Equipment DIVISION 15 – MECHANICAL

Section 15050 Process Piping, Valves and Accessories

Table of Contents CNG Fueling Station

2 City of Petaluma Biomass to Biofuel Project

1668020*00 © 2015 Kennedy/Jenks Consultants

Section 15400 Plumbing DIVISION 16 – ELECTRICAL

Section 16010 General Requirements for Electrical Work Section 16015 Testing of Electrical Systems Section 16020 ARC Flash Analysis, Short Circuit Study and Protective Device Coordination Report Section 16110 Raceways, Fittings, and Supports Section 16120 Low Voltage Conductors, Wires and Cables Section 16122 Medium Voltage Cable Section 16130 Junction and Device Boxes and Fittings Section 16140 Wiring Devices Section 16160 Panelboards Section 16180 Overcurrent Protective Devices Section 16402 Underground Electrical Work Section 16405 Switchboards Section 16442 Padmount Sectionalizers Section 16450 Grounding Systems

Section 16460 Padmount Transformers Section 16500 Luminaires DIVISION 17 – PROCESS INTEGRATION

Section 17010 Instrumentation and Controls, General Requirements Section 17120 Flow Measurement Section 17150 Pressure Measurement Section 17300 Control Strategies


02050 - 1 Demolition CNG Fueling Station

SECTION 02050

DEMOLITION PART 1 - GENERAL 1.01 DESCRIPTION

A. Provide all demolition required to perform the work covered under this contract including without limitation: 1. Remove existing construction shown to be removed. 2. Remove existing asphalt concrete paving as shown on the drawings. 3. Remove and replace existing construction and/or finishes as required to provide

access to perform other work included in this contract. 4. Include removal of mechanical and electrical work that is to be abandoned and

is contained in construction to be removed whether or not the mechanical and electrical work is shown. Disconnect and cap off utilities in accordance with applicable codes and safety regulations.

5. Where utilities that are not shown pass through construction that must be removed and those utilities serve other areas notify the Owner before disrupting service. If rerouting is required to maintain service, the Owner may issue a Change Order to accomplish the required work.

6. Store and protect items intended for reuse. 7. Assume ownership of debris and unwanted materials, remove from the site and

dispose of legally. 1.02 NOISE AND DUST CONTROL

A. Provide temporary partitions to control dust and noise and exclude unauthorized persons.

B. Perform work in a manner to cause least disturbance to building occupants and

least damage to work to remain. C. Maintain adequate means of safe, clear egress for building occupants. D. Employ all available techniques for construction noise abatement. Use remote,

well-mufflered air compressors and newest noise suppressed pneumatic and electric tools.

1.03 WARNING

A. The Contractor is advised that work under this Section may be hazardous. The Contractor is to take all necessary precautions to ensure the safety of workers and property. Removal of and/or working in areas containing even minor amounts of hazardous material including without limitation, asbestos, lead-based paint, PCBs or other hazardous materials requires special precautions, knowledge and procedures. If hazardous material is suspected, notify the Owner.

Demolition CNG Fueling Station

02050 - 2 City of Petaluma Biomass and Biofuel Project


1.04 SUBMITTALS

A. Digester gas piping and appurtenances purging and cutting Plan 1. Submit a digester gas piping purging and cutting plan for review in accordance

with Section 01330 that describes the proposed method for safely removing digester gas piping and components. The plan shall be submitted prior to completing any demolition work.

2. Include the specific approach to purge digester gas piping with nitrogen prior to initiating any disassembly.

3. Specifically address monitoring for digester gas, methane, lower explosive limit, oxygen content, and hydrogen sulfide to insure a safe working environment.

4. Minimize cutting of the digester gas piping. The Contractor shall not use a torch to cut digester gas piping. As part of the shutdown plan, the Contractor shall indicate whether piping needs to be cut, and if so, indicate the planned equipment and methodology to cut the pipe to avoid unsafe conditions.

5. The Digester Gas Purging and Cutting Plan shall be included in the sequence of construction for the complete digester gas piping system to be submitted per Specification Section 01324.

PART 2 – PRODUCTS (NONE) PART 3 - EXECUTION 3.01 REMOVAL OF BURIED PIPING

A. Contact Owner for assistance in field locating buried pipe to be demolished. After pipe is located on the surface, pothole to verify location and depth prior to digging. Locate any other adjacent piping prior to digging.

B. Once piping to be removed is exposed, notify Owner prior to cutting any buried

piping. Verify pipe is out of service and depressurized before cutting. After removing sections of pipe to be demolished cap the pipeline with a flanged coupling adapter with blind flange.

3.02 REMOVAL OF ASPHALT CONCRETE

A. Remove asphalt concrete as shown on the drawings to the extents required to permit new grading and new paving.

3.03 REMOVAL OF CONSTRUCTION IN AREAS TO RECEIVE NEW WORK

A. Protect mechanical and electrical work that serves other areas. Relocate concealed mechanical and electrical work that is required to preserve service to other areas.

B. Remove structural work designated for removal. Take precautions not to damage

structural work intended to remain. Where temporary shoring is needed, submit a



design prepared by an appropriately licensed engineer for review before proceeding.

C. If structural elements are encountered that were not shown, protect them from

damage and report their presence to the Owner. 3.04 REMOVAL OF LIMITED PORTIONS OF EXISTING CONSTRUCTION TO PERMIT

MODIFICATIONS

A. Provide careful, selective cutting and removal of existing construction as required to permit relocation or modification of piping, asphalt, or other items designated for demolition. Cut and remove the least amount of work possible except when a larger area needs to be removed to permit strengthening existing construction or when required to remove finishes to a natural break line such as a corner or change in material.

B. Protect existing construction to remain with temporary coverings. C. Treat existing mechanical, electrical or structural work as described in other parts of

this Section. D. When modifications are complete, replace removed work with new construction and

finishes to match adjacent existing work. Standards of material and workmanship shall be in accordance with other portions of this Specification or if not covered then in accordance with current practice for this class of work. Salvaged materials may be used for replacement if in good condition.

3.05 REMOVAL OF EXISTING CONSTRUCTION TO PROVIDE ACCESS TO PERFORM

WORK

A. Provide careful selective cutting and removal of existing construction where required to permit installation of new mechanical or electrical work, or installation of equipment.

B. Treat existing mechanical, electrical or structural work as described in other parts of

this Section. C. Replace and/or patch removed construction and finishes in accordance with other

parts of this Section. 3.04 PROTECTION OF WORK TO REMAIN

A. Protect all work to remain. Repair damage with materials, workmanship and finishes matching existing work when new.

B. Existing paved roads outside the work area will not be replaced in this contract. It is

essential that these paved roads be protected from any damage due to impact, dirt, abrasion, paints and solvents.




C. The Contractor shall protect all buildings, wastewater containing structures, digesters, conduits, equipment, instrumentation, and piping from demolition activities. Protection shall include, but not be limited to, plywood, canvas, plastic sheeting, supporting framing, and additional measures as required to protect existing and newly installed facilities.

3.05 CUTTING HOLES IN CONCRETE AND/OR CONCRETE UNIT MASONRY

A. The Contractor is cautioned that electrical conduits and reinforcing that are not shown on drawings may be concealed in concrete CMU construction. Use electronic detection equipment to locate concealed items before cutting holes. Take all required precautions to avoid damage to existing conduits or reinforcing.

B. New openings in existing concrete walls or slabs may be saw cut to opening

perimeter lines where drawings do not call for adding reinforcing trim bars to strengthen openings. Do not run saw kerfs past corners of openings. Complete concrete removal at opening corners by chipping and grinding. Take all required precautions to avoid water damage to existing construction or the Owner's property.

C. Where drawings call for adding reinforcing trim bars to strengthen openings, limit

saw cutting to a depth of 3/4-inch to avoid cutting existing reinforcing steel. Carefully chip out concrete to avoid damaging existing reinforcing steel which is to remain.

D. Use chipping guns to chip out small holes for pipes or conduits. Proceed carefully

to avoid damage to concealed conduits. Core drilling is permitted only at the Contractor's risk and only with the Owner’s permission. If core drilling is used, the Contractor shall: 1) use electronic detection equipment to locate conduit before drilling, 2) take precaution to avoid water damage to existing construction or the Owner's property, and 3) replace, at its own expense, any damaged electrical or signal wiring or conduits.

3.06 IF HAZARDOUS MATERIALS ARE ENCOUNTERED

A. If hazardous materials are discovered, comply with all applicable laws. 3.07 REMOVAL AND DISPOSAL OF MATERIAL

A. Use rubber tired covered buggies with rubber bumpers to transport debris through occupied sections of buildings.

B. Store debris in suitable covered containers within the work area or as directed by

the Owner and remove from site when full. Burning on the site is not permitted. C. Removed material (other than material to be reused) shall become the property of

the Contractor who shall remove it from the site and dispose of it in a legal manner.

3.09 CLEAN-UP



A. The Contractor shall remove from the site all debris resulting from the demolition operations as it accumulates and at least 2 times a week, upon completion of the immediate demolition work, the Contractor shall thoroughly clean each area.

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02301 - 1 Earthwork CNG Fueling Station

SECTION 02301

EARTHWORK PART 1 - GENERAL 1.01 SUMMARY

A. Section Includes: Perform all excavation, shoring, dewatering, backfilling, compaction and grading necessary or required for the construction of the work as covered by these Specifications and indicated on the Drawings. The excavation shall include, without classification, the removal and disposal of all materials of whatever nature encountered, including water and all other obstructions that would interfere with the proper construction and completion of the required work.

1.02 REFERENCES

A. American Society for Testing and Materials (ASTM). B. State of California, Department of Transportation, Standard Specifications 2010

(Standard Specifications). C. State of California, Department of Transportation, Manual of Test (California Test).

1.03 SUBMITTALS

A. Submit in accordance with Section 01330. B. Submit the following under the Product Review category.

1. Potholing Report as described in Paragraph 3.02. 2. Samples and Test Results: Furnish, without additional cost to the City, such

quantities of import materials as may be required by the City Representative for test purposes. Cooperate with the City Representative and furnish necessary facilities for sampling and testing of all materials and workmanship. Submit test results for import materials. Tests shall be performed within 60 days of the submission. All material furnished and all work performed shall be subject to rigid inspection, and no material shall be delivered to the site until it has been favorably reviewed by the City Representative, or used in the construction work until it has been inspected in the field by the City Representative.

3. Groundwater monitoring and dewatering plan. Include: a. Details of well construction, pumps, piping, controls, etc. b. Layout plan. c. Documentation of the system designer’s qualifications and experience.

d. Groundwater disposal plan demonstrating compliance with all regulatory requirements.

Earthwork CNG Fueling Station



1.04 QUALITY ASSURANCE

A. Source Quality Control: Test import materials proposed for use to demonstrate that the materials conform to the specified requirements. Tests shall be performed by an independent testing laboratory.

B. Field Quality Control:

1. The City will: a. Review and test materials proposed for use. b. Observe foundations, site grading and borrow operations. c. Observe placement and compaction of fill. d. Test soils during placement of fill.

2. Contractor shall excavate holes for in-place soil sampling. Contractor shall be responsible for costs of additional inspection and re-testing resulting from non-compliance.

3. Contractor shall: a. Excavate holes for in-place soil sampling. b. Test soils during placement of fill to verify conformance with material

requirements defined herein. c. Be responsible for costs of additional inspection and re-testing resulting

from non-compliance.

C. Testing Methods: 1. Durability Index: Manual of Test, State of California, Department of

Transportation. 2. Specific Gravity: ASTM D854 3. Laboratory Compaction: ASTM D1557, Method A or C. 4. In-place Density: ASTM D1556 or ASTM D2922. 5. Particle Size Analysis of Soils: ASTM D422. 6. Plastic Limit and Plasticity Index: ASTM D4318. 7. Soil Classification: ASTM D2487. 8. In-place Moisture Content: ASTM D3017.

D. Definitions

1. Relative Compaction: In-place density divided by the maximum dry density laboratory compaction expressed as percentage.

1.05 EXPLOSIVES

A. Do not use explosives unless specifically authorized, in writing, by the City Representative.

B. Any construction procedure elected by the Contractor that involves the use of

explosives shall be performed in accordance with all applicable Federal, State, and local laws and regulations. The Contractor shall obtain all permits required for such use of explosives and shall have complete responsibility for their transportation, storage, and use.



1.06 SUBSURFACE INVESTIGATIONS

A. Design for this project is based on geotechnical investigations documented in: 1. An Integrated Geotechnical Study, Lakeville Highway WRF – Parcel A,

Petaluma, California dated April 2005 submitted by Fugro West, Inc. 2. A Geotechnical Engineering and Geologic Hazards Study for the Ellis

Creek Water Recycling Facility, Biomass to Biofuel Project, submitted by Consolidated Engineering Laboratories on November 23, 2016 and revised on January 31, 2017.

B. These reports are available for examination by bidders from the City. While the

records of data obtained may be considered by the Contractor to be correct, any conclusions or recommendations made in the reports are for information to the Design Engineer and are not a part of the Contract Documents. The boring logs and their locations can be found in the Geotechnical Exploration report.

C. The bidders may make additional subsurface investigations at the site prior to the

bidding of the project. Prior to making any drillings or excavations, the bidder shall secure permission from the City, and property owners if on private property.

1.07 REFERENCE SPECIFICATIONS

A. Whenever the words "Standard Specifications" are referred to, the reference is to the State of California, Department of Transportation, Standard Specifications, latest edition.

1.08 ADDITIONAL SAFETY RESPONSIBILITIES

A. The Contractor shall select, install and maintain shoring, sheeting, bracing, and sloping as necessary to maintain safe excavations. The Contractor shall be responsible for ensuring such measures: (1) comply fully with 29 CFR Part 1926 OSHA Subpart P Excavations and Trenches requirements, (2) provide necessary support to the sides of excavations, (3) provide safe access to the City Representative’s sampling and testing within the excavation, (4) provide safe access for backfill, compaction, and compaction testings, and (5) otherwise maintain excavations in a safe manner that shall not endanger property, life, health, or the project schedule. All earthwork shall be performed in strict accordance with applicable law, including local ordinances, applicable OSHA, CalOSHA, California Civil Code, and California Department of Industrial Safety requirements.

PART 2 - PRODUCTS 2.01 MATERIALS

A. Crushed Rock: Class 2, 3/4-inch maximum aggregate base, Standard Specifications Section 26.

B. Pipe Bedding Materials:

1. Crushed rock, per Section 2.01A.




C. Imported Backfill: Imported nonexpansive soil or soil-rock material free of organic matter and meeting the following requirements: 1. Gradation ASTM D-421: 100% passing 2-inch and 15-70% passing #200 sieve. 2. Plasticity ASTM D-4318: Liquid Limit < 30 and Plasticity Index < 12. 3. Swell Potential ASTM D-4546B: Percent Heave < 2% and Swell Pressure < 300

psf at optimum moisture. 4. Resistance Value ASTM D-844: Minimum 25. 5. Organic Content ASTM D-2974: Less than 2%. A sample of the proposed import material shall be submitted for evaluation prior to delivery at the site.

D. Engineered Backfill: Soil prepared as necessary to be free from clods or rocks

larger than 2 inches in greatest dimension, and free from organic material. Excavated on-site material will be considered suitable for engineered fill and backfill if it contains no more than 3 percent organic matter, is free of debris and other deleterious substances, is less than or equal to 4 inches in greatest dimension, no more than 15% of which is larger than 2.5 inches, and conforms to the requirements specified above. In addition, rocks of maximum dimension in excess of two-thirds of the lift thickness shall be removed from any fill material to the satisfaction of the City Representative. Rocks and aggregate not meeting these requirements shall be removed from the site and disposed off site in a legal manner. Excavated material determined suitable for use shall be conditioned for reuse and properly stockpiled as required for later filling and backfilling operations. Conditioning shall consist of spreading material in layers not to exceed 8 inches and raking free of debris and rubble.

E. Water: The water used shall be reasonably free of objectionable quantities of silt,

oil, organic matter, alkali, salts and other impurities. Water quality must be acceptable to the City Representative.

F. Aggregate Base: Refer to Section 2.01A above. G. Detection Tape: Plastic metallic type consisting of a blue color coded polyethylene

or melinex film, a solid core aluminum foil detection layer and other layers as required. The tape shall be resistant to acids, alkalines and other components likely to be encountered in soils. It shall be designed for both conductive and inductive locating procedures. Furnish color coded tape as appropriate for the utility type per the APWA Uniform Color Code Standard imprinted with “CAUTION UTILITY TYPE BELOW”. Terra Tape D" by Griffolyn Company; Detectatape by Allen Systems; or equal.

PART 3 - EXECUTION 3.01 CONTROL OF WATER

A. All excavations shall be kept free from water and all construction shall be in the dry. 1. It should be presumed that the presence of groundwater will require dewatering

operations. Furnish, install, maintain, and operate all necessary pumping and other equipment for dewatering all excavations. At all times have on the project



sufficient pumping equipment for immediate use, including standby pumps for use in case other pumps become inoperable.

2. Provide a sufficient number of pumps so as to hold the groundwater level at an elevation of not less than 1 foot below the lowest elevation of the pipe, duct or other material to be placed.

3. Dispose of water in such a manner as to cause no injury or nuisance to public or private property, or be a menace to the public health.

4. The dewatering operation shall be continuous, so that the excavated areas shall be kept free from water during construction, while concrete is setting and achieves full strength, and until backfill has been placed to a sufficient height to anchor the work against possible flotation.

5. Continue dewatering during backfilling operations such that the groundwater is at least 1 foot below the level of the compaction effort at all times. No compaction of saturated materials will be allowed.

6. Dewatering devices must be adequately filtered to prevent the removal of fines from the soil.

7. The Contractor shall be responsible for any damage to the foundations or any other parts of existing structures or of the new work caused by failure of any part of the Contractor's protective works. After temporary protective works are no longer needed for dewatering purposes, they shall be removed by the Contractor.

8. Prevent disposal of sediments from the soils to adjacent lands or waterways by employing whatever methods are necessary, including settling basins.

C. The Contractor shall be responsible for furnishing temporary drainage facilities to

convey and dispose of surface water falling on or passing over the site. 3.02 EXISTING UTILITIES

A. General: The known existing buried utilities and pipelines are shown on the Drawings in their approximate location. The Contractor shall exercise care in avoiding damage to all utilities as he will be held responsible for their repair if damaged. There is no guarantee that all utilities or obstructions are shown, or that locations indicated are accurate. Utilities are piping, conduits, wire, cable, ducts, manholes, pull boxes and the like, located at the project site.

B. Check on Locations (Potholing): Contact all affected utility owners and request

them to locate their respective utilities prior to the start of "potholing" procedures. The utility City shall be given 7 days written notice prior to commencing potholing. If a utility City is not equipped to locate its utility, the Contractor shall locate it.

C. Clearly paint the location of all affected utility underground pipes, conduits and other

utilities on the pavement or identify the location with suitable markers if not on pavement. In addition to the location of metallic pipes and conduits, non-metallic pipe, ducts and conduits shall also be similarly located using surface indicators and detection tape if present and shall then be similarly marked.

D. After the utility survey is completed, commence "potholing" to determine the actual

location and elevation of all utilities where crossings, interferences, or connections to new pipelines or other facilities are shown on the Drawings, marked by the utility companies, or indicated by surface signs. Prior to the preparation of piping shop




drawings, or the excavating for any new pipelines or structures, the Contractor shall locate and uncover these existing utilities to a point 1 foot below the utility. Submit a report identifying each underground utility and its depth and location. Any variation in the actual elevations and the indicated elevations shall be brought to the City Representative's attention.

E. Excavations around underground electrical ducts and conduits shall be performed

using extreme caution to prevent injury to workmen or damage to electrical ducts or conduits. Similar precautions shall be exercised around gas lines, telephone and television cables.

Excavations shall have a surface dimension of no more than 18" x 18". Air spades

and vacuum excavators shall be used to limit the size of the excavation and damage to adjacent facilities. Backfill after completing potholing. In existing streets pave with 1 inch of cold mix asphalt concrete.

F. Interferences: If interferences occur at locations other than shown on the Drawings,

the Contractor shall notify the City Representative, and a method for correcting said interferences shall be supplied by the City Representative. Payment for interferences that are not shown on the plans, nor which may be inferred from surface indications, shall be in accordance with the provisions of the General Conditions. If the Contractor does not expose all required utilities prior to shop drawing preparation, he shall not be entitled to additional compensation for work necessary to avoid interferences, nor for repair to damaged utilities.

G. Any necessary relocations of utilities, whether shown on the Drawings or not, shall

be coordinated with the affected utility. The Contractor shall perform the relocation only if instructed to do so in writing from the utility and the City Representative.

H. Shutdowns: Planned utility service shutdowns shall be accomplished during period

of minimum use. In some cases this may require night or weekend work. Such work shall be at no additional cost to the City. Program work so that service will be restored in the minimum possible time, and shall cooperate with the utility companies in reducing shutdowns of utility systems to a minimum. 1. Disconnections: No utility shall be disconnected without prior written approval

from the utility owner. When it is necessary to disconnect a utility, the Contractor shall give the utility owner not less than 72 hours notice when requesting written approval. The Contractor shall program his work so that service will be restored in the minimum possible time.

I. Overhead Facilities: There are existing overhead electric and telephone

transmission lines at the site. These overhead utilities are not shown on the Drawings. Extreme caution shall be used when working in the vicinity of overhead utilities so as to prevent injury to workmen or damage to the utilities. The Contractor shall be required to comply with the applicable provisions of the California Construction Safety Orders when working anywhere on this project.

3.03 GENERAL CONSTRUCTION REQUIREMENTS

A. Site Access: Access to the site will be over public and private roads. Exercise care in the use of such roads and repair at own expense any damage thereto caused by



Contractor’s operations. Such repair shall be to the satisfaction of the City or agency having jurisdiction over the road. Take whatever means are necessary to prevent tracking of mud onto existing roads and shall keep roads free of debris.

B. Barriers: Barriers shall be placed at each end of all excavations and at such places

along excavations as may be necessary to warn all pedestrian and vehicular traffic of such excavations.

C. Demolition of Pavement: Where trenching or excavation occurs in paved areas, the

pavement shall be scored and broken ahead of the trenching or excavation operation. The extent of paving removed shall be limited to the minimum necessary for the excavation.

D. Dust Control: Take proper and efficient steps to control dust.

E. Permits: Refer to General Conditions.

F. Storage of Materials: Neatly place excavated materials far enough from the

excavation to prevent stability problems. Keep the materials shaped so as to cause the least possible interference with plant operations and drainage.

3.04 COMPACTION

A. Add water to the backfill material or dry the material as necessary to obtain moisture content within 2% of optimum. Employ such means as may be necessary to secure a uniform moisture content throughout the material of each layer being compacted.

B. After the material has been moisture conditioned, compact it with compaction

equipment appropriate for the use to achieve specified compaction. C. If the backfill material becomes saturated from rains or any other source because it

was not compacted to the specified density or was not backfilled and compacted to surface grade, through negligence or otherwise, remove the faulty material and replace it with suitable material compacted to the specified density. No additional payment will be made for doing such work or removal and replacement.

D. Compaction of embankment and backfill materials by flooding, ponding or jetting is

not permitted. E. When densities of compacted materials do not meet the requirements, remove

and/or recompact the material until the requirements are met. The Contractor will be backcharged the cost of retesting all failing tests, including the initial retest. Such backcharges will be deducted from the Contractor's Progress Payments.

F. Material Requirements

1. Pipe Bedding Material: Compact to a minimum 95 percent of maximum density, in accordance with AASHTO T-99 unless otherwise specified or shown on the Drawings.

2. Imported Backfill, Engineered Fill, Structural Backfill: Compact to a minimum 95 percent of maximum density, in accordance with AASHTO T-99 unless otherwise specified or shown on the Drawings.




3. General Backfill: Compact to a minimum 85 percent of maximum density in unpaved areas, in accordance with AASHTO T-99 unless otherwise specified or shown on the Drawings.

4. Foundation Stabilization: Compact to a minimum 95 percent of maximum density, in accordance with AASHTO T-99 unless otherwise specified or shown on the Drawings.

G. Testing Frequency:

1. Trench Backfill: Test every 100 feet of trench. 2. Earthwork: Test every 500 square feet for each 2 feet of fill. 3. Engineered/Imported Backfill:

a. Sub-base: Test every 200 square feet. b. Base:

i. Test every 200 square feet of building footprint, with no less than 2 tests per structure.

ii. Test every 200 cubic yards of material placed within 10 feet around the building.

3.05 SITE GRADING

A. Scarifying: Scarify to a minimum 12-inch depth all areas where fills are required. Moisture condition the scarified surface to within 2% of optimum water content, and compact in accordance with the requirements of Section 3.04 unless otherwise specified or shown on the Drawings.

B. Fills:

1. Do not place any fill until the City Representative has inspected, tested to his satisfaction, and favorably reviewed the prepared subgrade.

2. Construct fills as shown on the Drawings, true to line, grade and cross-section. Construct fills of imported backfill. Place material in approximately 8-inch-thick horizontal layers measured before compaction, and carried across the entire width to the required slopes. Compact all fills in accordance with the requirements of Section 3.04 unless otherwise specified or shown on the Drawings. Properly moisture condition before compaction.

3. Imported backfill used to build up the grade beneath the slab on grade for the Gas Treatment and Vehicle Fuel Systems shall be placed at least 100 days prior to the placement and compaction of the structural backfill for these structures.

4. Where fills are to be made and compacted on sloping ground surfaces, steeper than 5:1, such slopes shall be benched a minimum of 6 feet horizontally as the work is brought up. Recompact material thus removed by benching along with the new embankment material.

5. It may be necessary to overbuild slopes and trim back to the compacted core to achieve adequate compaction of slope faces.

C. Ditches: Cut ditches accurately to the cross sections and grades shown. Take care

not to overexcavate ditches, and backfill excessive excavation to grade. Trim all roots, stumps, rock and other foreign matter from the sides and bottom of the ditches. Compact the surfaces of ditch slopes and bottom.



D. Landscaped Areas: Use Landscape Fill in the top 2 feet of areas to be landscaped, compacted in accordance with the requirements of Section 3.04 unless otherwise specified or shown on the Drawings.

E. Removal of existing soil: The City Representative will determine in the field if

additional depth of native material shall be removed prior to placing fill.

3.06 TRENCH EXCAVATION

A. Excavation for pipe and other utilities such as duct banks shall be in open cut. The trench shall be as wide as necessary for sheeting and bracing and the proper performance of the work up to the maximum width permitted by the typical cross-sections shown on the Drawings. The sides of the trenches shall be vertical in paved areas. The bottom of the trench shall be constructed to the grades and shapes indicated on the Drawings. Should the Contractor desire to use other equivalent methods, he shall submit his method of construction to the City Representative for favorable review prior to its use.

B. Take care not to overexcavate. Accurately grade the bottom of the trenches to

provide uniform bearing and support for each section of the pipe or conduit at every point along its entire length, except for the portions of the pipe sections where it is necessary to excavate for bell holes and for the proper sealing of pipe joints, and as hereinafter specified. Dig bell holes and depressions for joints after the trench bottom has been graded. In order that the pipe rest on the bedding for as nearly its full length as practicable, bell holes and depressions shall be only of such length, depth and width as required for properly making the joint. Remove stones as necessary to avoid point bearing.

C. Backfill and compact overexcavations in accordance with the requirements of

Section 3.04 with bedding material. There shall be no additional payment to the Contractor for overexcavations not directed by the City Representative. Remove unsatisfactory material encountered below the grades shown as directed by the City Representative and replace with bedding material. Payment for removal and replacement of such unsatisfactory material directed by the City Representative shall be made in accordance with the provisions of the General Conditions.

D. Grade trenches so that they are uniformly sloped between the pipe elevations

shown on the Drawings. If no elevations are shown on the Drawings, provide 3 feet of minimum cover. Comply with the minimum and maximum trench widths shown on the Drawings. Notify the City Representative if the trench width exceeds the maximum allowable width for any reason.

E. For all piping or conduits to be placed in any excavated and backfilled area, such as

at manholes or for building connections, the structural backfill shall be first compacted to a level at least 3 feet from the top of the piping or conduit elevation and then retrenched to pipe grade.

F. Provide ladders for access to the trench by construction and inspection personnel.

3.07 EXCAVATION FOR STRUCTURES




A. All excavation for structures shall be done to the dimensions and levels indicated on the Drawings or specified herein. Excavate to such width outside the lines of the structure to be constructed as may be required for proper working methods, the erection of forms and the protection of the work.

B. Take care to preserve the foundation surfaces in an undisturbed condition. If the

Contractor overexcavates or disturbs the foundation surfaces shown on the Drawings or specified herein, without written authorization of the Engineer, he shall replace such foundations with concrete fill or other material approved by the Engineer in a manner that will show by test an equal bearing value with the undisturbed foundation material. No additional payment will be made for the added quantity of concrete fill or other material used because of overexcavation.

C. Inspection of Excavation: Notify the Engineer when excavation for the structure is

complete. No forms, reinforcing steel, concrete, or precast structure shall be placed until the excavation has been inspected by the Engineer.

D. Where unsatisfactory material is encountered below the grades shown for structural

excavations, it shall be removed and replaced with engineered backfill or imported backfill as directed by the Engineer and compacted. Payment for removal and replacement of such unsatisfactory material directed by the Engineer shall be made in accordance with the provisions of the General Conditions.

3.08 SUPPORT OF EXCAVATIONS

A. Adequately support excavation for trenches and structures to meet all applicable requirements in the current rules, orders and regulations. Excavation shall be adequately shored, braced and sheeted so that the earth will not slide or settle and so that all existing structures and all new pipe and structures will be fully protected from damage. Keep vehicles, equipment, and materials far enough from the excavation to prevent instability.

B. Take all necessary measures to protect excavations and adjacent improvements

from running, caving, boiling, settling, or sliding soil resulting from the high groundwater table and the nature of the soil excavated.

C. The support for excavation shall remain in place until the pipeline or structure has

been completed. During the backfilling of the pipeline or structure, the shoring, sheeting and bracing shall be carefully removed so that there shall be no voids created and no caving, lateral movement or flowing of the subsoils.

3.09 TRENCH BACKFILL

A. Place bedding and backfill materials true to the lines, grades, and cross-sections indicated on the Drawings and compacted to the degree specified on the Drawings. Place bedding and backfill materials in horizontal lifts not to exceed 6 inches in thickness measured before compaction. The difference in level on either side of a pipe shall not to exceed 4 inches.

B. Backfill material shall not be placed over the pipe or conduit until after the joints

have been completed and inspected by the City Representative.



C. It shall be incumbent upon the Contractor to protect the pipe or conduit from

damage during the construction period. It shall be his responsibility to repair broken or damaged pipe at no extra cost to the City. Carefully place backfill around and over the pipe and do not allow it to fall directly upon the pipe. Tamping of backfill over the pipe shall be done with tampers, vibratory rollers and other machines that will not injure or disturb the pipe.

D. Do not allow construction traffic nor highway traffic over the pipe trench until the

trench backfill has been brought back even with existing adjacent grade. 3.09 STRUCTURAL BACKFILL

A. Crushed Rock Subgrade: Place a layer of rock, compacted in accordance with the requirements of Section 3.04, under structures to the lines, grades and minimum thicknesses shown on the Drawings. Unless shown specifically otherwise in the Drawings, do not use rock as backfill above the elevation of the highest base slab of the structure.

B. Backfill Adjacent to Structures:

1. Backfill shall be structural backfill compacted in accordance with the requirements of Section 3.04 unless otherwise specified or shown on the Drawings.

2. Do not place backfill against structures until the concrete has been patched and cured.

3. Do not place backfill against structures until at least 28 days after the concrete was placed, or until the concrete has achieved a strength of at least 2,500 psi, whichever is earlier. Concrete strength shall be demonstrated by field cured cylinders tested at the Contractor's cost, prepared and tested in accordance with ASTM C31 and ASTM C39.

4. Do not place backfill against hydraulic structures until the structure has passed the specified leakage tests.

5. Place backfill in uniform, level layers, not exceeding 8 inches thick measured before compaction. Bring backfill up uniformly on all sides of the structure, and on both sides of buried walls.

3.10 FINISH GRADING

A. Finish grade the site to match existing conditions. Finish grading shall be uniform and pleasing and shall provide drainage from all areas to collection points. The finished surfaces shall be smooth and compacted.

3.11 DISPOSAL OF EXCAVATED MATERIAL

A. Dispose of unsuitable material or excavated material in excess of that needed for backfill or fill offsite in accordance with the requirements of Section 01440.

END OF SECTION




PAGE INTENTIONALLY

LEFT BLANK


02705 - 1 Asphalt Paving CNG Fueling Station

SECTION 02705

ASPHALT PAVING

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: Furnishing all labor, material, equipment, tools, and services required for the placing and compacting of asphalt concrete pavement and aggregate surfacing for roadways, parking lots, and walkways to the lines, grades, and dimensions shown on the Drawings and as specified herein. Also included is the repair and resurfacing of existing roadway and area paving damaged or removed during construction.

1.02 REFERENCE SPECIFICATIONS

A. Whenever the words "Standard Specifications" are referred to, the reference is to the State of California, Department of Transportation, Standard Specifications dated 2010.

B. ASTM International (ASTM): 1. D1556 Test Method for Density and Unit Weight of Soil in Place by the

Sand-Cone Method 2. D2922 Test Method for Density of Soil and Soil Aggregate in Place by

Nuclear Method (Shallow Depth)

1.03 SUBMITTALS

A. Submit in accordance with Section 01330.

B. Submit the following under the Product Information category. 1. Samples: Furnish, without additional cost to the City, such quantities of

construction materials as may be required by the City Representative for test purposes. The Contractor shall cooperate with the City Representative and furnish necessary facilities for sampling and testing of all materials and workmanship. All materials furnished and all work performed shall be subject to rigid inspection, and no materials shall be used in the construction work until it has been inspected by the City Representative.

2. Submit a signed verification from each source of supply for each construction material employed on this project indicating that the materials meet the Specification requirements.

3. Mix design for asphalt concrete and test results of California Test 367. 4. Submit manufacturer's certification of the actual volatile organic compound

(VOC) content for all pavement paints and bituminous pavement sealers proposed for use on this project. Submit certification of the actual VOC content for coatings manufactured after 1 September 1987. For coatings manufactured before 1 September 1987, submit VOC content and date of manufacture. VOC content shall be measured in grams per liter by weight of coating as applied excluding water and color added to the tint base.

Asphalt Paving CNG Fueling Station

02705 - 2 City of Petaluma Biomass to Biofuel Project


5. Submit verification that bituminous pavement sealers and paint products furnished meet applicable regulations as to allowable VOC content for the time and place of application and use intended.


A. Comply with "Standard Specifications" of State of California, Department of Transportation (CALTRANS) 2010.

1.05 REGULATORY REQUIREMENTS

A. All work, material, procedures and practices under this Section shall conform with requirements of the California Air Resources Board (CARB) and the Bay Area Air Quality Management District (BAAQMD).

PART 2 - PRODUCTS

2.01 PAVING MATERIALS

A. Aggregate Base: Standard Specifications, Section 26. Class and size as indicated on the Drawings; or if not indicated on the Drawings, use Class 2, ¾-inch maximum.

B. Prime Coat: Liquid asphalt, Grade SC-70 or MC-70, Standard Specifications, Section 93.

C. Tack Coat and Seal Coat: Emulsified asphalt, Grade SS-1 or SS-1h, Standard Specifications, Section 94.

D. Asphalt Concrete: Type A, ½-inch maximum, medium grading, Standard Specification Section 39. The asphalt binder shall be PG 64-16 meeting the requirements of Section 92.

2.02 HEADERS

A. Unless indicated otherwise on the Drawings, headers shall be installed as specified below.

B. At straight sections, wood headers shall be constructed of 2-inch by 6-inch construction heart redwood, held in place by 2-inch by 4-inch stakes, of the same materials, 2 feet long and set at 8-foot centers.

C. At curved sections, wood headers shall be constructed of three ½-inch by 4-inch construction heart redwood bender boards. Boards shall be lapped at one-third of the length of individual boards, with no two boards lapped at the same place. Hold boards in place with stakes same as above.

PART 3 - EXECUTION

3.01 GENERAL

A. This Specification shall cover newly surfaced areas as well as restoration of existing surfacing.

B. Adjust existing and new manholes, meter boxes, cleanouts, etc. to match the new grade.


02705 - 3 Asphalt Paving CNG Fueling Station

3.02 PAVEMENT CUTTING

A. After backfilling trenches and prior to paving, saw cut existing pavement parallel to the trench (using a concrete saw) to a minimum depth equal to or greater than one-half the thickness thereof.

B. The pavement shall be cut back 6 inches on each side of the trench or excavation wall.

C. Re-cut and restore any pavement damaged outside these lines at the expense of the Contractor.

D. Should voids develop under the existing pavements during construction, those affected pavements shall be neatly saw cut in straight lines and replaced after the voids have been filled.

3.03 PLACEMENT OF AGGREGATE BASE

A. Subgrade Preparation: 1. Water or dry subgrade as required to bring the soil to within 2% of the

optimum moisture content for proper compacting. 2. Compact to a relative compaction of not less than 95% in the upper 6 inches. 3. When compaction of the subgrade areas on fill and embankments has been

properly obtained, only such additional rolling will be required as necessary to obtain a thoroughly compacted subgrade immediately prior to placing the aggregate base thereon.

B. Aggregate Base Tolerance: 1. Do not place the aggregate base before the subgrade is approved by the City

Representative. 2. The finished aggregate base shall not vary more than 0.05 foot above, nor

0.10 foot below, the planned grade.

C. Aggregate Base Placing: 1. Spread the aggregate base material on the prepared subgrade by means of

suitable spreading devices. 2. The aggregate base material may be dumped in piles upon the subgrade and

spread by bulldozing ahead from the dumped material. 3. Each layer shall not exceed 0.50 feet. 4. Segregation of large or fine particles of aggregate shall be avoided, and the

material as spread shall be free from pockets of large and fine material.

D. Compaction: 1. Compact each layer of aggregate base material to not less than 95% relative

compaction as determined by Test Method Calif. No. 216 or ASTM D1556 (Sand Cone), or Calif. No. 231 or ASTM D2922 (Nuclear method when approved by the City Representative).

2. Compaction shall be in accordance with Section 26-1.03D of the Standard Specifications.

3. Water aggregate base after compaction as provided in Section 17 of the Standard Specifications.

3.04 ASPHALT CONCRETE INSTALLATION

A. Apply prime coat at a rate of 0.15-gallon per square yard. Blot any excess which has not penetrated the base with sand. Remove any loose sand.

Asphalt Paving CNG Fueling Station



B. Apply tack coat a rate of 0.05-gallon per square yard.

C. Spread and compact asphalt concrete in accordance with Standard Specifications Section 39 to the thickness shown on the Drawings.

D. Protect asphaltic concrete paving until surface has cooled sufficiently to permit traffic without damage.

E. Immediately remove spilled and splattered materials from adjacent surfaces.

3.05 PAVEMENT MARKINGS

A. Replace existing pavement markings that are removed or damaged by the construction.

B. Apply pavement markings in accordance with Section 84 of the Standard Specifications.

3.06 HEADERS

A. Install wood headers along pavement edges where indicated on the Drawings. Install new headers where existing wood headers are damaged during construction, or removed for construction. Install headers with uniform slope between spot elevation indicated on the Drawings or to conform to existing grades.

END OF SECTION


02820 - 1 Fence CNG Fueling Station

SECTION 02820

FENCES PART 1 - GENERAL 1.01 SUMMARY

A. All materials and work required for the furnishing and installation of chain link fence, and appurtenances, including temporary fence.

B. Related Sections:

1. Section 03300: Cast-In-Place Concrete 1.02 REFERENCES

A. American Society for Testing and Materials (ASTM): 1. A53 Specification for Pipe, Steel Black and Hot-Dipped, Zinc-Coated, Welded

and Seamless 2. A121 Specification for Zinc-Coated (Galvanized) Steel Barbed Wire 3. A702 Specification for Steel Fence Posts and Assemblies

B. State of California, Department of Transportation, Standard Specification (Standard Specification) 2010.

1.03 STANDARD SPECIFICATIONS

A. All work and materials shall conform to the requirements of Section 80 of the Standard Specifications, except as modified herein. Paragraphs 80-3.03, 80-3.04, do not apply. In case of any conflict between the Standard Specifications and the Contract Plans and Specifications, the latter shall control.

1.04 SUBMITTALS

A. Submit in accordance with Section 01300. B. Submit in the Product category complete descriptive information and technical

specifications on the chain link fence and appurtenances. PART 2 - PRODUCTS 2.01 TEMPORARY FENCING

A. Temporary fencing shall consist of hot-dip galvanized or painted steel, or pretreated or untreated wood posts and braces of suitable length and strength to provide for cantilever support of 5 strands of barbed wire with top strand placed 4 feet above the ground surface. Bottom wire shall be not more than 9-1/2 inches above ground surface and the remaining strands between top and bottom strands shall be equally spaced.

Fences CNG Fueling Station



B. Materials:

1. Steel fence posts and assemblies shall conform to ASTM A702. Posts and assemblies shall be T-shape Class B steel with anchor plates, painted or hot-dip galvanized and not less than 7-1/2 feet long. The anchor plate may be omitted if the posts and assemblies are firmly embedded to a minimum depth of 3 feet in a concrete footing with a minimum diameter of 6 inches.]

2. Pretreated wood posts shall conform to Section 80-2.02C (1) of the Standard Specifications.

3. Untreated wood posts shall conform to Section 80-2.02C (2) of the Standard Specifications.

4. Barbed wire shall conform to ASTM A121, Class 3, 12-1/2 gauge wire with 4-point round barbs.

2.03 CHAIN LINK FENCING

A. Chain link fence fabric shall be 10 feet high and shall be black vinyl coated 3/8-inch mini-mesh. Fabric shall have twisted top and bottom knuckled top and bottom twisted top and knuckled bottom knuckled top and twisted bottom selvages.

B. Unless otherwise shown on the Drawings, the fence shall have top and bottom

tension wires top rail and bottom tension wire, and outbound extension arms with three strands of barbed wire.

C. Fence posts, braces and top rails shall be Schedule 40 galvanized steel pipe

ASTM A53. Line posts shall be 2 inches in diameter. Corner and end posts shall be 2-1/2 inches in diameter. Gate posts shall be a minimum of 3-1/2 inches

in diameter. Braces and top rails shall be 1-1/4-inches in diameter. Posts shall have galvanized caps to exclude moisture. Truss rods shall be 3/8-inch-diameter galvanized steel. Turnbuckles, tension wires, tie wires and hog rings shall conform to Section 80-3.02D of the Standard Specifications.

D. Barbed wire shall be installed where shown on the Drawings. Barbed wire shall

conform to ASTM A121, Class 3, 12-1/2 gauge wire with 4-point round barbs. E. Redwood privacy slats shall be installed in the chain link fabric where shown on the

Drawings. Slats shall be rough cut 3/8-inch x 2-3/8-inch redwood in lengths to equal the fence height.

F. Concrete foundations for fence posts shall be as detailed on the Drawings and as

specified in Section 03 30 00. PART 3 - EXECUTION 3.01 TEMPORARY FENCING

A. Where it is necessary to temporarily remove or alter portions of the existing fence, the Contractor shall install adequate bracing to maintain original tension in the remaining fence. Temporary fencing shall be installed to maintain security. The


02820 - 3 Fence CNG Fueling Station

fencing shall be of adequate design to prevent inadvertent access by either people or livestock. Upon completion of the work, remove the temporary fencing and rebuild and restore all fences to their original position, or revised position as shown on the Drawings, using all new material. Salvaged existing materials may be used if undamaged and if approved by the Engineer.

3.02 REMOVAL AND SALVAGING OF EXISTING FENCING

A. General: Fencing shall be removed as noted on the Drawings. The fencing to be removed is in satisfactory condition to be salvaged and relocated.

B. Salvaging: The Contractor shall remove and stockpile fabric, posts and accessories

identified by the Engineer as salvageable in such a manner as to assure that no damage will be incurred. Should the Engineer determine that the salvaged posts have been bent, that the zinc coating on any of the salvaged materials has been scratched, or that the salvaged fencing materials have been otherwise damaged, they shall be replaced by new materials at no cost to the City.

3.03 INSTALLATION OF CHAIN LINK FENCING

A. Install chain link fencing and gates at the locations shown on the Drawings and in accordance with Section 80-4.02 of the Standard Specifications. Chain link fabric and barbed wire shall be stretched with mechanical equipment.

B. The area to be fenced shall be uniformly and smoothly finish graded before

beginning the fence installation. Fence shall be installed after roadway surfacing has been completed. Except where crossing a drainage ditch, the finish grade shall not deviate from a straight line by more than 3 inches. Where crossing a drainage ditch, a line post shall be provided at the top of slope on each side and the fabric shall follow a straight line between the posts. Within the ditch, short post sections shall be embedded to a depth of 4 feet at a maximum spacing of 12 inches on center across the ditch. Posts shall be long enough to overlap the fabric by 12 inches, and each post shall be fastened to the fabric by a minimum of 3 tie bands.

C. Corner and end post assemblies and the panels on each side of all gates shall be

as detailed on the State of California, Department of Transportation, Standard Plans and 2010 Plan A85. Line posts at 1,000-foot maximum intervals shall have top braces and cross truss rods with turnbuckles as detailed on Standard Plan A85 even though fabric is stretched with mechanical equipment. Top brace shall remain in place after fence is completed.

D. All posts shall be embedded into the ground in concrete footings as shown on the

Drawings. Install fence posts at 6-foot maximum spacing in the area of travel of rolling gates. Allow concrete footings to cure for seven days before installing fence.

E. Fence fabric shall be securely fastened to the outward side of the posts with the

lower edge at the ground level. Fencing and gates shall be properly braced to prevent sagging. Redwood privacy slats shall be installed vertically.

Fences CNG Fueling Station



F. Demonstrate that all gates swing smoothly or roll freely without binding or dragging, that all gates are lockable, and that all gate hardware operates properly. Demonstrate that all automatic gate operators function properly.

G. Surplus excavated material remaining after the fence has been constructed shall be

disposed of as specified in Section 01440.

END OF SECTION


03200 - 1 Concrete Reinforcing CNG Fueling Station

SECTION 03200

CONCRETE REINFORCING

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: 1. Reinforcing work, complete as indicated, specified and required.

1.02 REFERENCES

A. ASTM International (ASTM) Standard Specifications: 1. ASTM A615: Deformed and plain billet - steel bars for concrete

reinforcement.

B. American Concrete Institute: 1. Details and Detailing of Concrete Reinforcement (ACI 315). 2. Building Code Requirements for Reinforced Concrete (ACI 318).

C. Concrete Reinforcing Steel Institute: Manual of Standard Practice (CRSI Manual).

D. International Code Council: Evaluation Reports (ICC Reports).

1.03 SUBMITTALS


B. Product Data: 1. Bar supports and chairs. 2. Mechanical bar connectors, including ICC Reports. 3. Certified mill test results on reinforcement with recycled material content

requirements noted in General Conditions. 4. Tests on unidentified bars.

C. Shop Drawings: 1. Bar layouts. 2. Bar bending diagrams. 3. Assembly diagrams, including bar lap and splice locations and lengths, and

mechanical connector layout. 4. Accessories and inserts layout.


A. Material Tests: Not required for bars in bundles delivered from the mill and tagged with valid Identification Certificate. 1. Unidentified Bars: Test samples from each five tons or fraction thereof for

each size. If already delivered to site, test additional samples from each day of planned concrete placement. Perform one tension and one bend test from each sample for each size.

2. Test standard: ASTM A615.

Concrete Reinforcing CNG Fueling Station



3. Testing Laboratory: Selected by City Representative, to take samples and perform tests. Costs paid by Contractor.

4. WWF: Not acceptable.

B. Standard: CRSI Manual, except as otherwise indicated or specified.

1.05 DELIVERY, STORAGE AND HANDLING

A. Prevent permanent bending and protect bar surfaces from contact with soil, oil, or other materials that may decrease bond to concrete.

B. Bundle reinforcement and tag with suitable identification to simplify sorting and placing. Transport and store at site so material is not damaged. Store reinforcement off ground, place under cover and keep clean. Keep an adequate supply of reinforcement at site to avoid delays.

PART 2 - PRODUCTS

2.01 REINFORCING BARS

A. General: Deformed bars, ASTM A615, Grade 60.

B. Dowels: All dowels are deformed bars unless shown otherwise on the Drawings. 1. Deformed bars: ASTM A615, Grade 60.

2.02 WELDED WIRE REINFORCEMENT

A. Not Used.

2.03 TIE WIRE

A. Annealed steel, 16-gauge minimum.

2.04 MECHANICAL CONNECTORS

A. Type: Tension-compression.

B. Strength: Develop 125% of the reinforcing yield strength in tension and compression.

C. Manufacturer: 1. Tension-compression: Lenton by Erico Products, Inc., Dowel Bar Splice

Systems by Richmond Screw Anchor Co., or equal. 2. Future Extension Mechanical Butt Splice: Lenton Form Saver by Erico

Products, Inc., or equal. Provide plastic taper threaded plugs for “long-term” thread protection.

2.05 SUPPORTS AND ACCESSORIES

A. Conform to CRSI Manual Chapter 3, for Types SB, BB, BC, JC, HC, CHC, and others of standard types as required.

B. Use Class "1" plastic-coated chairs and spacers at waterbearing surfaces, roofs of waterbearing structures, and at all interior or exterior surfaces exposed to view or weather in the completed structure. Precast concrete block supports with embedded wire ties are not acceptable.


03200 - 3 Concrete Reinforcing CNG Fueling Station

C. Use precast concrete block supports with embedded wire ties or dowels for placement on grade or on membranes. Cast the blocks with concrete equal in strength, cement type and aggregate to the parent concrete.

D. Do not use aluminum or stainless steel supports or accessories.

2.06 FABRICATION

A. General: CRSI Manual Chapters 6 and 7, including tolerances.

B. Splice, development and embedment lengths: Furnish bars with lap lengths equivalent to ACI 318, Section 12, Class B splices for the specified concrete strength, bar size and location, unless noted otherwise.

C. Bending and Forming: Fabricate bars of indicated size and accurately form to shapes and lengths indicated and required. Fabricate by methods not injurious to materials. Do not heat reinforcement for bending. Reject bars with kinks or bends not scheduled.

D. Concrete Cover: Detail and fabricate the reinforcement to provide specified cover to outer edge of rebars and other installed items.

E. Dowels: 1. Provide deformed reinforcing bar dowels at all construction joints, unless

noted otherwise. 2. Provide same dowel size and spacing as the reinforcing to which they are

spliced, unless noted otherwise.

2.07 SOURCE QUALITY CONTROL

A. Verify bend tolerances are not exceeded.

B. Verify bar end cuts are within tolerance when mechanical connectors are to be used.

PART 3 - EXECUTION

3.01 INSTALLATION

A. General: CRSI Manual Chapter 8 including placement tolerances. No reduction of concrete cover is allowable for bars at concrete surfaces exposed in liquid or water-containing structures. 1. Cleaning: Before placing reinforcing, and again before concrete is placed,

clean reinforcement of loose mill scale, dried concrete, oil, or other coating that might destroy or reduce bond. Do not allow form coatings, release agents, bond breaker, or curing compound to contact reinforcement.

2. Placement: Place, support, and fasten reinforcement as indicated. Do not exceed the placing tolerances specified in ACI 117. Do not reduce cover requirements for placing tolerances. When necessary to move reinforcement beyond the specified placing tolerances to avoid interference with other reinforcement, conduits, or embedded items, submit the resulting arrangement of reinforcement for review. Accurately place reinforcement and securely wire tie in position, at an adequate number of points, where bars cross so as to prevent displacement. Tie stirrups to bars at both top and

Concrete Reinforcing CNG Fueling Station



bottom. Bend ends of tie wire inward allowing no encroachment into the concrete cover.

3. Concrete cover: Provide minimum concrete cover for reinforcement as noted on Drawings. Provide minimum concrete cover to the outer edge of ties, stirrups, bar spacers, hangers, and like items.

4. Reinforcement supports: CRSI Manual, Chapter 3. 5. Field bending: Not permitted, except where specifically shown, or approved. 6. Bar spacing: Between parallel bars, no less than 1-1/2 times the maximum

aggregate size and in no case less than 1-1/2 inches. At splices, bundle and wire together bars to accomplish this.

7. Reinforcement termination: Where reinforcement does not extend through a joint, termine the reinforcement 2 in. from the face of the joint.

3.02 FIELD QUALITY CONTROL

A. Inspect all reinforcement installations. Provide 48 hours' notice for inspection before concrete placement.

B. Verify placement tolerances are not exceeded.

C. Mechanical Connectors: Install favorably reviewed products, following the Manufacturer's recommendations, under continuous inspection.

D. Welding Reinforcement: Perform only when approved and only under continuous inspection. Notify the City Representative at least 48 hours in advance of any procedure involving welding.

END OF SECTION


03300 - 1 Cast-in-Place Concrete CNG Fueling Station

SECTION 03300

CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: 1. All cast-in-place concrete including bases for mechanical and electrical

equipment, and all manholes not specified to be precast. 2. Concrete shoring, forming, patching, grouting, sealing, curing and repairing. 3. Concrete accessories including joint fillers and sealants.

B. Related Sections: 1. Section 03200: Concrete Reinforcing 2. Section 03350: Concrete Finishing 3. Section 05090: Metal Fastenings 4. Section 05500: Metal Fabrications (Miscellaneous Metal)

1.02 REFERENCES

A. American Concrete Institute (ACI): 1. ACI 117 Standard Tolerances for Concrete Construction and Materials 2. ACI 301 Specifications for Structural Concrete for Buildings 3. ACI 306 Guide to Cold Weather Concreting 4. ACI 318 Building Code Requirements for Structural Concrete 5. ACI 347 Guide to Formwork for Concrete 6. ACI 350 Environmental Engineering Concrete Structures

B. ASTM International (ASTM) Standard Specification or Test Method: 1. ASTM C31 Making and Curing Concrete Test Specimens in the Field 2. ASTM C33 Concrete Aggregates 3. ASTM C39 Compressive Strength of Cylindrical Concrete Specimens 4. ASTM C40 Organic Impurities in Fine Aggregates for Concrete 5. ASTM C42 Obtaining and Testing Drilled Cores and Sawed Beams of

Concrete 6. ASTM C87 Effect of Organic Impurities in Fine Aggregate on Strength

of Mortar 7. ASTM C88 Soundness of Aggregates by Use of Sodium Sulfate or

Magnesium Sulfate 8. ASTM C94 Ready-Mixed Concrete 9. ASTM C131 Resistance to Degradation of Small-Size Coarse

Aggregate by Abrasion and Impact in the Los Angeles Machine

10. ASTM C136 Sieve Analysis of Fine and Coarse Aggregates 11. ASTM C142 Clay Lumps and Friable Particles in Aggregates 12. ASTM C143 Slump of Hydraulic-Cement Concrete 13. ASTM C150 Portland Cement 14. ASTM C156 Water Retention by Concrete Curing Materials

Cast-in-Place Concrete CNG Fueling Station



15. ASTM C171 Sheet Materials for Curing Concrete 16. ASTM C172 Sampling Freshly Mixed Concrete 17. ASTM C192 Making and Curing Concrete Test Specimens in the

Laboratory 18. ASTM C231 Air Content of Freshly Mixed Concrete by the Pressure

Method 19. ASTM C260 Air-Entraining Admixtures for Concrete 20. ASTM C289 Potential Alkali-Silica Reactivity of Aggregates (Chemical

Method) 21. ASTM C309 Liquid Membrane-Forming Compounds for Curing

Concrete 22. ASTM C494 Chemical Admixtures for Concrete 23. ASTM C595 Blended Hydraulic Cements 24. ASTM C618 Coal Fly Ash and Raw or Calcined Natural Pozzolan for

Use as a Mineral Admixture in Portland Cement Concrete 25. ASTM C827 Change in Height at Early Ages of Cylindrical Specimens

from Cementitious Mixtures 26. ASTM C869 Foaming Agents Used in Making Preformed Foam for

Cellular Concrete 27. ASTM C881 Epoxy-Resin-Base Bonding Systems for Concrete 28. ASTM C920 Elastomeric Joint Sealants 29. ASTM C1077 Laboratories Testing Concrete and Concrete Aggregates

for Use in Construction and Criteria for Laboratory Evaluation

30. ASTM C1107 Packaged Dry, Hydraulic-Cement Grout (Nonshrink) 31. ASTM C1240 Use of Silica Fume as a Mineral Admixture in Hydraulic-

Cement Concrete, Mortar, and Grout 32. ASTM D882 Tensile Properties of Thin Plastic Sheeting 33. ASTM D1056 Flexible Cellular Materials - Sponge or Expanded Rubber 34. ASTM D1752 Preformed Sponge Rubber and Cork Expansion Joint

Fillers for Concrete Paving and Structural Construction 35. ASTM D2419 Sand Equivalent Value of Soils and Fine Aggregate 36. ASTM E96 Water Vapor Transmission of Materials

C. State of California, Department of Transportation (CALTRANS): 1. Test 217 Sand Equivalent 2. Test 227 Evaluating Cleanness of Coarse Aggregate

D. American Association of State Highway and Transportation Officials (AASHTO): 1. T26 Standard Method of Test for Quality of Water to be Used in

Concrete

E. California Building Code (CBC) 2016 Edition

F. International Code Council (ICC)

1.03 SUBMITTALS


B. Product Data: 1. Concrete mix product certification: Submit certified laboratory test results that

the mix proportions and materials comply with these Specifications. a. Cementitious materials.



b. Coarse and fine aggregates. c. Admixtures. d. Water. e. Ready-mix plant certification. f. Mix designs. g. Mix design test results (see Paragraph 2.05.F for required testing).

2. Formwork products: a. Forms, if fabricated off construction site. b. Form ties or through-bolts. c. Form coatings.

3. Miscellaneous products: Submit technical data including installation instructions, independent laboratory test reports (ICC), and handling and storage instructions. a. Curing materials and curing program. b. Joint fillers c. Sealants d. Epoxy compounds, including adhesives and grouts e. Non-shrink grouts f. Methods and materials for concrete repairs

C. Shop Drawings: 1. Construction joint layout. 2. Sequence of concrete placement. 3. Program and method of concrete placement. 4. With regard to defects in newly constructed concrete, the Contractor shall

identify and investigate the defects and submit for review repair plans specific for each noted defect. See Paragraph 3.10 for concrete repair requirements.

D. Samples: Submit any item of Product Data not fully assembled by a single manufacturer.


A. Construction Standard: Applicable requirements of the IBC, ACI 301, ACI 318 and ACI 350.

B. Concrete Products and Materials Tests: Certified by independent commercial testing laboratories. Submit certification on cementitious products and aggregates performed within the past 6 months.

C. Concrete Mix Designs: By an independent commercial testing laboratory, complying with ASTM C1077 and favorably reviewed by the City Representative. Concrete mix design proportions shall be established on the basis of field experience and trial mixtures with the materials to be employed in accordance with ACI 318 Chapter 5.

D. Concrete Mix Test Results: 1. Submit in accordance with requirements of Paragraph 2.05.F. 2. Allow adequate time for review of submittals and adjustments to comply with

the Specifications.

E. Preconstruction Meeting:




1. Attend meeting with City Representative and Design Engineer, bringing representatives of concrete supply, pumping, placement and finishing subcontractors plus testing laboratories.

2. Review preliminary concrete placing plans prior to plan submittals. 3. Meeting agenda includes:

a. Mix design. b. Formwork products. c. Miscellaneous products. d. Construction joint layout. e. Concrete placement. f. Finishes required. g. Curing and protection methods. h. Field Testing. i. Other special inspection requirements. j. Hot weather concrete requirements. k. Cold weather concrete requirements. l. Resolve any difficulties foreseen by any interested party m. Other Issues

4. Resolve any difficulties foreseen by any interested party.

F. Concrete Tests, as Placed: Performed by the City’s Representative: 1. Test frequency: Each mix type placed, each day placed. 2. Concrete sample: ASTM C172. Provide all material required. 3. Compressive strength: A set of minimum four standard 6-inch x 12-inch

concrete cylinders shall be cast for each 100 cubic yards or fraction thereof for concrete greater than 2,500 psi. It is the Contractor’s responsibility to consider casting additional pairs of 6-inch x 12-inch concrete cylinders at time of placement, at no cost to the City, in case the 28-day test show under-strength concrete, and additional tests at 56 days and beyond are required to demonstrate concrete strength meeting project requirements. a. Making, storing, initial cure, and final cure of cylinders: ASTM C31.

Provide site storage and initial cure, 16 hours minimum and 24 hours maximum.

b. Test of cylinders: ASTM C39. Testing laboratory will transport cylinders from site, cure, test, and provide report. Test two cylinders at age of 7 days, two at 28 days, and additional pairs thereafter as required if the 28-day test shows under-strength concrete.

4. Slump: Test will be performed on each 50 cubic yards or fraction thereof. Test each sample used for strength tests. a. Testing: ASTM C143. b. Results outside the limits indicate possible cause for rejection of

concrete. The City Representative shall be the sole judge. 5. Air content: Test will be performed on concrete samples used for strength

tests. Furnish calibrated equipment required to perform the test. a. Testing: ASTM C231.

6. Temperature a. Testing: ASTM C1064.

G. Additional Tests: 1. General: Contractor shall provide and pay for additional material and strength

tests on new test specimens when test results fail to meet the specified requirements. Strength tests shall be considered satisfactory if the



requirements of ACI 318 Section 5.6.3.3 are satisfied. If, in the opinion of the City Representative, results of tests on concrete cylinders indicate the possibility of substandard concrete in the structure, cored samples may be required to be taken from the concrete.

2. Coring and testing: ASTM C42. The City Representative will investigate low-strength test results in accordance with the requirements of ACI 318 Section 5.6.5; however, the requirements of Section 5.6.5.4 are not applicable. If, in the opinion of the City Representative, the results of the core tests indicate that concrete has been placed which does not meet this specification, the City may require defective concrete strengthened by means of additional concrete, reinforcing steel or replacement of the defective concrete, all at no additional cost to the City.

3. Repair: Repair rejected concrete by removing and replacing or other acceptable repair methods as required by Engineer. To bring rejected concrete into compliance, use repair methods that meet specification requirements for strength, function, durability, dimensional tolerances, and appearance. Submit for acceptance the proposed repair methods, materials, and modifications. The Contractor is responsible to bring concrete into compliance with the requirements of the Contract Documents.


A. Cementitious Materials: If required at site, store immediately after delivery in a dry, weather-tight, properly ventilated structure, with adequate provisions for prevention of moisture absorption and overheating of the cement.

B. Aggregates: If required at site, store in piles which afford good drainage and which are protected to prevent the inclusion of foreign material. Stockpile the various sizes or gradations of aggregates separately.

C. Lumber: Store all lumber, including plywood for forms, to prevent direct contact with the ground. Protect the stored lumber from the elements by a suitable covering, such as polyethylene film or waterproof building paper, suitably held in place.

PART 2 - PRODUCTS

2.01 GENERAL

A. Obtain materials from an NCRMA certified manufacturer or supplier, or one qualified through ASTM C94. Provide new materials of first-class ingredients guaranteed to perform the service required.

2.02 CONCRETE MATERIALS

A. Cementitious Materials: 1. General: Use only one brand of each cementitious material. The color shall

not significantly alter the typical grey concrete color. 2. Portland Cement: ASTM C150, Type II. Comply with the requirements for low

alkali cement in ASTM C150 Table 2. 3. Pozzolan: ASTM C618, Mineral Admixture Class N. 4. Blended Cement: ASTM C595 Type 1P (MS). 5. Flyash: ASTM C618, Class F, with the following restrictions:




a. Loss on Ignition: 4% maximum b. SO3 Content: 3% maximum c. Moisture Content: 1% maximum

B. Concrete Aggregates: 1. General: ASTM C33:

a. Provide free from organic materials, waste products, clay balls, shale, and mica and thoroughly washed before use.

b. Provide aggregate meeting the combined gradation requirements as specified in Paragraph 2.02.C. For thin sections, such as slabs or walls 10 inches thick or less, or for sections that require special placement due to shape, form or congestion of reinforcing, provide 1-inch maximum size.

c. Provide aggregates that do not deleteriously react with the alkalies in the cement.

d. Grading: ASTM C136. Submit results of sieve analysis. e. Reactivity: ASTM C289. Submit graphical data showing compliance.

2. Coarse Aggregates: a. Provide clean, hard, durable gravel, crushed gravel, crushed rock, or

combinations. b. Deleterious substances: Submit compliance with ASTM C33, Table 3

and as follows: 1) Clay lumps and friable particles: ASTM C142. Not more than 5%. 2) Abrasion: ASTM C131. Not more than 45%. 3) Soundness: ASTM C88. Not more than 10%. 4) Cleanness: Caltrans Test 227 OR ASTM C142. For three tests,

not less than 70, with an average greater than 75. Max friable/clay materials in coarse aggregate at 2% for exposed architectural concrete, 3% for liquid retaining concrete structures, and 5% for all other structural concrete.

c. Do not use aggregate containing more than 10% of inferior materials, flat or elongated particles, cracked or laminated rock, or rock than can be readily broken after immersion in water for one hour.

3. Fine Aggregates: a. Provide natural sand or a combination of natural and manufactured

sand, of siliceous, granitic or igneous origin, hard and durable. b. Deleterious substances: Submit compliance with ASTM C33 Table 1

and as follows: 1) Organic impurities: ASTM C40 and C87. Not less than 95%

relative strength by ASTM C87. 2) Sand equivalent: CALTRANS Test 217 OR ASTM D2419. For

three tests not less than 70, with an average greater than 75.

C. Combined Aggregates: Provide a mixture of fine aggregate and coarse aggregate uniformly graded between the screen sizes specified below.



Sieve Size 1-inch Maximum 2-inch --

1-1/2-inch 1001-inch 90-100¾-inch 55-100

3/8-inch 45-75No. 4 35-60No. 8 27-45

No. 16 20-35No. 30 12-25No. 50 3-15

No. 100 0-5No. 200 0-2

2.03 WATER

A. Provide water meeting AASHTO T26 for washing aggregates, for mixing concrete, for patching grout and for curing that is free from oil and contains not more than 1,000 parts per million (ppm) of chlorides as Cl, nor more than 1,300 ppm of sulfates as SO4. Do not allow impurities that will cause a change in the setting time of the Portland Cement of more than 25%, nor a reduction in the compressive strength of mortar at 14 days of more than 5%, when compared to the results obtained with distilled water.

B. Do not allow impurities that cause discoloration of the concrete or produce etching of the surface.

C. The City Representative may require tests of the water should there be a question of the quality. Costs of such tests would be borne by the City, unless the quality does not meet the requirements in Paragraph A above.

2.04 ADMIXTURES

A. Air Entraining: ASTM C260

B. Accelerating: ASTM C494, Type C or E

C. Retarding: ASTM C494, Type D

D. Water Reducing: ASTM C494, Type A

E. High Range Water Reducing: ASTM C494, Types F or G, second or third generation type. Add at the batch plant, after all other ingredients have been mixed and initial slump has been verified.

F. Shrinkage Reducing: ASTM C157. Eclipse by W.R. Grace, Tetraguard AS20 by Master Builders, or equal.

G. Corrosion Inhibition and Permeability Reduction (Silica Fume): ASTM C1240. Force 10,000 or 10,000D (dry) by W.R Grace, Rheomac SF 100 (dry) or 110 by Master Builders, or equal.

H. When two or more admixtures are used, they must be added to the mix separately (through dispensers or manually) and must not be mixed with each other prior to adding to the concrete mix. Add admixtures to concrete mix ingredients in liquid form by a special dispensing unit, approved by the manufacturer of the admixture




as suitable for accurately dispensing the admixture. Install an alarm or indicator, which will immediately inform the batch plant operator if the dispensing unit malfunctions. Dispense admixtures uniformly into the mixing water as it is added to the concrete batch.

I. No admixture containing any chloride ions is acceptable.

J. Manufacturers: WR Grace & Co., Master Builders, Inc., or equal.

2.05 CONCRETE MIX DESIGN

A. General: 1. Employ an independent commercial testing laboratory complying with

ASTM C1077 and favorably reviewed by the City Representative to design all concrete mixes and carry out all necessary testing. Concrete mix design proportions shall be established on the basis of field experience or trial mixtures with the materials to be employed in accordance with ACI 318 Section 5.3.

2. If the testing laboratory has satisfactory mix designs available from prior projects, submit test record statistics to demonstrate compliance with the requirements of this Section and ACI 318 Section 5.3. Include calculations for f’cr based on source quality test records.

3. If new mix designs are required, proportion each mix design based on trial batches and submit the mix designs that demonstrate satisfactory test results in accordance with ACI 318 Section 5.3.

4. Allow for the variability of concrete strength from test to test by increasing the required average compressive strength over the specified strength as specified in ACI 318 Section 5.3.

5. Design the mixes far enough ahead of concrete placement to allow completion of trial batch testing and submittal of the test results and mix design to the Design Engineer for review.

6. Take sole responsibility for selection of laboratory, submittal of materials to laboratory in time for all tests, and overall timing of all aspects of testing program, including submittals.

7. Prepare mix designs for concrete placement by the batch process and/or by pumping, as required, and state the process on the design submittal.

8. Allow for the hot or cold weather and the time required to transport the concrete from the mixer to the site and to place within the forms. If accelerating or retarding admixtures will be required for only a proportion of the concrete placements, submit test results that include the full range of options.

9. Do not exceed the water-cementitious material ratios. Vary the water-reducing admixtures to accomplish an increase in slump or workability time.

10. Proportion cementitious materials, aggregates, and water by weight. 11. Check periodically the weight of moisture contained within the stockpiled

aggregates. Compensate for this water when proportioning the concrete mix and adjust when change occurs.

12. Do not use chlorides in concrete mixes.

B. Mix Proportions:



Concrete Type C Specified 28-Day

Compressive Strength (lb/in2)4,000

Maximum Coarse Aggregate Size (in)

1

Air Content at Point of Placement (%)

2-1/2

Maximum Water-Cementitious Material Ratio

0.50

Minimum Cementitious Material Content (lb/yd3)

570

Maximum 28-Day Drying Shrinkage (%) – Mix Test

--

Cement Type V

C. Cementitious Material: Either Portland Cement, cement with fly ash, cement with natural Pozzolan, or blended cement.

D. Pozzolan or Flyash: Optional. Not less than 10%, nor more than 20% of the weight of the cementitious materials. Do not use pozzolan or flyash as an admixture in concrete made with Portland-Pozzolan Cement.

E. Modified Mix Design: Provide a modified mix design of the concrete type indicated in the table above for horizontal concrete joints, as specified in Paragraph 3.09, for environmental structures consisting of the designated concrete mix with one-half of the coarse aggregate removed.

F. Mix Test Requirements: 1. Compression: ASTM C192 for cylinder preparation. ASTM C39 for cylinder

tests. Submit 7-day and 28-day curing test results in accordance with Paragraph A above.

2. Slump: ASTM C143. Slump range is 3 to 4 inches. After high-range water reducer added, range is 6 to 9 inches.

3. Air Content: ASTM C231. Air content range is ±1%. 4. Unit Weight: ASTM C138. 5. Shrinkage: The mix tests requirements shall be in accordance with

ASTM C157, except as described below. NOTE: the following requirements differ from ASTM C157 and must be strictly followed in order to obtain favorable review for a concrete mix design. One set of three test specimens shall be prepared. a. Moist curing: Specimens shall be removed from molds at 23 ±1 hours

after batching and shall be placed in water for at least 30 minutes and shall be measured within 30 minutes to determine original length. Specimens shall be submerged in saturated lime water until 7 days after batching.

b. Measurements: Measurements to determine shrinkage shall be made after 7, 14, 21, and 28 days of drying after 7 days of moist curing. Compare to the preliminary measurement made after 1-day and the basic measurement made after 7 days curing, which will be used for calculations.

c. Test prism size: 4 x 4 x 11 inches.




d. Report all test results, with the 28-day tests results governing acceptance. Plot the results at other time intervals as a test of validity of the readings.

6. After favorable review of the mix design, no variations of the constituents are permitted during the project without prior submittal and favorable review.

2.06 READY-MIX CONCRETE

A. Supply concrete for the project using truck mixers and a ready-mix plant certified by the National Ready-Mix Concrete Association. Submit certification.

B. Alternatively, qualify the supplier according to ASTM C94 Sections 8 through 11, inclusive.

2.07 DRY PACK GROUT

A. Very stiff mix grout; one-part Portland Cement to two-parts sand (by weight) and water. Wet the mixture only sufficiently to moisten the materials to the point where they will ball when squeezed by hand.

2.08 NON-SHRINK GROUT

A. ASTM C1107, with no shrinkage as measured by ASTM C827. Furnish a premixed product, consisting of properly proportioned amounts of non-metallic, dimensionally stable material to which water is added.

2.09 CEMENT MORTAR

A. For concrete repairs. For crack and spall repairs of existing concrete, see Section 3.10.

B. One-part Portland Cement, two-parts fine sand (by weight) and water. Use only the amount of water needed to make the mix workable for the intended use.

C. Provide a mixture of white and regular cements as required to make a mortar that after curing 28 days will match the adjacent concrete. Prepare several trial batches and make test samples in an inconspicuous location for review.

D. When a mix has been selected for color match, batch all mortar by weight in accordance with the formula for the selected mix.

2.10 EPOXY BONDING SYSTEM

A. General: ASTM C881: 1. Provide Type IV for bonding hardened concrete to hardened concrete;

Type V for bonding freshly mixed concrete to hardened concrete; and Type III as a binder in epoxy mortar or concrete, or for use in bonding skid-resistant materials to hardened concrete.

2. Provide Grade 1 or 2 for horizontal surfaces and Grade 3 for vertical surfaces.

3. Provide Class A if placement temperature is below 40°F, but not less than allowed by the manufacturer; Class B if placement temperature is between 40 and 60°F; or Class C if placement temperature is above 60°F, but not more than allowed by the manufacturer.

4. Provide: Sikadur 32, Hi-Mod manufactured by the Sika Chemical Corporation, or approved equal.



2.11 PREFORMED JOINT FILLER

A. Miscellaneous Structures Above Grade: ASTM D1752 Type 1, 1-inch thick unless indicated otherwise on the Drawings.

2.12 SEALANT

A. General: ASTM C920, of type, grade and class appropriate for use.

B. Exterior Exposure: Sikaflex-2c, by Sika Corp., Select Seal U-200 by Select Products Corp., or equal.

C. Prepare surfaces and provide primer and sealants in strict accordance with manufacturer's recommendations.

D. Backing Rod: Extruded, closed cell, polyethylene foam rod, compatible with sealant. Provide 5/8-inch-diameter rod for 1/2-inch joint, 1-1/4-inch rod for 1-inch joint.

E. Bond Breaker Tape: Resilient, non-staining, 100% vulcanized butyl rubber, scrim reinforced, self-adhering, extruded sealant tape containing no asphalts.

2.13 CURING MATERIALS

A. Cure by fog spray, or by one of the following methods after discontinuance of the fog spray. Slabs shall be continuously wet cured with sheet materials or wet blankets after discontinuance of the fog spray; liquid curing compound alone is insufficient.

B. Liquid Curing Compound: A water-based membrane-forming resin suitable for exterior or interior use as a curing and hardening compound on freshly placed concrete. 1. Provide an emulsion of synthetic resinous solids dispersed in water

containing no waxes, paraffins or oils. Provide the fugitive type that will oxidize and disintegrate completely within 60 days when exposed to sunlight in exterior applications or that can be removed by washing with dilute muriatic acid or TSP in interior applications.

2. Water retention requirements: ASTM C309, Type I or II, Class B, when tested in accordance with ASTM C156.

3. Use white pigmented material for exterior applications and clear material for interior applications.

4. Comply with the applicable local air quality district. 5. Exterior surfaces: Aqua Resin Cure-White by Dayton-Superior; 1200-White

by W.R. Meadows; or equal. 6. Interior surfaces: Spartan-Cote by Dayton-Superior; Vocomp 20 by W.R.

Meadows; or equal.

C. Sheet Materials: ASTM C171. Waterproof paper, plastic sheeting or white burlap-polyethylene sheet. 1. Plastic sheeting: fungus-resistant, minimum 4-mil thick, clear and free of

defects, having ASTM E96 perm rating of not more than 0.5. 2. Waterproof paper: Two layers of non-staining kraft paper laminated with latex

adhesive and reinforced with glass in both directions. Seal joints with 2-inch-wide tape with water-resistant adhesive.




D. Wet Blankets: Clean cotton mats (burlap, except for white burlap-polyethylene sheeting, is unacceptable). Provide material free from any substance that will have a deleterious effect on the concrete. Use a thickness sufficient to retain moisture between programmed applications of water.

E. Evaporation Retardant: Eucobar by the Euclid Chemical Company; E-CON by L&M Construction Chemicals, Inc.; or equal.

2.14 FORMS

A. Provide forms for exposed concrete surfaces with a clean, smooth plywood or metal face. Exposed concrete surfaces include beams, columns, slabs, interior and exterior walls, and surfaces of tank, chamber and tunnel walls except those in contact with earth.

B. Furnish plywood with a waterproof, synthetic resin bonded face manufactured for formwork. Furnish steel forms that incorporate reinforcement, inserts, pipe fittings, box-outs, and other details shown on the Contract Drawings without modification to these details.

2.15 FORM TIES

A. General: 1. Provide commercially manufactured steel rods or through-bolts capable of

withstanding applied pressures. 2. Do not use wire, wire ties or wood spreaders. 3. Provide form ties designed that when forms are removed, no metal shall

remain within 1-1/2-inch to the finished concrete surface.

B. Cone-Snap Tie: 1. Furnish ties adjustable in length or of proper fixed length, with no metal closer

than 1-1/2-inch to the finished concrete surface. 2. Use a plastic cone spacer at each end of the form tie to allow a full 1-1/2-inch

breakback and part of tie to be removed shall leave a cone shaped depression in the concrete with a minimum diameter of 1-inch at the surface.

3. Provide ties for walls resisting water or earth pressure with waterstop washers of diameter ¾-inch greater than the rod, bonded to rods at the wall centerline, or with other favorably reviewed water seal devices.

C. Taper Ties or Through Bolts: 1. Alternatively, provide tapered removable through-bolts at least 1-inch in

diameter at smallest end. 2. Manufactured neoprene or polyurethane tapered plug to be installed at the

wall centerline.

2.16 FORM COATING COMPOUNDS

A. Do not stain or impart any material or residue to the concrete surface detrimental or incompatible with any specified paint or coating system to be applied later, or unacceptable for contact with drinking water.



2.17 SOURCE QUALITY CONTROL

A. Forms: Verify that components pre-assembled offsite are satisfactory for the purpose. Verify that designs, products and samples have been submitted for Product Review.

B. Concrete: 1. Verify that ready-mix batch plant delivery tickets contain all product

information necessary for acceptance of the concrete delivered to site. 2. Verify that the mixing and trucking equipment have adequate capacity to

deliver the concrete batches to site on time, thoroughly mixed and discharge without segregation.

PART 3 - EXECUTION

3.01 PROPORTIONING CONCRETE MATERIALS

A. Do not place concrete prior to favorable review of submittals for reinforcing steel, materials specified in this Section and the mix proposed. Unfavorable results of actual pours may require a redesign of mixes in addition to corrective work related to any defects.

B. Do not make substitutions to the constituents tested in the design of concrete mixes without favorable review of the revised mix and the new test results.

3.02 BATCHING AND MIXING CONCRETE MATERIALS

A. Ready or Transit Mixed Concrete: 1. Deliver completely mixed to the project site. 2. Do not add water unless approved by the City Representative. Do not add

mixing water during hauling. Add water after delivery and only from the “hold-out” volume indicated on the mix ticket. Should water be added, revolve the mixing drum not less than 30 revolutions at mixing speed after adding and before commencing discharge.

3. Deliver each load at the job site accompanied by a ticket showing mix design number, volume of concrete, the weight of cement in pounds and the total weight of each ingredient in pounds. Also show the time at which the materials were batched and the reading of the revolution counter at the time the truck mixer was charged.

4. No re-tempering of partially hardened material is permitted. Do not use partially hardened concrete in the work.

B. Batching in Adverse Weather: 1. Cold Weather: Perform work in accordance with ACI 306 along with the

following requirements. When the atmospheric temperature is below 40°F, or is likely to fall below 40°F during the 24-hour period after placing, heat the materials before mixing, so that the temperature of the mix at the batch plant shall be between 65° and 80°F. Do not heat the mixing water or the cement over 160°F. Remove lumps of frozen material and ice from the aggregates before they are placed in the mixer.

2. Hot Weather: When temperatures are above 90°F, reduce the temperature of the concrete mix by using iced mixing water, and protecting aggregates and cement from direct rays of the sun. Do not place concrete exceeding 80°F.




3. Should the provisions noted in 1. and 2. above not be possible or practicable, postpone the batching until favorable weather conditions prevail.

3.03 FORMS

A. General: 1. Take responsibility for adequacy of the form, bracing, and shoring. Satisfy

ACI 347. 2. Form concrete unless specified otherwise. 3. Construct forms confirming to the shape, line and grade specified. 4. Provide tight seams, or seal with tape, to be mortar-tight. 5. Brace and shore all forms properly to ensure stability against pressure from

any source, without failure of any component part. 6. Keep the deflection of wall or slab form sheathing or framing for beams within

1/270 of the span. Consider camber in designing the supports of beams and slabs.

7. If inadequate support is provided by the forms, remove all placed concrete and replace, as directed.

8. Provide for temporary openings for cleaning out, observation, pouring and vibration of concrete.

9. If the concrete mix design includes a high-range water reducing additive, design the forms with enough strength to resist the high liquid concrete pressure without distortion.

B. Chamfers: 3/4-inch at outside corners and edges, including the top edges of walls, machinery bases and curbs. Use mill run chamfer strips. Provide rounded top edges of sidewalks, walkways and where directed.

C. Formed Surfaces: 1. Ensure that the reinforcement has been favorably reviewed before closing up

the wall forms. 2. Provide exposed, unpainted concrete surfaces that are uniform in

appearance and color. Apply non-staining mineral oil, form coating or form release compound before placing the forms. Remove any excess coating with cloths. Scrape and clean any reused forms before coating again.

3. Provide flush fitting caps over any unused form tie holes. 4. Do not use mineral oil on formed surfaces that are to be painted, coated, or

bonded to other concrete.

D. Form Ties and Through-Bolts: 1. Provide sufficient number and strength to prevent spreading of forms while

placing concrete. 2. Remove the removable portion immediately after stripping the forms. Avoid

spalling the exposed concrete surfaces. 3. Locate tapered ties, if used, with the larger diameter on the water side of the

form. 4. Provide a separate support system for the curtains of reinforcing, with a

minimum 1-inch clearance between rebar and form ties or bolts.

E. Construction Joints: 1. Ensure the end forms of walls are removable without releasing the side

forms. Provide seals around reinforcement to prevent mortar leaks.



2. Overlap the hardened concrete of the first pour with forms for the second pour. Brace the ends of the forms against the hardened concrete to prevent joint offsets and mortar leakage. Align any exterior features required on the finished surface.

3.04 ALLOWABLE VARIATIONS FOR FORMED SURFACES

A. Tolerances: ACI 301 and as noted below:

B. Variations in Size or Thickness: 1. Footings:

a. Length and width: ±1/2-inch b. Reduction in thickness: 5%

2. Slabs and walls: a. Thickness of 6 inches or less: 0-inch b. Thickness of more than 6 inches: ±1/4-inch

C. Allowable Tolerances (Location, Lines and Grades): 1. Horizontal misplacement or eccentricity

of footings 2% of footing width, but no more than 1-inch

2. Variation of vertical dimensions at all floor levels from specified position:

±1/2-inch per 100-foot

3. Variation of vertical dimensions from specified position:

±1/4-inch

4. Variation from level or from slopes specified for floors, ceilings, water channels and conspicuous lines

±1/4-inch per 20 feet

5. Variation in location from specified position for sleeves, pits, floor, and wall openings:

±1/4-inch

D. General: Set and maintain concrete forms to ensure that, after removal of the forms and prior to patching and finishing, no portion of the concrete work will exceed any of the tolerances. Measure variations in floor levels before removal of supporting shores. Accept responsibility for variations due to deflections resulting from concrete quality or curing other than that specified. The specified variation for one element of the structure will not be applicable when it will permit another element of the structure to exceed its allowable variation.

3.05 REMOVAL OF FORMS

A. General: Comply with the recommendations of ACI Committee 347. Remove without damage to the concrete and with complete safety of the structure. Ensure that the concrete has hardened sufficiently and the members have attained sufficient strength to safely support the imposed loads.

B. Removal Time: Minimum duration after completion of concrete placement: 1. Walls and wall or slab construction joints 12 hours 2. Sides of beams and girders 12 hours 3. Columns 12 hours 4. Underside of suspended slabs, walkways,

beams and girders 21 days, and full design compressive strength verified by data from additional field cured cylinders, if removed at less than 28 days.




C. Cold Weather: Forms shall remain in place for the full protection period in accordance with ACI 306 and City Representative may further increase the minimum form removal times if the temperature is 50°F or lower.

D. Reshoring: Submit for favorable review, any requirement for accelerated partial stripping and reshoring of forms that may be necessary to maintain the construction program. Removal times for two-way suspended slabs are contingent on reshoring and shall be favorably reviewed by the City Representative.

3.06 REUSE OF FORMS

A. Between concrete placements, inspect all form surfaces and repair to uniform texture for all concrete surfaces to be exposed. Fill all unused holes, cracks and defects.

3.07 PLACING CONCRETE AND GROUT

A. General: 1. Provide satisfactory redundancy in the delivery system so that work can

continue in the event of a breakdown. 2. Do not use aluminum materials in pumping lines, transfer hoppers or chutes

longer than 12 feet. Provide conveyor belts instead of chutes when the distance is longer than 50 feet. Use a storage hopper at the start of the line.

3. For pumped concrete, provide a hose with an angle-change, to create a back-pressure at the outlet.

4. Provide illumination if necessary inside the forms, so that the placed concrete will be visible from the deck at top of formwork.

5. Provide thermometer for measuring concrete temperature when weather conditions are predicted to go beyond the range 50°F to 80°F.

6. All surfaces in contact with concrete, including forms and reinforcing steel, shall be within 10°F of the concrete prior to placement of concrete.

7. Do not place concrete on frozen subgrade. Subgrade shall be above 32°F and within 10°F of concrete prior to placement of concrete. Remove frost before placing concrete and recompact thawed soil disturbed by frost.

B. Preliminary Work: 1. Remove hardened concrete and foreign materials from the inner surface of

the mixing and conveying equipment. Remove all debris from the space to be occupied by the concrete.

2. Remove water from the space to be occupied by the concrete before concrete is deposited. Divert any flow of water into an excavation through proper site drainage to a sump, or by other methods. If required by the City Representative, grout up any water vent pipes and drains after the concrete has thoroughly hardened.

C. Embedded Items: 1. Place all equipment, bolts, anchors, sleeves, inserts, structural steel

members, angles and similar items which require embedment in the concrete. 2. Hot-dip galvanize all ferrous metal sleeves, inserts, anchors, and other

embedded ferrous items unless shown otherwise. Set anchor bolts for equipment in templates, carefully plumbed and checked for location and elevation with an instrument, and held in position rigidly by double-nutting to the template to prevent displacement while concrete is being poured.



3. Ensure that any aluminum items inserted in the concrete are isolated by a bituminous or asphaltic coating in accordance with Division 5 Specifications.

4. Move reinforcement bars as necessary to avoid interference with other reinforcing steel, conduits, or embedded items, but not so as to impair design strengths of the member. If bars are moved more than two bar diameters, submit the resulting arrangement of bars for review.

5. Inspect the installation of all embedded items and reinforcing.

D. Placing: 1. Transfer the concrete to the place of final deposit as rapidly as practicable by

methods that prevent the separation or loss of ingredients. Under no circumstances deposit partially hardened concrete in the work. Deposit concrete in the forms as nearly as practicable in its final position to avoid re-handling. Maintain, until the completion of the pour, a plastic concrete surface, approximately horizontal.

2. Deposit concrete without segregation of the aggregate and without displacement of the reinforcement.

3. Maximum height of free fall for concrete during placement: a. Concrete with maximum 4-inch slump: 4 feet b. Concrete with high-range water reducing admixture and minimum

6-inch, maximum 9-inch slump: 8 feet 4. Deposit concrete continuously or in layers 12 to 20 inches in depth so that no

concrete will be deposited on concrete that has hardened sufficiently to cause the formation of seams or planes of weakness within the section. If a section cannot be placed continuously as originally planned, locate construction joints during the placement.

5. Use every means to secure a dense, impervious, homogeneous concrete, free from voids or pockets. If honeycomb, air, or rock pockets occur, repair the structure to the complete satisfaction of the City Representative, and modify the placing method or mix design, to prevent recurrence of deficient concrete. Provide such repairs and modifications at no additional cost. Extensive honeycomb or pockets may be cause for rejection of the work.

E. Time Limit: Place all concrete in its final position in slab or forms within 1-1/2 hours of batching or before the drum has revolved 300 revolutions, whichever comes first in accordance with ASTM C94. Alternatively, as part of the mix design, provide admixtures that delay the initial set and state the proposed length of time in the submittal.

F. Temperature Limits: Place all concrete in its final position in slab or forms at: 1. Less than 90°F, measured in the mix. 2. More than 40°F, measured both in the mix and in the air, with air temperature

predicted to rise above 50°F. 3. More than 50°F, measured in the mix, 40°F measured in the air, with air

temperature falling. 4. Temperature measurements above refer to on-site measurements. Refer to

the vibration, concrete joints and curing sections for other requirements.

3.08 VIBRATION

A. Compact the concrete with high frequency, internal mechanical vibrating equipment, and when required, supplement by hand spading and tamping.




Consolidate slabs 6 inches or less in depth by hand tampers, spreading and settling with a heavy leveling straightedge.

B. Operate vibrators with vibratory element submerged in the concrete, with frequency between 8,000 and 12,000 impulses per minute when submerged.

C. Furnish sufficient vibrators to complete the compaction as specified without causing delay in the depositing of concrete. Provide at least one spare unit for each structure when concrete is being placed and at least one vibrator for each 25 cubic yards per hour of concrete placement.

D. Vibrate by direct action in the concrete for approximately 10 seconds at approximately 12-inch intervals, not against forms or reinforcements. Do not move concrete horizontally by vibration. Work the concrete around the reinforcement, and around embedded fixtures and into the corners of the forms. Penetrate 6 to 12 inches into previously poured layers as new layers are poured, provided the running vibrator penetrates by its own weight. To secure even and dense surfaces, free from aggregate pockets, honeycomb, or air pockets, supplement vibration when required by forking or spading by hand or hammering the forms lightly opposite the freshly deposited concrete. Revibrate the final layer. Stop vibrating when concrete is thoroughly compacted and has ceased to decrease in volume and give off air bubbles.

E. When placing concrete with 8-inch or more slump, reduce the time of vibration to 5 seconds and follow the admixture manufacturer's recommendations for technique.

3.09 CONCRETE JOINTS

A. General: 1. Provide joints:

a. In accordance with favorably reviewed joint layout, placement sequence, and placement program submittal.

b. As shown on the Drawings and as noted below in these Specifications. c. As required for constructability.

2. Provide minimum curing times before the second placement: a. 10 days after each adjacent concrete placement for infill pours (i.e. in-

between two existing sections) or checkerboard (existing concrete on two or more sides) placement patterns.

b. 2 days after the first concrete placement at the joint. 3. During placement of the new concrete, ensure there are no interruptions to

the 14-day curing time and 14-day load restriction plan for the adjacent pours.

B. Control Joints: 1. Space typical control joints in slabs on grade not exceeding 10 feet, or as

shown on the Drawings. Control joints shall not be provided in water containment structures.

2. If cast-in with the concrete, positively locate the preformed joint filler and hold rigidly in place during concreting.

3. If saw-cut, use a wheeled power saw as soon as the concrete surface is firm enough. Saw-cut control joints must be constructed within 12 hours after concrete placement. Fill the groove with sealant over a backer rod.



C. Construction Joints: 1. General:

a. Produce quality concrete, with full continuity of reinforcing and water tightness across the joints.

b. Space typical slab joints not exceeding 20 feet in the direction of the transverse or secondary reinforcing, typically the smaller reinforcing nearer to the center of the slab thickness. Space typical vertical wall joints no more than 30 feet apart.

c. After the first concrete placement at the joint, do not walk on or disturb any reinforcing extending into the second placement area for at least 48 hours.

2. Surface Preparation: a. Existing concrete surfaces against which new concrete or grout will be

placed shall be prepared in accordance with the following (in the order listed unless otherwise noted): 1) Steam and Detergent Clean: Conform to ASTM D4258 and

remove all grease, oil, and similar contaminants. Use jet of high-pressure steam at a minimum temperature of 180-deg F sufficient to remove the contaminants. Add detergents or nonsolvent emulsifying agents to facilitate contaminant removal. Before surfaces dry, remove all residual detergents and emulsifying agents by thoroughly rinsing with clean water. Repeat steam cleaning until surfaces are clean and water does not bead on surfaces. The pH of final surfaces shall conform to the acceptance criteria of ASTM D4262. Testing of surfaces for moisture content per ASTM D4258 is not required.

2) Water Blast: Roughen the existing concrete surfaces with high-pressure water using equipment specifically designed for water blasting of concrete surfaces. Minimum waterblasting pressure and flow: 2000 psi and 15 gpm. Conform to ASTM D4259. Remove all deteriorated, soft, and weak concrete; loose aggregate; contaminants; and existing coating to sound concrete. Provide minimum surface amplitude of 1/4-inch.

b. Before depositing new concrete on or against newly placed concrete that has hardened, clean and roughen the entire surface of the joint exposing clean coarse aggregate solidly embedded in mortar matrix. Provide typically 1/4-inch roughness or amplitude of the concrete surface measured from the top of the exposed aggregate to the bottom of pockets between stones.

c. Drench the prepared joint with clean water and remove prior to the concrete pour.

d. Use special care in vibrating adjacent to construction joints to ensure thorough consolidation of the concrete. Additional hand tamping may be required.

D. Expansion Joints: 1. Stop all steel reinforcing clear of the joint at each side. 2. Prepare a smooth first concrete surface with all voids filled. 3. Provide preformed joint filler, securely fastened to the existing concrete as

directed by the Manufacturer. 4. Install bond breaker and sealant after curing is completed and when directed.




E. Bonding to Pre-existing Concrete: Mechanically roughen the old surface to a 1/4-inch amplitude, as defined in construction joint paragraph above. Apply epoxy bonding system material prior to concreting and in accordance with the manufacturer’s instructions. See Paragraph 2.10.

3.10 REPAIR OF DEFECTS IN NEWLY CONSTRUCTED CONCRETE

A. Inspect all concrete surfaces immediately after carefully removing forms. Defective work includes concrete out of line, level or plumb; cracks; poor joints; rock pockets; honeycomb; voids; spalls and exposed reinforcing. Patch all minor defects, including form tie holes, before the concrete is thoroughly dry. Do not interrupt the curing program. Ensure that repairs match the existing surface for color and texture.

B. Minor Defects: 1. Clean thoroughly, including removal of any curing compound. Cut out to solid

concrete but to a depth of not less than 1 inch. Prepare the edges of the cut slightly more than perpendicular to the surface of the concrete, so as to form a key.

2. Repair with cement mortar. Use minimum water, consistent with the requirements of handling and placing. Thoroughly compact the material into place and screed off to leave the patch flush with the surrounding surface.

3. Keep the surface damp for at least 48 hours.

C. Major Defects: 1. Large areas involving voids or rock pockets extending through the section

may be cause for rejection of the work. 2. If acceptable repairs can be made without adversely affecting the structural

integrity of the work, cut out the section and either dry pack, or reform and re-pour to match the adjacent concrete. Do not cut the reinforcing, but cut keyways into the adjacent sound concrete to securely fasten the patch to the original work. Prepare edges of the damaged area with a minimum of a 1-inch cut perpendicular to the concrete surface.

3. Coat all surfaces with epoxy bonding compound immediately prior to patching. Place the concrete patch before the epoxy has set. Follow the epoxy bonding manufacturer's recommendations.

4. Provide a patch with strength and modulus of elasticity compatible with the parent concrete. Cure in accordance with the following article.

3.11 CURING AND PROTECTION

A. General: Maintain concrete above 50°F and below 90°F in a moist condition and without external loadings for 14 days after placement. For slabs, after the specified initial moist cure, provide further moist curing, utilizing sheet materials or wet blankets for 14 days after placement. Apply liquid membrane curing after the 14-day wet curing period. For walls after the specified initial moist cure, provide further moist curing, impervious-sheeting curing, or application of liquefied membrane-curing compound, as noted.

B. Slabs: 1. Initial moist cure: Provide a 36-hour uniform spray treatment immediately

following final troweling and before the surface can dry out, but after bleeding



has stopped. Use clean water and special fog spray nozzles of type and number required to keep entire surface moist. Keep all traffic off the floor surfaces.

2. Continued cure: After 36 hours, continue fog curing, or before the surface dries out, continue curing by utilizing sheet materials or wet blankets in order to keep the surface of the slab continuously wet for the balance of the 14 days. After 14 days apply a liquid membrane curing compound: a. Place waterproof curing paper smoothly upon the moist concrete

surface with all joints and edges lapped a minimum of 4 inches and continuously sealed with tape. Do not use paper that will leave an impression on the finish. Repair, replace and reseal, torn or scuffed sheets.

b. Install polyethylene plastic sheeting and maintain in the same manner as for curing paper.

c. Apply liquid membrane curing compound, if favorably reviewed for this purpose. Apply while slab is still damp from the fog spray. 1) Agitate compound thoroughly by mechanical means during use

and apply uniformly in a two coat continuous operation by appropriate power-spraying equipment. Apply the two coats at right angles. Apply between 150 and 200 sq. ft. per gallon of undiluted compound, total coverage. Form a uniform, continuous, coherent film that will not check, crack, or peel and free from pinholes or other imperfections. Apply an additional coat immediately to areas where the film is defective.

2) Keep alternate specified covering readily available for use in the event conditions occur which prevent correct application of the compound at the proper time.

3) Respray surfaces that are subjected to heavy rainfall within 3 hours after the curing compound has been applied (when slab reaches a moist condition and there is no standing water) with two additional coats of curing compound by the foregoing method and coverage.

4) Allow foot traffic only after 36 hours of cure time and only when slab is protected with paper or sheeting.

5) Allow building material storage only after 14 days of cure time and only on plywood sheets and wood sleepers that spread the load and protect the finish.

C. Walls: 1. When forms are in place, keep concrete damp by spraying the outside and

top of the forms with water. 2. When forms are in place, but loosened, keep concrete damp by streaming

water down inside the forms. 3. When forms are removed, continue curing by one of the following methods

for the balance of the 14 days. a. Provide continuous perforated hose sprays at the top of wall covering

the entire wall, both sides, with water. b. Place water-retaining blankets continuously over the wall surfaces and

hose periodically with water, 24 hours a day. c. Apply liquid membrane curing compound, if favorably reviewed for this

purpose. Follow the procedures for slabs contained in paragraph above.




D. Other Surfaces: 1. Provide a curing program equivalent to either slab or wall system, as

appropriate. 2. Include construction joint surfaces when applying curing compound. 3. Cover, or protect joint openings, exposed reinforcing, surfaces to be painted

and other areas where curing compound may enter and interfere with a special finish.

4. Remove curing compound sprayed on reinforcing or construction joints by sandblasting after curing is completed, or before placing the next pour. If the cones of tie holes are sprayed with curing compound, lightly ream prior to patching.

5. For curing of certain interior and other slabs using hardening or coloring compounds, refer to Section 03350.

E. Cold Weather Requirements: Provide adequate equipment for heating the placed concrete during freezing or near freezing weather: 1. Whenever the surrounding air temperature is below 40°F, or may fall below

40°F within the 24-hour period after placing concrete, maintain all freshly poured concrete at not less than 50°F for 5 days.

2. Keep the housing, covering, or other protection in place and intact at least 24 hours after the artificial heating is discontinued.

3. Do not use manure, salt, calcium chloride, or other chemicals on the concrete to prevent freezing.

F. Hot Weather Requirements: Provide additional cooling to concrete when temperatures rise above 90°F, or low humidity, wind and temperature combine to cause high surface evaporation, over 0.2 lb/sq. ft./hour: 1. Provide additional water if curing by fog spray or ponding or saturated

blankets. 2. Provide shade to surfaces exposed to direct sunlight. 3. Apply an evaporation retarder during the finishing operation, following the

manufacturer’s recommendation.

3.12 CONCRETE FINISHES

A. Refer to Section 03350.


A. Concrete Placement: 1. Verify that forms and reinforcement are accurately placed and secured in

position. Confirm that both forms and reinforcement have been favorably reviewed.

2. Verify that tie wire ends have been bent back away from the forms. 3. Verify that all sleeves, castings, pipes, conduits, bolts, anchors, and any other

items required, are accurately and securely placed within or on the forms. 4. Verify adequate vibrators are available. 5. Verify construction and expansion joint faces have been prepared for the next

concrete placement. 6. Check that the mix design is compatible with the method of placement of the

concrete, by pump or by batch. 7. For wall placements, verify that the modified concrete mix required at

construction joints is to be delivered.



8. Verify the concrete delivered to site is satisfactory, including checks on the batch tickets, quality assurance tests and direct observation of the batches.

B. Concrete Curing: 1. Verify procedures and equipment is available for controlling concrete

temperature during hot and cold weather conditions. 2. Verify actual time of application of evaporation retardant, fog spray and curing

materials for each placement. 3. For cold weather applications, record at least twice a day for the six days of

special concrete curing and protecting procedures the temperature of the concrete at multiple locations (including surfaces, edges and corners), the daily maximum and minimum concrete temperature, location where temperature was taken, air temperature, weather conditions, and other special conditions. Measure concrete temperature in accordance with ACI 306.

3.14 CLEANUP

A. Upon completion of all work performed under this Section, remove from the site all excess materials, storage facilities and temporary facilities. Smooth and clean of debris all areas that were used or occupied during concrete construction operations and leave in first-class condition.

END OF SECTION




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03350 - 1 Concrete Finishing CNG Fueling Station

SECTION 03350

CONCRETE FINISHING PART 1 - GENERAL 1.01 SUMMARY

A. Section Includes:

1. Concrete finishes for all horizontal and vertical concrete surfaces. 2. Sealers and hardeners for concrete.


1. Section 03300: Cast-in-Place Concrete

1.02 REFERENCES A. American Society of Testing and Materials (ASTM):

1. ASTM C156 Test Method for Water Retention by Concrete Curing Materials 2. ASTM C309 Specification for Liquid Membrane-Forming Compounds for

Curing Concrete 3. ASTM C1028 Test Method for Determining the Static Coefficient of Friction of

Ceramic Tile and Other Like Surfaces by the Horizontal Dynamometer Pull-Meter Method

4. ASTM E96 Test Methods for Water Vapor Transmission of Materials

B. California Building Code 2016 Edition (CBC). C. International Code Council (ICC) ES Evaluation Reports.

1.03 SUBMITTALS

A. Submit in accordance with Section 01330. B. Qualifications: A list of all five projects completed by the proposed subcontractor

within the most recent 3 years that have concrete finishes similar to those specified for this project.

C. Product Data: Describe all products proposed for use.


A. Contractor Qualifications: Use skilled cement finishers to perform all work.

B Regulatory Requirements: Comply with applicable requirements in the International Building Code, adopted edition, including without limitation Chapters 10, 11, 11A and 11B.

Concrete Finishing CNG Fueling Station



PART 2 - PRODUCTS 2.01 CURING AND SEALING COMPOUND

A. General: 1. Water-base acrylic curing, sealing and dustproofing compound. 2. Leave a protective clear transparent film on the concrete surface that is

non-yellowing and resistant to deterioration due to exposure to ultraviolet light. 3. ASTM C-309, Type I, Class B. 4. AASHTO M-148, Type I, Class B.

B. Manufacturers:

1. First coat Vocomp-20, second coat Vocomp-25-1315 by W. R. Meadows Inc.; 2. Burke Spartan-Cote WB Cure/Seal/Hardener; 3. or equal.

2.02 MORTAR FOR FILLING VOIDS

A. Mortar for filling voids: One part Portland cement, two parts sand by volume mixed with only enough water to form a ball when squeezed by hand. A mixture of white and grey Portland cement is required for color match (approximately 1 part white to 2 parts grey). Add mineral oxide colors as required to match colored concrete. Substitute non-reemulsifiable, acrylic bonding agent for one-third of mixing water. Test several different mixes for color match and obtain favorable review prior to proceeding.

PART 3 - EXECUTION 3.01 CONCRETE SURFACE FINISHES FOR SLABS

A. General: 1. Provide a surface finish on all exterior and interior horizontal concrete slabs that

has a coefficient of friction when measured in accordance with ASTM C1028 not less than 0.60 for level surfaces and 0.80 for surfaces sloped 1:20 or more.

2. For all exterior paving surfaces provide a minimum slope of 1% (1/8-inch per foot) to drain surface water to catch basins, drains or edges of pavement adjacent to landscaping and drainage swales. Review grades shown and recommend any adjustments necessary to achieve minimum specified slope.

3. Slope interior floor surfaces containing floor drains to drain water to the drains. Review elevations shown on Drawings for adequate slopes before setting grades. Report any conditions that will not provide adequate drainage or that will produce excessively steep slopes before proceeding.

4. Finish slabs so they do not deviate more than 1/4-inch (6.3 mm) in 10 feet from a straight edge. Finish elevations to within 1/8-inch (3.2 mm) elevations shown or required to match adjacent existing conditions. Provide "as-built" slopes for drainage no less than those shown or specified.

5. Allowed Tolerance for individual risers and treads in any flight of stairs:



a. 1/4-inch (6.3 mm) between the lowest and highest riser. b. 3/8-inch (9.5 mm) between the deepest and shallowest tread measured in

the direction of travel. 6. Slope all treads 1/8-inch (3.2 mm) down toward the nosing for drainage. 7. Finish edges and surfaces smooth, true and clean. 8. Apply finish to slabs as soon as the concrete can support the weight of the

workmen. 9. Increase the humidity of the air directly above the concrete surface, prior to and

during finishing operations by adding a fine fog mist of water to the air with mist nozzles when atmospheric conditions (temperature, humidity, and wind) are such that rapid evaporation of mixing water from the concrete is likely to occur.

B. Curing and Sealing:

1. Apply two coats curing and sealing compound to slabs not receiving an elastomeric coating. Apply the first coat when the concrete is wet; apply the second coat 30 days later.

C. Wood or Magnesium Float Finish and Preliminary Steps for Other Finishes:

1. This finish is the initial step for all other finishes. 2. Place and consolidate concrete. 3. Screed to grade using a strike-off board guided on accurately set screeds. 4. Work the surface with a bull or darby float to embed large aggregate,

consolidate surface mortar and create a smooth true surface. 5. Do not overwork the surface or add dry materials such as sand or cement. 6. When surface has taken initial set and bleed water has disappeared work

surface with wood floats followed by magnesium floats (if a magnesium float finish is called for) to even out slight irregularities and further consolidate surface.

7. When concrete has set further so that excess water and fine material will not be brought to the surface, either begin the first steel troweling if this is the preliminary step for other finishes or work the surface with magnesium or wood float if this is the final step in a Float finish. Work the surface sufficiently to consolidate the mortar and produce a finished surface at the proper grade that is free of voids, ripples or other defects. Apply a final swirl texture finish in a fan pattern with the wood or magnesium float. Retool slab edges and control joints. Leave a uniform smooth border around all slab edges and each side of control joints.

D. Trowel Finish:

1. Complete the work required under “Preliminary Steps for Other Finishes.” 2. Apply a second steel troweling after the concrete has set sufficiently so mortar

does not adhere to the edge of the trowel and sufficient pressure can be applied to further consolidate the surface.

3. Apply a third steel troweling when the concrete has set sufficiently so the trowel produces a ringing sound. Apply sufficient pressure so the trailing edge of the trowel will produce a dense smooth surface without burning.

4. Apply a fourth troweling and additional trowelings as required to produce a dense smooth finish.

E. Broom Finish:

1. Complete work required under “Preliminary Steps for Other Finishes.”




2. Apply a second and third steel troweling after the concrete has set sufficiently so mortar does not adhere to the edge of the trowel and sufficient pressure can be applied to further consolidate the surface.

3. Broom texture the surface of the slab at right angles to the normal direction of traffic. Use a stiff fiber bristled broom for Coarse Broom Finish and a fine hair broom for Fine Broom Finish. Match selected control sample.

F. Detail Work: Applies to all concrete flatwork and to exposed top edges of all formed

concrete. 1. Edging Slabs: Tool a 3/8-inch radius on all exposed edges of slabs, curbs and

other exposed horizontal edges unless a formed chamfered edge is called for. Repeat tooling with each floating or troweling operation.

2. Apply a Trowel finish to the top of the formed walls, curbs and machine bases. 3. Control Joints and Feature Grooves:

a. Cut 1-inch-deep control joints with rounded edges in all paving slabs where indicated but not more than 8 feet apart in each direction. Repeat tooling with each floating or troweling operation.

b. Run decorative feature grooves with a 1/4-inch-deep rounded tool before the final troweling in paving where shown.

3.02 CONCRETE FINISHES FOR FORMED SURFACES

A. General: 1. See the Schedule of Concrete Finishes at the end of this Section for the

location, and extent and type of finish required. Where a specific finish is not called for, finish surfaces to match similar adjacent items.

2. Complete all patching and finishing within 10 days after curing is completed.

B. Filled Finish: 1. Remove fins, drips, runs and other projections by scraping. Correct offsets

larger than 1/8-inch by power grinding a taper of at least 1:16. 2. Fill solidly form tie holes and "bug" holes over 1/2-half inch in maximum

dimension with cement mortar described in Part 2. 3. Finish filled holes flush with adjacent surface of the wall. 4. Keep surface damp for 48 hours.

C. Filled And Rubbed Finish:

1. Complete work required for a Filled finish. 2. Remove fins, drips, runs, offsets and other projections by scraping, chipping or

grinding as required to produce a smooth, flat surface free of offsets. The maximum permitted deviation from a true plane surface when tested with an 8-foot-long straight edge is 1/8-inch. The minimum taper required to correct offsets is 1:32.



3.03 SCHEDULE OF CONCRETE FINISHES

FINISH LOCATION OF FINISH 1. Wood or

Magnesium Float

3.01B Provide prior to all other finishes.

2. Trowel Finish 3.01C Top of equipment pads. 3. Broom Finish 3.01D Tops of slabs. 4. Filled and

Rubbed Finish 3.02C Storage dome walls.

SEE SECTION 03 30 00 FOR CURING FORMED CONCRETE

END OF SECTION




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05090 - 1 Metal Fastenings CNG Fueling Station

SECTION 05090

METAL FASTENINGS PART 1 - GENERAL 1.01 SUMMARY

A. Section Includes: 1. All anchors, including mechanical and adhesive anchors, adhesive rebar

dowels, eye bolts, turnbuckles, cable clamps, bolts, nuts, washers, inserts, and other metal fasteners not specified elsewhere.


1. Section 03200: Concrete Reinforcing 2. Section 03300: Cast-in-Place Concrete 3. Section 05500: Metal Fabrications (Miscellaneous Metal)

1.02 REFERENCES

A. American Institute of Steel Construction Specifications: 1. ANSI/AISC 360-10 Specification for Structural Steel Buildings

B. Research Council on Structural Connections: 1. RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts, 2004

C. American Iron and Steel Institute (AISI)

D. American National Standards Institute:

1. ANSI B18-2-1 Square and Hex Bolts and Screws 2. ANSI B18-2-2 Square and Hex Nuts 3. ANSI B18-21-1 Lock Washers 4. ANSI B18-22-1 Plain Washers

E. American Society for Testing and Materials Standard Specifications:

1. ASTM A123 Zinc (Hot-Dipped Galvanized) Coatings on Iron and Steel Products

2. ASTM A153 Zinc Coating (Hot-Dip) on Iron and Steel Hardware 3. ASTM A325 Structural Bolts, Steel, Heat-Treated 4. ASTM A370 Test Methods and Definitions for Mechanical Testing of Steel

Products 5. ASTM A500 Cold-Formed Welded and Seamless Carbon Steel Structural

Tubing in Rounds and Shapes 6. ASTM A525 Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip

Process 7. ASTM A563 Carbon and Alloy Steel Nuts 8. ASTM B633 Electrodeposited Coatings of Zinc on Iron and Steel 9. ASTM E8 Test Methods for Tension Testing of Metallic Materials 10. ASTM F436 Hardened Steel Washers 11. ASTM F844 Washers, Steel, Plain (Flat), Unhardened for General Use

Metal Fastenings CNG Fueling Station

05090- 2 City of Petaluma Biomass to Biofuel Project


12. ASTM F959 Compressible-Washer-Type Direct Tension Indicator for Use with Structural Fasteners

13. ASTM F1554 Anchors Bolts, Steel, 36, 55, and 105-ksi Yield Strength

F. International Code Council (ICC) 1. Evaluation Service Reports 2. AC 193 Acceptance Criteria for Mechanical Anchors in Concrete

Elements 3. AC 308 Acceptance Criteria for Post-Installed Adhesive Anchors in

Concrete Elements G. California Building Code (CBC) 2016 Edition

1.03 SUBMITTALS

A. Submit in accordance with Section 01330. B. Product Data:

1. Adhesive for adhesive anchors and reinforcing steel dowels, and mechanical anchors.

2. Insulation between dissimilar metals.

C. Samples: Manufacturer's latest standard product: Specify special or unique products.

D. ICC Evaluation Service evaluation reports for submitted post-installed anchors,

demonstrating compliance with the CBC and ICC-ES AC 193 or AC 308 for Mechanical and Adhesive anchors, respectively, and approval for use in cracked concrete in Seismic Design Categories A-F.

E. List of all anchors to be used including: 1. Location, diameter, material type, number and length of anchors 2. Testing plan for anchors, including percentage of anchors to be tested and

allowable loads for anchors and testing loads. 3. Certified Verification Testing Report: a. Certified by an independent testing laboratory or registered professional

engineer. b. Detailing results of testing required in paragraph 1.04.C.2.


A. General: 1. Furnish materials and fabricated items from an established and reputable

manufacturer or supplier. 2. Supply all new materials and fabricated items made from first class ingredients

and construction and guaranteed to perform the service required. 3. For adhesive anchorage, Contractor shall be trained by anchor product

manufacturer representative and be provided with a certificate or card of completion, to be available upon request by the Special Inspector.



B. Codes and Standards: 1. Bolting:

a. General: AISC Specifications.

C. Tests: 1. General: The City shall provide Special Inspections, defined by CBC

Chapter 17 and as noted in the ICC-ES report for post-installed anchors. The Contractor shall provide and pay for verification testing for mechanical and adhesive anchoring systems described below. Installation inspection shall be periodic Special Inspection or continuous special inspection as required by the ICC ES report or by the Design Engineer or Specialty Engineer.

2. Verification Testing for mechanical expansion and adhesive anchoring systems: a. Do not begin installation until testing plan has been favorably reviewed by

the City Representative. Contractor shall be responsible for all damage, including damage to adjacent structural elements, resulting from use of loads not favorably reviewed by the City Representative.

b. Test required anchors to tension loads verified in advance by the City Representative, representing the design allowable tension capacity of the anchor, or 0.5 times the design ultimate tension capacity of the anchor:

c. Expansion and adhesive anchors shall be tested as follows: 1) Test 50% of anchors used for non-structural applications, such as

equipment anchorage. 2) Test 100% of anchors for applications not listed above.

d. Undercut anchors that allow visual confirmation of full set need not be tested.

e. Special Inspection of anchors shall include visual inspection of anchor layout, minimum embedment, anchor spacing, and edge distance.

f. Test anchors by a calibrated torque wrench, direct pull with a hydraulic jack, or a calibrated spring loaded devices. Testing shall be performed on a single anchor and shall be done in a “confined” manner, where the testing equipment prevents concrete breakout in tension. Torque wrench method shall not be used for screw anchors, or where additional torque will damage the installed condition.

g. Anchors tested using the torque wrench shall achieve the load within ½ turn of the nut. Prior to testing, the nut shall be snug to the manufacturer’s recommended installation tightness.

h. Anchors tested using a hydraulic ram shall be tested to the required load for a minimum of 15 seconds and shall not exhibit any discernable movement during the loading, such as loosening of the washer under the nut or an observable gap.

i. Anchors which do not pass the test shall be considered defective work, and shall be corrected at no additional cost to the City, including any indirect costs necessary to relocate or reinstall anchors.

D. Additional Tests: The Contractor shall pay for additional Special Inspections and

provide and pay for additional verification testing of repairs and/or replacement of defective work.





A. Handle, ship and store material in a manner that will prevent distortion, rust, damage to the shop coat or any other damage.

B. Store material in a clean, properly drained location out of contact with the ground. C. Ensure that dissimilar metals are not in contact with each other. D. Replace or repair all damaged material in an approved manner.

PART 2 - PRODUCTS 2.01 METAL FASTENERS

A. General

1. For buried, submerged, or conditions where anchors or fasteners will be continuously or intermittently wet, except where otherwise shown or specified, all bolts, anchor bolts, mechanical anchors, adhesive anchors, washers, and nuts shall be 316 stainless steel .

2. For exterior or exposed conditions provide 316 stainless steel except where otherwise shown or specified.

3. Not used. B . Bolting – Steel

1. Bolts: High Strength Bolts: ASTM 325, heavy hex, Type 1 (High Strength Bolts) OR ASTM A307, Grade A (Regular Hexagon Bolts)

2. Nuts: ASTM A563, heavy hex, Grade DH (High Strength Nuts) OR ASTM A563, Grade A (Regular Hexagon Nuts)

3. Washers: ASTM F436, Type 1, hardened (High Strength Bolt Washers) OR ASTM F 844 (Regular Bolt Circular Washers)

4. Lock Washers: ANSI B18.21.1 5. High Strength Direct Tension Indicators: ASTM F959. 6. Dimensional Requirements: a. Bolts: ANSI B18.2.1. b. Nuts: ANSI B18.2.2.

C. Bolting – Stainless Steel 1. Stainless Steel Bolts: AISI 316. ASTM A193 or F593.18-8 material is not

acceptable. 2. Stainless Steel Nuts: ASTM A194 or F594. 3. Washers: AISI 316 washers meeting the dimensional requirements of ASTM

F436 4. Dimensional Requirements: a. Bolts: ANSI B18.2.1. b. Nuts: ANSI B18.2.2.



D. Cast-in-Place Anchor Bolts 1. Headed Anchors: ASTM F1554, Grade 36, unless Grade 55 or 105 is shown on

Drawings. High Strength anchors on Drawings shall be Grade 55 minimum. 2. Threaded & Nutted Anchors: ASTM F1554, Grade 36 with threaded ends and

double hex nuts at the anchored end, or with washer between anchoring nuts if shown on the drawings. Use heavy hex nuts for rods 1¾” diameter or greater. Provide Grade 55 or 105 if shown on the Drawings and use heavy hex nuts. High Strength anchors on Drawings shall be Grade 55 minimum.

3. Welded Headed Studs or Welded Hooked Studs: AWS D1.1, Grade B, fut = 60 ksi, fy = 50 ksi.

4. Hooked Anchors (J and L Bolts): Are not allowed unless specifically shown on the Drawings as they do not provide equivalent performance. If shown, provide ASTM F1554, Grade 36, unless Grade 55 or 105 is shown on Drawings. High Strength anchors on Drawings shall be Grade 55 minimum.

5. Provide minimum embedment shown on the Drawings, or a minimum of eight bolt diameters.

E. Mechanical Anchoring Systems (friction anchors are not acceptable)

1. Mechanical Undercut Anchoring Systems (required for overhead applications) a. Anchor: Undercut anchor shall be of an undercut style with brazed tungsten

carbides on the embedded end that perform the self-undercutting process. b. Carbon Steel Bolt and Sleeve:

1) Bolt: ISO 898, class 8.8, or SAE Grade 5. 2) Sleeve: AISI 1010. 2) Nuts: ASTM A563 Grade A and meeting the dimensional requirements

of ANSI B18.2.2. 3) Washers: SAE 1005-1033 or AISI 1040 and meeting the dimensional

requirements of ANSI B18.2.2 Type A Plain. 4) Plating: Zinc plated in accordance with ASTM B633, SC1, Type III

Fe/Zn 5. c. Stainless Steel Bolt and Sleeve:

1) Bolt: AISI 316 or 316Ti. 2) Sleeve: AISI 316 or 316Ti or Type 304 stainless steel. 3) Nuts: DIN 934, grade 8. 4) Washers: DIN 6796 or Type 18-8 stainless steel.

d. Submit a product evaluation report by ICC-ES showing Cracked Concrete testing compliance per A.C.193.

e. Provide embedment depth, edge distance, and anchor spacing as shown on the Drawings and in accordance with manufacturer’s recommendations for published allowable loads.

f. Manufacturer: Hilti, Inc. HDA Undercut Anchor, Simpson Torq-Cut (pending ICC approval) Atomic+ Undercut by Powers Fasteners or equal.

2. Mechanical Expansion Anchoring Systems a. Anchor: Expansion anchor shall be preassembled expanding sleeve or

wedge type with a single piece three section wedge. Anchors shall meet the description of Federal Specification A-A 1923A or A-A 1922A, Type 4. Anchor will bear a length identification code that is visible after installation. Provide hex head stud style unless flat or rod coupler styles are noted on Drawings.

b. Carbon Steel Anchors: 1) Anchor Body: ASTM A510 or AISI 1018 or AISI 12L14 or SAE J403.




2) Nuts: ASTM A563 Grade A and meeting the dimensional requirements of ANSI B18.2.2.

3) Washers: SAE 1005-1033 or ASTM F844 and meeting the dimensional requirements of ANSI B18.2.2 Type A Plain.

4) Plating: Zinc plated in accordance with ASTM B633, SC1, Type III Fe/Zn 5.

c. Stainless Steel Anchors: 1) Anchor Body and Wedges: ASTM A276 or ASTM A493 with chemical

composition of either AISI 304 or 316 or 316L. 2) Nuts: ASTM F594 with chemical composition of either AISI 304 or 316

or 316L. 3) Washers: ASTM A240 with chemical composition of either AISI 304 or

316 or 316L. d. Submit a product evaluation report by ICC-ES showing Cracked Concrete

testing compliance per A.C. 193. e. Provide embedment depth, edge distance, and anchor spacing as shown

on the Drawings and in accordance with manufacturer’s recommendations for published allowable loads.

f. Manufacturer: Hilti, Inc. Kwik Bolt TZ, Simpson Strong-Bolt, Powers Fasteners, Power-Stud +SD1 or Power-Stud +SD2 (except ¼” diameter and not for use in masonry), or equal.

F. Adhesive Anchoring Systems

1. Adhesive (Epoxy) Injection Anchoring Systems a. Adhesive: Adhesive consisting of two-component epoxy base resin and

hardener material meeting the requirements of ASTM C-881 Types I and IV, Grade 3, Class C. The adhesive shall be supplied in manufacturer’s standard side-by-side cartridge and dispensed through a static-mixing nozzle supplied by the manufacturer.

b. Anchor Rod, Reinforcing Steel or Insert: Threaded Rod or insert with chamfered threaded end for ease of starting nut on one end and 45 degree chisel or cut point on opposite end (where insert is required by manufacturer). Furnish nuts and washers to meet the requirements of the rod or insert. Unless noted otherwise on the Drawings provide hot dip galvanize rods or inserts or stainless steel. Stainless steel rods or inserts shall be provided in buried or submerged locations. Reinforcing Steel shall meet the requirements of Section 03200. All Reinforcing Steel indicated to be embedded in existing concrete shall be embedded using the epoxy injection systems. 1) ASTM A36 or A307 (standard carbon steel anchor). 2) ASTM A193 Grade B7 (high strength carbon steel anchor). 3) Reinforcing bars as specified in Section 03200 with chisel or cut point. 4) AISI 304/ASTM A276 or AISI 316L/ASTM A276 stainless steel meeting

the mechanical requirements of ASTM F-593 (Condition CW). c. Submit a product evaluation report by ICC-ES showing Cracked Concrete

testing compliance per A.C. 308. d. Provide embedment depth, edge distance, and anchor spacing as shown

on the Drawings and in accordance with manufacturer’s recommendations for published allowable loads.

e. Manufacturer: Hilti HIT-HY 200 Adhesive Anchoring System, or equal.



2.02 MISCELLANEOUS ITEMS A. Turnbuckles: ASTM F1145 and AISI C-1035. B. Eye Bolts and Eye Nuts: ASTM F541 and AISI C-1030. C. Clevises: AISI C-1035. D. Threaded Rods (Tie Rods): ASTM A36 E. All metal fasteners not specified elsewhere.

2.03 GALVANIZING

A. Hot-dip galvanize all exterior and exposed steel items, except when specified otherwise. 1. Steel hardware, nuts, bolts, washers, anchors, and threaded rods: ASTM A153. 2. Where specified, electroplate nuts, bolts and washers with zinc coating of

0.001-inch minimum thickness in accordance with ASTM B633 Class SC4. Where specified, provide a 4-mil DFT coating of zinc silicate.

3. Size nuts so that they screw on threaded bolts readily after galvanizing or coating.

B. Repair Materials: Gal-Viz by Thermacote Welco, Pasadena, CA; ReGalv by

Rotometals, Inc., San Francisco, CA; or equal.

PART 3 - EXECUTION 3.01 ERECTION

A. Structural Steel Work: 1. Connections:

a. Provide anchor bolts and other connections between structural steel and foundations.

b. Set all anchor bolts by template, with provisions to hold bolts rigid and in correct position with respect to plan and elevation.

c. Install adhesive and expansion anchorages by personnel with satisfactory previous experience using the same Products, following the manufacturer's recommendations and in compliance with the latest ICC-ES report.

d. Detail any undesigned connections in accordance with the AISC Specification.

e. Do not increase any hole diameter or slot length without the City Representative’s approval.

f. Washers: 1) Provide washers for slotted holes. Washers shall be hardened for

high-strength bolts (fy > 36 ksi) and shall be 3/8-thick plate washer for long-slotted holes.

2) Provide washers under the turned element for bolts installed with the Calibrated Wrench Pre-tensioning method.




3) Provide washers for bolts installed with the Direct-Tension-Indicator Pre-tensioning method.

2. Where metal is fastened to concrete, make the connections by anchor bolts, or by anchors embedded in concrete, such as adhesive, or expansion anchors.

3. Provide grout pads below base and bearing plates of non-shrink non-metallic grout having a minimum thickness of 3/4-inch unless otherwise noted. Do not bear directly on concrete slabs or equipment bases.

4. Provide leveling nuts on anchor bolts, below base plates, and adjust prior to grouting.

5. Where anchorage requires drilling into existing concrete, contractor shall locate all reinforcing steel at least 14 days prior to drilling and shall notify City Representative of any conflicts immediately upon discovery. Contractor shall not drill through or cut any reinforcing steel without express written direction from the City Representative.

B. Mechanical Anchoring Systems: Mechanical anchoring systems shall be installed in

accordance with the ICC-ES Evaluation Report for the specific anchor. 1. Mechanical Undercut Anchoring Systems (required for overhead applications)

a. Drill a hole in the base material using drill bit diameter and embedment depth in accordance with the manufacturer’s instructions. CAUTION: Oversized holes in the base material will reduce the anchor’s load capacity and cannot be used.

b. Remove dust from holes with compressed air. c. Assemble the anchor with the nut and washer so the top of the nut is flush

with the top of the anchor. d. Place the anchor in the fixture and drive into the hole until washer and nut

are tight against the fixture. e. Install nut and washer and tighten to the required installation torque.

2. Mechanical Expansion Anchoring Systems a. Drill a hole in the base material using drill bit diameter and embedment

depth in accordance with the manufacturer’s instructions. CAUTION: Oversized holes in the base material will reduce the anchor’s load capacity and cannot be used.

b. Remove dust from holes with compressed air. c. Assemble the anchor with the nut and washer so the top of the nut is flush

with the top of the anchor. d. Place the anchor in the fixture and drive into the hole until washer and nut

are tight against the fixture. e. Install nut and washer and tighten to the required installation torque.

C. Adhesive Anchoring Systems: Adhesive anchoring systems shall be installed in

accordance with the ICC-ES Evaluation Report for the specific anchor. Adhesive anchoring systems are not allowed in overhead applications. 1. Adhesive Anchoring Systems

a. Drill a hole to the specified depth and diameter. b. Clean hole with a wire brush. Remove dust from holes with oil-free

compressed air. Jetting holes with water is not permitted. c. Install adhesives only in clean holes free of standing water.

1) Dispense portion of adhesive off to the side to check for proper mixture, and consistent color before using.



2) Fill hole halfway to 2/3rds, starting from bottom of hole to prevent air pockets. Withdraw nozzle as hole fills up.

3) Substrate temperature should be kept above the minimum allowed temperature as specified by the manufacturer for the entire curing process.

4) Insert anchor, turning slowly until the anchor contacts the bottom of the hole. Do not disturb anchor during the specified cure time.

5) For holes 10” and deeper contractor shall use a piston plug for adhesive anchor installation

D. Repair of Connections: The Contractor shall pay for all necessary additional tests

made on weld or bolts required to repair or replace faulty work performed during the original fabrication or during erection.

E. Repair of Galvanized Coating:

1. Repair surfaces damaged by cutting or welding by the heated repair method. Repair handrails or other surfaces that will not be painted and that are field welded or damaged by the heated galvanize repair method.

2. Heat substrate to 600°F, or apply hot process touch-up material right after welding before metal has cooled below 600°F.

3. Rub bar of specified galvanize repair material over surface of hot substrate to apply a uniform coating of zinc. Wire brush hot coating with a clean wire brush to smooth out and bond zinc coating to substrate to apply a uniform coating of zinc.


A. Mechanical and Adhesive Anchoring Systems: 1. Anchoring systems shall be installed in accordance with the ICC-ES Evaluation

Report for the specific anchor. All anchors shall be tested in accordance with paragraph 1.04C.

2. Set torque-controlled expansion-type anchors to the recommended installation torque using a calibrated torque wrench. Following attainment of 10% of the specified torque, 100% of the specified torque shall be reached within 7 or fewer complete turns of the nut. If the specified torque is not achieved within the required number of turns, the anchor shall be removed or abandoned.

3. Set displacement-controlled expansion-type anchors to the recommended displacement. If the concrete cracks during installation of the anchor, the anchor shall be removed or abandoned.

4. Anchors should exhibit no discernable movement during load testing. 5. Holes drilled for anchors that do not set properly or fail in a tension test may not

be reused, and shall be filled with non-shrink grout. B. Erection Sequence: Verify each stage is completed before proceeding to the next. C. Tolerances: AISC Standard Practice.

END OF SECTION




PAGE INTENTIONALLY

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05500 - 1 Metal Fabrications (Miscellaneous Metals)

CNG Fueling Station

SECTION 05500

METAL FABRICATIONS (MISCELLANEOUS METALS)

PART 1 - GENERAL

1.01 SUMMARY A. Section Includes:

1. Structural steel, stainless steel or aluminum, such as beams, channels, angles, tees, bars, pipe, tubing and plates (connection and base plates).

2. Fabricated metal items, such as guardrails, pipe supports, brackets, hangers, equipment supports, and lift hooks.

3. All other metal fabrications and miscellaneous metal not covered under other sections.


1. Section 05090: Metal Fastenings

1.02 REFERENCES A. American Institute of Steel Construction Specifications:

1. Specifications for Structural Steel Buildings, AISC 360-10, 2010 Edition 2. Steel Construction Manual, 14th Edition.

B. American National Standards Institute: 1. B18.23.1 Beveled Washers

C. ASTM International (ASTM) Standard Specifications:

1. A36 Specification for Carbon Structural Steel 2. A53 Specification for Pipe, Steel, Black and Hot-Dipped Zinc-Coated Welded

and Seamless 3. A123 Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel

Products 4. A153 Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware 5. A283 Specification for Low and Intermediate Tensile Strength Carbon Steel

Plates 6. A307 Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile

Strength 7. A500 Specification for Cold-Formed Welded and Seamless Carbon Steel

Structural Tubing in Rounds and Shapes 8. A501 Specifications for Hot-Formed Welded and Seamless Carbon Steel

Structural Tubing 9. A653 Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron

Alloy-Coated (Gavannealed) by the Hot-Dip Process 10. A786 Specification for Hot-Rolled Carbon, Low-Alloy, High-Strength Low-Alloy

and Alloy Steel Floor Plates

Metal Fabrications (Miscellaneous Metals) CNG Fueling Station



11. F844 Specification for Washers, Steel, Plain (Flat), Unhardened for General Use

12. F2329 Specification for Zinc Coating, Hot-Dip, Requirements for Application to Carbon and Alloy Steel Bolts, Screws, Washers, Nuts, and Special Threaded Fasteners

D. Publications of the National Association of Architectural Metal Manufacturers

(NAAMM): 1. "Metal Product Outline; Division 5 Metal" 2. “Metal Stair Manual” 3. "Metal Finishes Manual" 4. “Pipe Railing Manual” 5. "Metal Bar Grating Manual"

E. The Society for Protective Coatings (SSPC), Volume 2. Standards for Surface

Preparation are specified by SSPC followed by SP and a number indicating the specified type of surface preparation.

F. American Welding Society:

1. AWS D1.1 Structural Welding Code - Steel 2. AWS D10.4 Recommended Practices for Welding Austenitic

Chromium-Nickel Stainless Steel Piping and Tubing 3. AWS A4.3-93R Standard Methods for Determination of the Diffusible

Hydrogen Content of Martensitic, Bainitic, and Ferritic Steel Weld Metal Produced by Arc Welding

4. AWS A5.1 Mild Steel Covered Arc Welding Electrodes 5. AWS A5.3 Aluminum and Aluminum Alloy Electrodes for Shielded

Metal Arc Welding 6. AWS A5.4 Covered Corrosion-Resisting Chromium-Nickel Steel

Welding Electrodes 7. AWS A5.5 Low Alloy Steel Covered Arc Welding Electrodes 8. AWS A5.9 Corrosion-Resisting Chromium-Nickel Steel Base and

Composite Metal Cored and Stranded Welding Electrodes and Welding Rods

9. AWS A5.10 Aluminum and Aluminum Alloy Bare Welding Rods and Electrodes

10. ANSI/AWS B4.0-98 Standard Methods for Mechanical Testing of Welds - U.S. Customary

11. AWS B5.1-2003 Standard for the Qualification of Welding Inspectors 12. AWS C4.1 Oxygen Cutting Surface Roughness Gauge and Wall

Chart for Criteria Describing Oxygen-Cut Surfaces G. California Building Code (CBC) 2016 Edition. H. International Code Council (ICC).

1.03 SUBMITTALS


B. Product Data: Fully describe every product proposed for use.



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1. Hangers, pipe and equipment supports (shelf items). 2. Stainless steel and aluminum items (not fabricated). 3. Certified mill test results on structural metals. 4. Electrode manufacturer’s data and product data, including electrodes to be used

for dissimilar metals. 5. Insulation between dissimilar metals.

C. Manufacturer’s product data sheets or catalog data for SMAW, FCAW and GMAW composite (cored) filler metals to be used

D. Shop Drawings: 1. Framing plans, sections, and details. 2. Show dimensions, finishes, joining, attachments, inserts, and relationship of work

to adjoining construction. 3. Call out member sizes and lengths, and finish. 4. Indicate all shop and erection details including cuts, copes, connections, holes,

threaded fasteners and welds. Indicate welds using AWS "Welding Symbols." 5. Show field measured dimensions of this and adjacent work and location of

inserts on fabrication drawings. 6. Submit plan layout and details for guardrails

E. Quality Assurance: 1. Welder performance qualification test records “welders certification”. 2. Written Welding Procedure Specifications (WPSs) in accordance with AWS D1.1

requirements for each different welded joint proposed for use whether prequalified or qualified by testing.

3. Procedure Qualification Record (PQR) in accordance with AWS 1.1 for all procedures qualified by testing.

1.04 QUALITY ASSURANCE A. General:

1. Furnish materials and fabricated items from an established and reputable manufacturer or supplier.

2. Supply all new materials and fabricated items made from first class ingredients and construction and guaranteed to perform the service required.

3. The Contractor is responsible for preparing and submitting written Welding Procedure Specifications (WPSs). WPSs for each joint type shall indicate proper AWS qualification and be available where welding is performed. WPSs shall be included with any shop drawings referencing welds. WPSs shall include the manufacturer and specific electrode.

B. Codes and Standards:

1. Metalwork: a. Steel: AISC Specification.

2. Welding: a. Steel: AWS D1.1. b. Stainless Steel: AWS D10.4.

3. Welders: a. Qualify welders in accordance with AWS D1.1 for each process, position,

and joint configuration.




b. All welding operators are subject to examination for requalification at any time during the progress of the work.

C. Contractor’s Qualifications: 1. Welding procedures, welders, and welding operations shall be qualified for the

type of work required in accordance with AWS Standard Qualification Procedures.

D. Regulatory Requirements: Comply with the following codes and reference standards

unless higher standards are specified, shown or required by applicable codes: 1. "Specification for the Design, Fabrication and Erection of Structural Steel for

Buildings," American Institute of Steel Construction (AISC), latest edition. 2. Structural Welding Code of the American Welding Society, AWS D1.1, latest

edition. 3. California Building Code (CBC), adopted edition, especially Paragraphs 1013,

Guardrails, Paragraph 1012, Handrails and Paragraph 1009, Stairs. 4. Stair, guardrail and accessibility design requirements in Title 24, OSHA and

CCR Title 8 Cal-OSHA. E. Tests:

1. General: The Owner will provide Special Inspections, defined by CBC Chapter 17, for welding, mechanical expansion, and adhesive anchoring systems.

2. Weld Tests: a. Visual inspection:

1) Check fit-up of joint materials. Verify satisfactory alignment of material. Verify gaps and bevels of penetration welds.

2) Check during welding. Verify satisfactory technique is used. 3) Check after welding completed and cleaned by wire brush or chipping

hammer. 4) Inspect with magnification when necessary and under strong,

adequate light. 5) Inspect for the following defects:

a) Surface cracking. b) Porosity. c) Excessive roughness. d) Unfilled craters. e) Gas pockets. f) Undercuts. g) Overlaps. h) Size. i) Insufficient throat and concavity.

b. Nondestructive testing: Ultrasonic testing, except where not feasible due to the type or location of the weld. Magnetic particle, liquid penetrant or radiograph tests when ultrasonic testing is not feasible. 1) Ultrasonic inspection technique and standards: AWS D1.1 Part C. 2) Particle inspection method: ASTM E709. 3) Penetrant inspection method: ASTM E165. 4) Radiography tests: AWS D1.1, Part B.

c. Extent of testing: 1) Special moment-resisting frames. Define test locations of primary

member connections.



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F. Additional Tests: Contractor shall provide and pay for all necessary additional tests made on welds or bolts required to repair or replace faulty work performed during the original fabrication.

G. Mechanical Expansion and Adhesive Anchoring Systems:

1. See Section 05090.

1.05 DELIVERY, STORAGE AND HANDLING A. Deliver anchorage devices that will be embedded in the work of other trades in

sufficient time to permit their timely installation. Provide proper setting drawings, templates and directions for installation.

B. Handle, ship and store material in a manner that will prevent distortion, rust,

damage to the shop coat or any other damage. C. Ensure that dissimilar metals are not in contact with each other. D. Replace or repair all damaged material in an approved manner. E. Store materials above ground on platforms, skids or other supports. Store all

fasteners and welding electrodes in a weathertight and dry location until ready for use. Store packaged materials in their original labeled containers.

PART 2 - PRODUCTS

2.01 MATERIALS, GENERAL

A. Standard Structural Steel Shapes, Bars, Angles, and Plates: ASTM A36.

B. W-Shapes and WT-Shapes: ASTM A992, fy = 50 ksi, fu = 65 ksi.

C. Steel Tubing: ASTM A500, (cold formed) Grade A, or ASTM A501 (hot formed), welded or seamless.

D. Steel Pipe: Seamless, conforming to ASTM A53, Type E or S, Grade B.

E. Bolts and Nuts: ASTM A307, Grade A.

F. Plain Washers: ASTM F844.

G. Beveled Washers: ANSI B18.23.1.

H. Stainless Steel: AISI Type 316, ASTM A276

I. Anchorages to Concrete: In accordance with Section 05090.

J. Non-Shrink Grout: In accordance with Section 03300.

2.02 GALVANIZING A. Where galvanizing is specified, it shall be hot-dip galvanized. Hot-dip galvanize all

exterior ferrous metal work and all noted interior ferrous metal work. B. Hot-dip galvanize all sheet steel, plain or shaped in accordance with ASTM A653,

G-90 Commercial Grade.




C. Hot-dip galvanize all products fabricated from rolled, pressed and forged steel

shapes, plates, bars and strip 1/8-inch thick or heavier, in accordance with ASTM A123.

D. Hot-dip galvanize all steel hardware, nuts, bolts, washers, anchors, and threaded

rods in accordance with ASTM A153 or F2329. Size thread clearance to allow for galvanized coating; rerun threads after galvanizing, if required, to assure a smooth fit.

2.03 GALVANIZING REPAIR A. Repair damaged galvanizing by heated repair method. Repair materials: ReGalv by

Rotometals, Inc., San Francisco, CA; or equal. Specifier knows of no equal.

2.04 ISOLATION COATINGS A. Provide neoprene or phenolic washers and isolation bolt sleeves or insulating

compound at all stainless steel fasteners to non-stainless steel interfaces. Isolation washers shall be capped under a stainless steel washer. Insulating compounds shall be TefGel by Ultra Safety Systems Company, Lanocote by Forespar, or equal.

2.05 WELDING ELECTRODES, FILLER METALS A. Steel: AWS A5.1 or A5.5, E70XX category. B. Stainless Steel: AWS A5.4 or A5.9. C. For welding dissimilar metals, submit the appropriate electrodes for Product Review.

2.06 FABRICATIONS

A. Structural Steel Work: Comply with the applicable provisions of the AISC Specification, the AISC Standard Practice and AWS D1.1. Weld only in accordance with favorably reviewed WPSs, which are to be available to welders and inspectors during the production process. Provide workmanship equal to standard commercial practice in modern structural shops. 1. Fabricate and assemble in the shop to the greatest extent possible, and deliver

to the project as a unit ready for installation. Coordinate the work, making all provisions necessary for the passage of all applicable work into, and attachment to, the structures. Make joints carefully and neatly, with corners mitered and spliced, bolted, screwed, or welded together.

2. Make proper allowance for the expansion and contraction of the metals, and of the materials to which they are fastened.

3. Make completely watertight joints on exterior work. 4. Shape all members correctly, with no kinks, twists, dents, or other blemishes

prior to erection. Evenly spring all curved work. 5. Make exposed edges free of burrs, sharp edges or corners. Make corners

rounded or chamfered. Grind exposed welds smooth when specified. 6. Include supplementary parts necessary to complete each item, even though

such work may not be definitely specified. Provide all such miscellaneous



CNG Fueling Station

metalwork required by the project in accordance with good accepted standard practice.

B. Stainless Steel Work:

1. Use the proper type of stainless steel electrodes or welding rods complying with AWS D10.4. Grind all welded joints smooth and polished, using wheels never used on carbon steel. Provide welds that eliminate damage to stainless steel parts in appearance, strength and resistance to corrosion.

2. Remove by grinding and polishing, all scratches, marks, pits and other blemishes on exposed surfaces incurred during fabrication of the material, until the entire surface possesses the same finish as the adjacent work.

C. Base and Bearing Plates: Furnish under all columns, pipe supports, including rack

type, supports for tanks, equipment frames and cabinets, and similar items. Provide rounded or chamfered corners.

D. Dissimilar Metals: Insulate the faying surfaces with a brush coat of cut-back

asphaltic or coal tar paint or by gasketing. Submit for favorable review. E. Metals in contact with cementitous or other material: Provide finish coating prior to

erection.

F. Steel Guardrails: 1. Fabricate from 1-½-inch-nominal-diameter Schedule 40 steel pipe. Maximum

post spacing 5 feet. 2. Hot-dip galvanize, after fabrication, guardrails and handrails exposed to the

exterior and where noted to be galvanized. 3. Avoid posts at inside or outside corners. Locate posts close enough to the

corner in each direction so the diagonal distance between posts does not exceed the maximum allowed rail spacing. Form the corner with tight radius pipe bends or manufactured elbows. Miters are not permitted. Where a post at a corner is unavoidable, use a manufactured three-way side outlet flush welded elbow.

4. Make all wall returns, connections of a top rail to a post at the end of a run and other changes in direction with smooth tight radius pipe bends or flush welded manufactured elbows. Miters not permitted.

5. Make all pipe bends on bending jigs designed to produce accurate bends without buckling or deforming the pipe walls.

6. Make tee and cross intersections with manufactured flush weld type fittings or by carefully coping and welding the pipe.

7. Weld all joints with continuous beads. Thoroughly fuse without undercutting or overlap. Size welds to develop the full strength of the members joined after grinding. Grind and sand all groove welds flush.

8. Grind all fillet welds to a uniform radius tangent to the members joined after grinding. Round all edges and corners to a minimum radius of 1/8-inch. Sand with progressively finer grits removing all tool marks, imperfections, and scratches before proceeding to the next finer grit. Finish with 80 grit.

9. Close exposed ends of pipes by welding 3/16-inch-thick closure plate inside and flush with pipe end.

10. Return ends of handrails 90 degrees to walls, close exposed end and mount with 1/8-inch maximum space between end of rail and wall.




11. Bend or offset handrails where required to provide 1-½-inch minimum code required clearance between handrail and edge of floor slab, columns, ducts, pipes, pilasters or other obstructions.

12. Cut and grind post ends to precise length and angle for where field welding to stair stringers is required.

13. Provide expansion slip joints at 40-foot centers. Use an internal sleeve 4 inches long fastened to one side. Bevel exposed edges of pipe at joint.

PART 3 - EXECUTION

3.01 ERECTION TOLERANCES A. Conform to straight plumb and horizontal lines which also form a true flat plane to

within 1/8-inch in 2 feet and ¼-inch in 10 feet and 1/2 maximum overall. B. Curved surfaces shall conform to a true arc of a circle to within 1/8-inch in 12 inches

and ¼-inch maximum overall.

3.02 INSTALLATION GENERAL A. Fabricate and pre-fit metal work in the shop, in transportable components ready for

field erection. B. Make proper allowance for expansion and contraction of the metals and of the

materials to which they are fastened. C. Where metal is fastened to concrete, make the connection by means of sleeves and

fastenings embedded in concrete or by expansion shield anchor bolts or wedge anchor bolts. Wood plugs, plastic plugs or powder driven studs are not acceptable.

D. Construct steel work in accordance with AISC Standard practices to withstand the

forces normally applied and in compliance with CBC and OSHA requirements. E. Grind welds smooth on all metal work exposed to view. Provide work that has:

1. Surfaces that are flat, straight, square, plumb and level. 2. Smooth curves, free of flat spots, and of uniform radius or, if intended to be of

changing radius, follow a flowing fair curve. 3. Make transitions between curved and straight portions of work at tangent points

to achieve smooth and free flowing lines and surfaces without flat spots or abrupt changes in direction.

F. Provide 1/8-inch radius corners and edges on all exposed work. G. Perform all welding in accordance with AWS Code D1.1. Employ methods and

techniques to achieve strength and good appearance. H. Field Assembly: Set members to lines and elevations indicated. Align and adjust

members before making permanent connections.



CNG Fueling Station

I. Galvanized Metal Repair: Repair damaged galvanized metal by the heated substrate method as specified in Paragraph 2.03.

J. Touchup Painting (Ferrous Metals): After field assembly, clean all bare metal and all

abrasions to shop coat, and spot paint with same primer used in the shop.

3.03 GUARDRAILS AND HANDRAILS A. Provide workmanship of the highest quality performed by mechanics skilled in

executing high quality architectural metal work. B. Set shop fabricated guardrail sections into position and align the top rail so that it is

true to specified tolerances. Do filet joining neatly and inconspicuously. C. Install horizontal sections of guardrail with the top rail exactly horizontal. Vary the

height of the rail as required to accommodate sloping deck surfaces. Maintain code required minimum and maximum rail heights.

D. Support guardrails with temporary braces and shoring to maintain true alignment

until all final connections and grouting are completed.

3.04 MISCELLANEOUS A. Furnish the following for field installation:

1. Miscellaneous metal work not specified in other sections.

3.05 REPAIRS A. Repair or replace all defective work including:

1. Unsightly welds. 2. Discontinuous welds. 3. Uneven connections. 4. Variations exceeding specified tolerances. 5. Kinks, bends. 6. Other defects affecting the quality, strength, utility and appearance of the work.

3.06 CLEANING A. Wash thoroughly using clean water and detergent. B. Do not use acid solutions, steel wool or other abrasives. C. Remove stubborn grease stains with mineral spirits.

END OF SECTION




PAGE INTENTIONALLY

LEFT BLANK


07900 - 1 Joint Sealants CNG Fueling Station

SECTION 07900

JOINT SEALANTS

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: 1. Sealant work required:

a. For a watertight project. b. To provide sanitary conditions. c. Required by code and not specifically covered in another section.

2. Seal between all plumbing fixtures and adjacent surfaces. 3. Minimum standards for all sealant work whether covered in this Section or in

other sections.

1.02 REFERENCES

A. Federal Specifications: 1. TT-S-00-230C Sealing Compound: Elastomeric Type, Single Component

(For Caulking, Sealing and Glazing in Buildings and Other Structures)

2. TT-S-00-227E Sealing Compound: Elastomeric Type, Multi-Component (For Caulking, Sealing and Glazing in Buildings and Other Structures)

3. TT-S-00-1543A Sealing Compound: Silicone Rubber Base (For Caulking, Sealing and Glazing in Buildings and Other Structures)

1.03 SUBMITTALS

A. Submit the following in accordance with Section 01330. 1. Product Data: Fully describe all products proposed for use. 2. Samples: Physical samples of cured sealants for selection of colors. 3. Manufacturer’s Instructions: Application instructions for all products used.


A. Qualifications: Provide sealant work performed by a licensed Specialty Sealant and Waterproofing Contractor who is exclusively engaged in sealant application work. All work to be performed by qualified journeymen proficient in the craft of sealant application.

B. Regulatory Requirements: Comply with the California Building Code, 2010 edition.

1.05 PROJECT CONDITIONS

A. Environmental Requirements: Apply sealant only when temperature and humidity conditions are at the levels recommended by the sealant manufacturer.

Joint Sealants CNG Fueling Station



1.06 SPECIAL GUARANTEE

A. Provide a written Special Guarantee in accordance with Section 01780 covering replacement of sealant work that fails within 2 years of the date of project acceptance. Failure includes: 1. Becoming brittle or cracking due to exposure, contraction or expansion. 2. Failure to resist abrasion of normal use and traffic. 3. Tear failure due to movement within 50% of joint width for Class A sealants. 4. Cohesive or adhesive failure due to movement within 50% of joint width for

Fed. Spec. Class A sealants. 5. Water infiltration for joints intended to exclude water, air infiltration for joints

intended to exclude air.

PART 2 - PRODUCTS

2.01 MATERIALS

A. Sealant Type "A": Exterior and interior horizontal traffic deck sealant two-part self-leveling polyurethane with a Shore "A" hardness greater than 34, conforming to Fed. Spec. TT-S-00227E Type I, Class A, in color selected. Acceptable products are: 1. Mameco "Vulkem" No. 245 used with #401 primer. 2. PRC #230 used with recommended primer. 3. Or equal.

B. Sealant Type "B": Exterior and interior vertical surface sealant for use in joints in concrete, metal and similar materials, conforming to Fed. Spec. TT-S-00230C Type II, Class A, in color selected. Acceptable products are: 1. One part polyurethane: Mameco "Vulkem" No. 116. 2. One part polyurethane: Sika Sealant Division Sikaflex 1a. 3. Or equal.

C. Sealant Type "C": Paintable silicone sealant suitable for sealing cracks, voids, joints, etc. in exterior or interior surfaces that are to be painted or left unpainted. Acceptable products are: 1. G.E. Paintable Silicone Sealant. 2. Dow Corning Paintable Silicone Sealant. 3. Or equal.

D. Sealant Type "D": Silicone sealant meeting Fed. Spec. TT-S-001543A, Class A for use in expansion joints in precast concrete. Acceptable products are: 1. Dow Corning 795 Silicone. 2. G.E. Silpruf. 3. Or equal.

E. Sealant Type "E": Mildew Resistant Silicone Sealant: One part silicone sealant for sealing non-porous interior surfaces where conditions of high humidity and temperature extremes exist. Dow Corning #786 Mildew Resistant Silicone Sealant; General Electric #1700 Sanitary Sealant; or equal.

F. Sealant Type "F": Two-component, modified polyurethane sealant intended to resist up to five parts per million of chlorine or ozone in water, for interior and exterior use. Acceptable products are: 1. Select Products Co. "Select Seal U-920."


07900 - 3 Joint Sealants CNG Fueling Station

2. Sika Corp. "Sikaflex-2C." 3. Or equal.

G. Sealant Type "G": Silicone glazing sealant, Shore "S" 30 durometers: Dow Corning Silastic 732-RTV; General Electric STC-1200; or equal.

H. Sealant Backup: Polyethylene rod stock. Acceptable products are: 1. Dow Corning "Ethafoam." 2. Hercules, Inc., HBR Backer Rod. 3. Or equal.

I. Sealant Tape: Resilient, nonstaining, 100% vulcanized butyl rubber, scrim reinforced, self-adhering, extruded sealant tape containing no asphalts. Acceptable products are: 1. Protective Treatments, Inc., #303 2. Tremco #440, 3. Or equal.

PART 3 - EXECUTION

3.01 CONDITION OF SUBSTRATE

A. Allow concrete to cure for at least 28 days before applying sealants.

B. Inspect substrates to receive sealant work for: 1. Deviation beyond allowable tolerance for joint width and required clear joint

depth. Joint width shall not be less than 1/4-inch or the width shown. 2. Presence of contaminants, which cannot be removed by normal joint

cleaning. 3. Presence of moisture. Joint surfaces shall be dry.

C. Do not start work until unsatisfactory conditions are corrected.

3.02 3.02 PREPARATION OF SURFACES

A. Clean surfaces to which sealant is to be adhered: 1. For Concrete: Sandblast joint surfaces taking care to protect exposed finish

surfaces. 2. For Metal: Sand or scrape and solvent clean with a non-film forming solvent.

B. Insure that cleaned surfaces are not contaminated before applying sealant.

3.03 APPLICATION

A. Follow sealant manufacturer's published instructions.

B. Install sealant backup the proper distance from face of joint for joint proportioned in accordance with sealant manufacturer's recommendations. Use polyethylene rod stock larger than joint so that backup can be firmly held in place.

C. Apply primer and/or cleaner conditioner recommended by sealant manufacturer for substrate. Avoid getting primer on the face of material or on areas that will not be covered by sealant.

D. Mask edges of joint with masking tape where required to avoid contamination of exposed surfaces adjacent to joint.

Joint Sealants CNG Fueling Station



E. Apply self-leveling sealant by pouring, pumping or with a caulking gun. When using pump or caulking gun fill joint from the bottom up to avoid air entrapment. Fill joint flush with surface of adjacent material without overfilling or spilling sealant on exposed surfaces.

F. Apply vertical grade sealants by hand or power operated caulking gun. Use a caulking tip the proper width for the joint required. Fill the joint from the bottom up to insure a fully filled joint without entrapped air bubbles or voids. Use lubricant recommended by sealant manufacturer to tool joints. Force sealant against sides and bottom of joint and into all crevices; press out air bubbles and voids. Tool sealant surface smooth and flush with adjacent surfaces for butt joints or to an even, straight-sided fillet of uniform width and slope for fillet joints.

G. Where the substrate or adjacent sealants are incompatible with the specified sealant, submit a sealant suitable for the required use and of equivalent life expectancy to the specified sealant.

3.04 EXPANSION JOINTS

A. Apply sealant in expansion joints when the joint opening width is approximately halfway between dimensional extremes of thermal movement.

B. Place sealant backer rod the proper distance from face of joint to insure that sealant bead depth is never more than half the bead width at any time between dimensional extremes of joint.

3.05 CLEANUP

A. Upon completion, remove protective masking and clean any sealant from adjacent finished surfaces beyond edge of joint.

END OF SECTION


09960 - 1 High Performance Coatings CNG Fueling Station

SECTION 09960

HIGH PERFORMANCE COATINGS

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: 1. Coat or paint all facilities and equipment which are part of this Contract as

delineated in Paragraph 3.07, except: a. Metal completely embedded in concrete (except aluminum). b. Piping buried in ground or encased in concrete. c. Galvanized grating, galvanized bolts, and galvanized grating frames. d. Rubber. e. Stainless steel. f. Bronze, brass. g. Nameplates and grease fittings. h. Factory finished electrical panels. i. Factory fusion epoxy coated items (except for field touchup). j. Aluminum handrail and aluminum guardrail. k. Concrete, except as defined herein, as specified elsewhere, or as

shown on the Drawings.

B. Related Sections: 1. Section 10400: Signage

C. The Contractor is to base this bid on using the products specified.

1.02 REFERENCES

A. Where standards of surface preparation are described by citing SSPC specification numbers reference is made to the standards published by SSPC – The Society for Protective Coating.

B. American Society of Testing and Materials (ASTM): 1. ASTM D4060 Test Method for Abrasion Resistance of Organic Coatings

by the Taber Abraser 2. ASTM D2794 Test Method for Resistance of Organic Coatings to the

Effects of Rapid Deformation (Impact) 3. ASTM D4541 Test Method for Pull-Off Strength of Coatings Using

Portable Adhesion Testers 4. ASTM F1249 Test Method for Water Vapor Transmission Rate Through

Plastic Film and Sheeting Using a Modulated Infrared Sensor

High Performance Coatings CNG Fueling Station



1.03 DEFINITIONS

A. Dry Film Thickness (DFT) - The prime coat and the sum of all fully cured applied coats for the paint system.

B. Exterior Surface - Surface that is not inside a building or structure and is exposed to the weather. Epoxy surfaces that are affected by the ultraviolet rays from the sun shall be considered an exterior surface if the sun can shine on the surface.

C. Stripe Coat - Coating applied to the edge, corner, welds or bolts, which is applied prior to application of additional system coats.

D. Submerged - Surfaces that are under water or the vertical extension of those walls that are partly under water during normal operating conditions.

1.04 SUBMITTALS


B. Prior to ordering material, submit a complete schedule of materials to be used. Include manufacturer's brand name, product name, and designation number for each coat of each system to be used. Submit product literature, catalog cutsheets, application instructions, service recommendations, and other pertinent information on each of the specified coatings.

C. Submit a detailed coatings plan and schedule at least 14 days before any coating/blasting work begins. Include a detailed list of all components (for example, specific equipment, specific sections of piping, etc.) to be coated and the coating system to be applied to each component. Receive favorable review of the plan and schedule prior to the start of any coating work.

D. Provide the following information on each paint product: 1. Abrasion resistance, ASTM D4060, 1 kg load at 1000 cycles, CS-17 wheel. 2. Impact resistance, ASTM D2794, direct and reverse. 3. Moisture vapor transmission, ASTM F1249. 4. Adhesion, ASTM D4541.

E. If materials other than those listed are submitted, submit additional information to fully define the proposed substitution. Submit information on the materials as necessary to fully define the proposed substitution. The City Representative may further require the Contractor to furnish additional test results from an independent paint laboratory comparing the proposed substitution with one of the named products, at no additional cost to the City. For substituted materials, provide a list of references, including contact person and phone number, where proposed substitute paint system has been used in similar exposures. Provide a minimum of five references (no duplicate owners or agencies).

F. Provide Material Safety Data Sheets (MSDSs) for all products.

G. Manufacturer’s Certification: That products furnished meet applicable Air Quality Management District regulations as to allowable volatile organic compound (VOC) content for the place of application and use intended.

H. Submit a full range of the manufacturer's standard and let down finish colors for review and selection by the City. After final colors have been selected, submit two 8-1/2- x 11-inch samples on cardboard of each color indexed as to manufacturer and color designation. Color chips 3/4-inch x 1-1/2-inch may be used for pipe color



codes. Colors may require special blending to meet City’s requirements to match existing color systems. Colors shall be in accordance with the City’s Paint Identification System included at the end of this specification section.

I. Submit four pipe and equipment color code charts, 11 x 14 inches in size, with typed labels and using color chips. Upon favorable review, frame charts and mount under glass, suitable for hanging in work areas.

J. Submit documentation of the coating applicator’s experience.

K. Submit documentation of all required certification or training of coating applicators.


A. Environmental Regulatory Requirements: 1. All work, material, procedures, and practices under this Section shall conform

to the requirements of the local Air Resources Board or Air Quality Management District having jurisdiction. Prime or finish coat painting done in locations other than the project site shall be in accordance with air quality regulations in effect at the place the coating is applied. Products specified herein are, to the best of the Design Engineer's knowledge, in compliance with the applicable volatile organic compounds (VOC)1 levels allowable at the date these Specifications were issued for bid.

2. The Air Resources Board or Air Quality Management District having jurisdiction may prohibit the sale or application of paints and enamels containing more than the stipulated percentages of volatile organic solvents manufactured after a stated date. Provide material meeting applicable regulations effective at the date of manufacture, or if not available, provide top of the line materials developed as replacements for specified materials and meeting applicable regulations as to VOC solvents content.

3. If the Contractor applies coatings that have been modified or thinned other than as recommended by manufacturer, he will be responsible for any fines, costs, remedies or legal actions that may result.

B. The protective coatings named in this Specification are used to establish the standards of quality and utility required. They are compatible as related to color, selection, and material. Documentation required to be submitted to demonstrate the equality of the proposed substitutions shall include letters from the manufacturer’s of the proposed substitute coatings indicating the suitability of the substitute coatings for the required services and documentation to substantiate any claims made by the coating manufacturers. In addition, the City Representative may require, at no additional cost to the City, the submission of test results from an independent coating laboratory comparing the proposed substitutions with the named products. Listing a manufacturer by name in this Section shall not relieve the Contractor of the responsibility for ensuring that all products furnished by the Contractor are in total compliance with all specified requirements.

C. Applicators shall be experienced in the application of industrial coatings of the types specified for application on this project and on facilities similar to those being coated as part of this project. Applicators shall demonstrate that they have routinely and successfully applied coatings of the types specified herein for the previous five (5) years or longer by submitting a list of a minimum of five (5)

1 Measured in grams per liter by weight of coating as applied, excluding water and color added to be base tint.




projects on which they have applied coatings of the type specified for application on this project on facilities similar to those being coated as part of this project in the last five (5) years. This list shall indicate the type of coatings applied and the type of facilities on which they were applied. In addition, the list shall include the names and telephone numbers of owners of the facilities on which the coatings were applied. Further, individual applicators of Systems 2 and 3 coatings shall be trained and qualified by the coating manufacturer and shall submit documentation of such per Paragraph 1.05 D.2

1.06 WARNINGS

A. Be advised that application of paint, epoxy and protective coating materials may be hazardous. Take all necessary precautions to ensure the safety of workers and property.

B. Be advised that as a part of this work abrasive blasting is required. This may require the use of special equipment. Become familiar with the existing site conditions and take all steps necessary to protect adjacent facilities and personnel, at no additional cost to the City. In addition, abrasive blasting and painting is called for in, on or around mechanical equipment, which may be damaged by grit, dust, or painting overspray. Mask, wrap, enclose and provide all protection required to safeguard this equipment at no additional cost to the City.

C. Perform abrasive blasting activities in a manner that will not cause a nuisance to employees of the City or adjacent public and private property and equipment. Provide tenting or other containment as necessary at no additional cost to the City.


A. Deliver all coating materials in unopened containers with manufacturer's label, which must include name, batch number and date and VOC content.

B. Store in an assigned area onsite with concurrence from the coating manufacturers. Maintain storage area clean and fire safe. Dispose of used rags, thinner and buckets daily. Store solvents in closed approved storage containers.

C. Submerge solvent soaked rags in water.

1.08 PROJECT CONDITIONS

A. Environmental Requirements: 1. Apply coatings only under ambient and surface conditions recommended by

manufacturer of material to be applied. 2. Provide adequate ventilation. Mechanical ventilation shall be used to control

potential exposure of workers to airborne contaminants as set forth in Section 1536 of the Construction Safety Orders and Section 5155 of the General Industry Safety Orders. Methods of ventilation shall meet the requirements set forth in ANSI-Z9.2, latest revision.

3. Use heated dehumidification equipment for areas receiving System 2 coatings. Atmospheric conditions shall conform to the requirements of the manufacturer of the material to be applied and these specifications, whichever are more stringent.

4. Provide 40- to 50-foot candles of illumination on all surfaces in areas to be painted including floors, walls and ceiling even though they do not require coating. Conform to SSPC Guide 12.



5. Use temporary dust barriers to close off areas being painted from areas where other work is being performed.

1.09 COLORS AND SAMPLES

A. Colors shall be in accordance with the City Paint Identification Schedule included at the end of this specification section.

B. Before starting work, obtain favorably reviewed color schedule.

C. Colors are to be factory mixed, using light-fast colorants proportioned by accurate measurement into proper type base. All coatings must be formulated to perform in the climate and environment to which they will be exposed.

1.10 WARRANTY

A. Warranty shall be in accordance with the General Conditions.




PART 2 - PRODUCTS

2.01 MATERIALS

A. Coatings used in each system to be the product of one manufacturer.

B. Shop applied prime coats shall comply with the requirements of this Section.

C. Substituted coating systems (when favorably reviewed) shall be of the same generic type as those specified.

D. Coating systems shall not contain lead.

E. Materials: Paints and protective coatings listed in the Paint Systems and the Schedule in Part 3 of this Section refer to the following manufacturers and are specified as levels of quality. It is understood that the words "or equal" are included herein.

Sherwin Williams (SW) Kop Coat (K) Tnemec Co. (T) Polibrid (PB) Protecto Wrap (PW) Tapecoat (TC) Chemical Products Co. (ZRC) Ameron (A) Global EcoTechnologies (GE)

2.02 PAINT SYSTEMS

System 1A: General Ferrous Exposed to Atmosphere 1st Coat - bare metal High Solids Epoxy (A) Amerlock 400 (T) Series 135

Finish Coat(s) High Solids Epoxy (A) Amerlock 400 Total DFT = 12 - 15 mils (T) Series V69

Final coat for exterior surfaces DFT = 4 mils additional

Aliphatic Polyurethane (A) Amercoat 450HS (T) Series 74

System 2: (Not Used)

System 3: (Not Used)



System 4: Bleeding Surfaces: (Not buried) 1st Coat(s) High Solids Epoxy (A) Amerlock 400 (T) Series 135

2nd Coat High Solids Epoxy (A) Amerlock 400 DFT = 12 mils (T) Series 69

Finish coat - exposed surfaces DFT = 2 mils additional


System 5: Prefinished Machinery Coating (Other than prime coat) One coat Aliphatic Polyurethane (A) Amershield DFT = 2 mils (T) Series 74 System 6: Galvanized Steel and Non-Ferrous Metals 1st Coat(s) High Solids Epoxy (A) Amerlock 400 (T) Series 135

2nd Coat High Solids Epoxy (A) Amerlock 400 DFT = 8 mils (T) Series 69

Finish coat – exterior surfaces DFT = 2 mils additional


System 7: Miscellaneous Service Coating One full brush coat Coal Tar (K) Bituplastic #33 (T) 46-40 Tnemecol System 8: Buried Valves One full brush coat (PW) 160/160 H Mastic DFT = 20 - 30 mils

(TC) TC Masti

System 9: Not Used

System 10: Not Used System 11: Not Used System 12: Plastic and Fiberglass Surfaces 1st Coat

DFT = 3 mils High Solids Epoxy

(T) Series N69 (A) Amercoat 400

2nd Coat DFT = 3 mils

Aliphatic Polyurethane (T) Series 1075 (A) Amershield VOC




PART 3 - EXECUTION

3.01 SURFACE PREPARATION

A. Perform surface preparation in accordance with the Application Schedule included herein and the latest revision of the following requirements or the coating manufacturer's requirements, whichever is more stringent: 1. Shop Prime: Shop applied coatings and related surface preparation shall

comply with the requirements of this Section. 2. Steam Clean: Conform to ASTM D4258 and remove all grease, oil, and

similar contaminants. Use jet of high-pressure steam at a minimum temperature of 180-deg F sufficient to remove the contaminants. Add detergents or nonsolvent emulsifying agents to facilitate contaminant removal. Remove all residual detergents and emulsifying agents by thoroughly rinsing with clean water. The pH of final surfaces shall conform to the acceptance criteria of ASTM D4262. Allow surfaces to dry.

3. Detergent Wash and Rinse: Wash with detergent strong enough to remove oils and grease. Remove all residual detergent by thoroughly rinsing with clean water. The pH of final surfaces shall conform to the acceptance criteria of ASTM D4262. Allow surfaces to dry.

4. Water Blast: Remove all dirt, dust, and foreign matter with high pressure water. On metal, remove all but the most tightly adhered rust, mill scale and paint. On concrete, conform to ASTM D4259 and remove all deteriorated, soft, and weak concrete; loose aggregate; contaminants; and existing coating to sound concrete. At a minimum, the final concrete surface texture shall resemble 40-60 grit sandpaper. Minimum waterblasting pressure and flow: 5000 psi and 15 gpm. Allow surfaces to dry.

5. Abrasive Blast: a. Metal:

1) Near-white: Conform to the requirements of SSPC-SP 10, "Near White Blast Cleaning.” Surface profile on steel shall be 1.5 to 2.0 mils for System 1, 3.0 to 5.0 mils for System 2. All blasted surfaces shall be continuously maintained under the atmospheric and surface conditions specified using heated dehumidification equipment.

2) Commercial: Conform to the requirements of SSPC SP-6, “Commercial Blast Cleaning.” Coat all blasted surfaces within 8 hours of blasting.

3) Remove all weld spatter by grinding or chipping prior to blasting per NACE SPO-178.

4) Conduct a blotter test daily at the start of all abrasive blasting operations. Blotter test shall conform to ASTM D4285.

b. Concrete: Conform to the requirements of ASTM D4259. Remove all deteriorated, soft, and weak concrete; loose aggregate; contaminants; and existing coating. The final surface shall be sound. At a minimum, the final surface texture shall resemble 40-60 grit sandpaper. Vacuum surface clean immediately prior to application of coating.

6. Brush Clean: Remove dirt, dust, loose rust and foreign matter in accordance with specification SSPC-SP 2, "Hand Tool Cleaning."

7. Solvent Clean: Solvent clean metallic surfaces to be painted to remove all oils or grease in accordance with specification SSPC-SP 1, "Solvent



Cleaning." Use solvents recommended by manufacturer of paint to be used in each area. In addition, lightly hand sand copper piping.

8. Hand Tool Clean: SSPC SP-2, "Hand Tool Cleaning”. 9. Power Tool Clean: SSPC SP-3, "Power Tool Cleaning"

B. Grind smooth all sharp edges and rough areas that will hinder the application of a pinhole-free coating prior to the application of any coating.

C. All equipment shall have air dryers and oil moisture separators installed. All air lines shall be equipped with cable whip checks.

3.02 APPLICATION

A. All steel coating application to be done in accordance with the latest revision of the applicable SSPC Paint Application standard. When successive coats of coating system of the same colors are specified, tint alternate coats sufficiently to produce enough contrast to indicate complete coverage of the surface.

B. Apply all material in strict accordance with manufacturer's instructions. Apply first coat immediately after surface preparation. Keep all coatings at a consistency and applied in accordance with the printed directions of the manufacturer. The coating shall be done by hand, spray or roller as approved by the City Representative in conformance to individual coating manufacturer's recommendations. The City Representative and coating supplier will review all surfaces to be coated on the job prior to application of any coatings. Once the Contractor begins undercoating or priming, this will be his guarantee that the surface is acceptable to coat. All coated surfaces are to be free from drips, ridges and brush marks. The following stipulations also apply: 1. Thinning permitted only when recommended by the manufacturer and only

with thinner recommended for use with the particular product. 2. The use of additives to improve working characteristics or to lengthen or

shorten set time is prohibited. 3. Items difficult or impossible to coat after installation are to be coated before

installation and touched up after installation. 4. Apply each coat to a uniform, even coating; lay material on in one direction

and finish at right angles. Allow material to thoroughly dry between coats. Scuff, sand and remove all runs, sags, overspray, surface roughness and other defects between each coat. Dust and wipe surface clean before applying next coat.

5. Cutting in is to be sharp and straight, free from overlaps or fuzzy edges. Redo any imperfect work.

6. Apply not less than the number of coats or dry film thickness specified. Apply additional coats if required for uniform coverage, full hiding, and to achieve film continuity. Finished work to be uniform in color, full coverage, smooth and free of sags and brush marks.

7. Apply coating only when temperature is above 55°F and when the temperature of the surface to be coated is no less than 35°F above the dew point temperature and on the rise. Perform coating operations only under favorable environmental conditions. Take all steps necessary to protect and completely cure the work. Correct defective work to the full satisfaction of the City Representative.

8. Apply the last finish coat on all work after all major construction is complete and the work areas have been cleaned up and are dust free.




9. Cutting in is to be sharp and straight, free from overlaps or fuzzy edges. Redo any imperfect work. Mask off all repairs.

C. Systems 2 and 3 Coatings: 1. Apply Systems 2 and 3 coatings by plural component spray, except for areas

of pinhole repair. Glue guns and glue sticks approved by the coating manufacturer may be used for pinhole repair if favorably reviewed by the City Representative. These shall not be used as filler material for imperfections or bug holes.

2. All spray equipment shall be thoroughly flushed before and after each use with an appropriate thinner.

D. Contractor shall provide ratio checks in clean measuring cups prior to daily start up of coating application operations, and at anytime at the request of the City Representative. Ratio checks shall be conducted at the end of the spray lines.

E. All gauges on pumps shall be in working order prior to startup. If a defective gauge is found, coating operations will not begin until the gauge is removed and replaced.

F. Evaluate surface preparation using field abrasive blasting standards. Evaluation shall include inspection of blasted surfaces for dust and abrasive residue using clear adhesive coated tape. Evaluation shall be made immediately prior to coating application. All surfaces shall be vacuumed clean prior to any application of coatings.

G. Sample shall be sprayed on plastic prior to each application. Document each sample with the date prepared and location to be coated. Samples will be retained by the City.

H. Contractor shall perform hardness testing after each application.

3.03 PIPE AND EQUIPMENT IDENTIFICATION

A. Identify all piping and equipment exposed to the atmosphere, both interior and exterior, and including pipe located in concrete pipe trenches, by a combination of color coding, stenciling or pressure-sensitive tape and direction arrows.

B. Identify painted pipe 4 inches in diameter and larger by stenciling identification names and directional arrows. Identify unpainted pipe and pipe less than 4 inches in diameter by color vinyl pressure-sensitive lettered labels and arrows as described in Section 10 14 00. Place names and arrows every 16 feet and wherever a pipe enters or leaves a room or a pipe trench. Provide lettering size as follows:

Pipe Diameter Lettering Size (Height)

1-1/4" or less 1/2" 1-1/2" to 2" 3/4" 2-1/2" to 6" 1-1/4" 8" to 10" 2" Over 10" 3-1/2"

C. Provide pipe identification names as listed in the Piping Schedule on the Drawings. Abbreviate any names exceeding 20 letters. Directional arrows are to be in black and be proportional to lettering. Color of equipment and pipe shall be as shown on



a schedule to be provided by the City Representative. Gloss enamel is to be used for stenciling.

D. Paint equipment in the same color as the pipe to which it is connected.

E. Paint conduit and ductwork in colors to match adjacent walls/ceilings.


A. The following is a list of equipment which shall be used by the Contractor, applicators, and coating manufacturer's representative. One set of the equipment listed, that is certified and in good working condition, shall be made available to the City Representative for his use until final acceptance of the work. 1. Air Temperature and Relative Humidity: Bacharach Sling Psychrometer,

Model #12-7012. 2. Surface Temperature: Surface Temperature Thermometer, Model

#PTC/312F, 0-250º F. 3. Material Temperature: Model #6212 Taylor Paint Thermometer, 25-125ºF., 8

inch stem. 4. Wet Film Thickness: Nordson Wet Film gage, Model #790-010, 0-20 mils. 5. Dry Film Thickness: Elcometer 456 Dry Film Thickness Gage. 6. Anchor Pattern: Keane-Tator Profile Comparator. 7. Surface Preparation: SSPC-SP VIS 1-89 Visual Surface Preparation

Standards. 8. Holiday Detection: Elcometer 236 Holiday Detector. Equal equipment of other reputed names may be used instead with favorable review.

B. Prior to the start of work each day and during the progress of the work through each day, the Contractor shall make his/her own inspections and measurements of the relative humidity, surface and air temperatures, wet film thickness and dry film thickness. Dry film thickness of each coat shall be made in accordance with SSPC-PA 2. The City Representative may perform his/her own measurements in addition to the Contractor’s required measurements.

C. Pinhole, Continuity and Film Thickness Testing: 1. Perform continuity and pinhole checks of all coated surfaces by holiday

detection per NACE SPO-188 and perform thickness checks with a magnetic thickness gauge.

2. The City Representative may perform his/her own continuity, pinhole and thickness checks in addition to the Contractor's required checks. The appropriate equipment and necessary support, if requested, is to be provided by the Contractor.

3. All pinhole, continuity and thickness testing shall be performed in accordance with applicable SSPC standards.

4. Pinhole-free conditions and specified film thicknesses for each coating system shall be achieved over all of the coated surfaces.

5. Repair all deficiencies in film integrity and thickness in accordance with the coating manufacturer's instructions and to the satisfaction of the City Representative.

6. Electrical resistance meter tests: a. Test voltage per NACE SPO-188.




b. Contractor’s attention is directed to the fact that resistance meter tests typically indicate that to achieve coating applications free of pinholes, sharp edges and rough areas need to be ground smooth. Further, at least two and usually three or more stripe coats must be applied along all edges, angles, bolts, nuts, crevices formed by joining members, etc. in addition to the coats specified for a coating system.

D. The Contractor shall perform testing during his painting operation to check and correct his work prior to the City Representative’s check.

E. Provide scaffolding, ladders, lighting and labor as required to facilitate the City Representative’s check of the coating work. Repair any areas of coating damaged during and by the testing operation.

F. Adhesion Testing: Where there is a question of paint or coating adhesion to surfaces, demonstrate to the City Representative's satisfaction that the coating adhesion to the area in question is equal to or greater than that which the coating manufacturer literature states may be achieved by his product. An "Elcometer Adhesion Tester (Type II)" is to be used by the Contractor to accomplish this demonstration.

G. Continuity, Pinhole and Adhesion Testing Support: Provide scaffolding, ladders, lighting and labor as required to facilitate the City Representative's check. Repair any areas damaged during and by the testing operation. Re-test all repairs to the satisfaction of the City Representative.

3.05 CLEANING AND COMPLETION

A. At the completion of this portion of the work, remove all debris, remove all paint and stains from work for which paint finish is not intended, touchup all marred surfaces, and leave all buildings and structures in a clean condition, ready for use.

B. Refinish all damaged or imperfect painting to the satisfaction of the City Representative prior to final acceptance of the facility.

C. Finish work, except waterproofing mastics, is to present an even, pleasing and uniform color and appearance. Surfaces exhibiting coatings with shadows, streaks, overlap marks, sags, drips, roughness overspray, non-uniform color or non-uniform sheen will be considered as improperly applied and will not be considered acceptable.

D. Leave all machinery nameplate data tags clean and readable and all grease fittings clean and usable.

3.06 SPARE COATINGS

A. Furnish one-gallon (minimum) container of each type and color of finish product used. Label containers. Each product shall have a minimum of 11 months of shelf life at project completion.

3.07 APPLICATION SCHEDULE

A. Provide coatings in accordance with the following exposure schedule:



Exposure

Surface Preparation

Paint System

Note (see below)

General ferrous exposed to atmosphere

Bare Metal: Near-white abrasive blast Shop Primed: Hand Tool Cleaned

1A 1

Submerged metal or Metal exposed to sewage fumes

Near-white Abrasive Blast 2 2

New submerged concrete or concrete exposed to sewage fumes

1. Allow for 28-day cure

2. Abrasive Blast 3 3

Existing submerged concrete or concrete exposed to sewage fumes

1. Steam Clean 2. Detergent Wash

and Rinse 3. Water Blast

none 4

Bleeding surface Solvent Clean per coating manufacturer’s recommendations

4 5

Prefinished machinery coating

Solvent Clean and Hand Tool Cleaning

5 6

Exposed galvanized steel, copper and other non-ferrous metals

Solvent Clean and lightly hand sand

6 7

Vent pipes exposed at building roofs and metal mounted in contact with walls

Solvent Clean and Hand Tool Clean

7 8

Buried valves, flanges, etc. Solvent Clean and Hand Tool Clean

8 9

Factory finish coated items not requiring field painting

Touchup - 10

Plastic pipe, including PVC Lightly hand sand, wipe clean

12 13

Notes to Application Schedule

1. These surfaces include, but are not limited to: general miscellaneous ferrous

metal; machinery; pumps; blowers; compressors; supports; valve handwheels




and stands; valve bodies; piping systems; structural steel; steel elements; except where other systems in this schedule are more specifically applicable. Metal surfaces identified to receive the coating before application of polyurethane sealant shall be blast-cleaned to an SSPC -10 “Near White Metal Blast.” Polyurethane sealants shall be prepared in accordance with the coating and sealant manufacturer’s recommendations. All surfaces shall be coated before they become contaminated and metal surfaces shall be coated before they rust.

2. Ferrous (iron and steel) surfaces shall be blast-cleaned to an SSPC-SP 10 "Near White Metal Blast". Blast cleaning shall be done using proper equipment and abrasive to provide clean, uncontaminated surfaces with a sharp, angular profile of 3 to 5 mils. Continuously operate heated dehumidification equipment within the areas to be coated from the start of surface preparation to completion of final cure such that specified surface and atmospheric conditions are sustained.

3. Apply this system to new concrete surfaces located on the interior of the gas storage tank in accordance with Paragraph 3.01. Concrete shall fully cure, at least 28-days, prior to application.

4. Clean concrete using this system prior to crack repair. 5. All items furnished with asphalt or coal tar (bleeding) shop coats, which would

otherwise be covered by System 1. 6. All piping, valves, pumps, drives, machinery, and equipment that have factory

finish coats that will be exposed to atmosphere. This system provides for repair of above named items and color uniformity with rest of field coat items.

7. Exposed galvanized ducts, exposed metal electric conduit, other galvanized steel items except those specifically excluded, exposed copper pipe and other non-ferrous metal items.

8. Coat metal items which are surface mounted on exterior, basement or gallery masonry walls, plaster walls and concrete surfaces. Coat such metal items only on the contact surfaces unless otherwise specified; specifically include electrical panels, control cabinets, fixtures and guardrail support brackets.

9. All panels and equipment with factory finishes identified elsewhere as not requiring field paint that were damaged during shipping, storage, or installation: touch-up in a manner compatible with the factory coating with respect to paint type, color, and texture. Touch-up fusion epoxy-coated items only with material provided by the fusion epoxy fabricator. If more than 5% of the surface requires touchup, return the items to the fabricator for recoating.

10. This system is to provide a protective coating for all plastic piping surfaces. For exterior surfaces, it shall protect against ultraviolet light degradation. This system provides for color uniformity with the rest of the field coated surfaces.

END OF SECTION


10400 - 1 Signage CNG Fueling Station

SECTION 10400

SIGNAGE

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: Signs, decals, tags, and pipe markers.

B. Related Sections: 1. Section 09960: Protective Coatings

1.02 REFERENCES

A. American National Standard Specifications, ANSI A13.1, "Scheme for the Identification of Piping Systems."

B. National Fire Protection Association (NFPA) No. 704, Standard System for the Identification of the Hazards of Materials for Emergency Response.

1.03 SUBMITTALS


B. Fully describe all items proposed for use.

C. Shop Drawings: Scaled drawings or photostats of custom-made signs, showing style and size of lettering and colors.

D. Samples: Manufacturer’s standard color palette for selection.


A. Regulatory Requirements: Comply with the following: 1. Americans with Disabilities Act (ADA). 2. California Building Code, CCR T-24, especially Chapters 11A, 11C and 11D. 3. California Code of Regulations, CCR Title 8, CAL/OSHA. 4. Federal Occupational Safety and Health Act (OSHA): Referenced sections,

specifications for accident prevention signs and tags and exit signs. 5. Porcelain Enamel Institute Sign Division of the PEI:S-103, recommended

standards for porcelain enamel signs.

B. Comply with the manufacturer's published recommendation for installation of materials used.

PART 2 - PRODUCTS

2.01 METAL SAFETY SIGNS

A. Manufacturer : Meeting OSHA requirements; 40-mil thick aluminum with baked enamel finish. One of the following or equal: 1. Seton Name Plate Co., Branford, Connecticut, Special Wording.

Signage CNG Fueling Station



2. Edemco, Buffalo, New York.

B. Danger Signs: 1. Background: White. 2. Heading: White lettering on red oval with white border in black rectangular

panel. 3. Message: Black lettering on white. 4. Size: As scheduled.

C. NFPA 704 Signs: 1. Size: 10 inches wide by 10 inches high, Diamond shaped. 2. Material: Porcelain Enamel, 18-gauge. 3. Text, format, and color:

a. Conforming to NFPA 704 b. Text as scheduled below.

4. Provide eyelet holes at each corner for mounting. 5. Schedule of signs required:

Quantity Text

4 1,4,0,CNG (Size: 10"w x 10"h)

(1 - Black letter at the 9 o’clock of the diamond on a blue background,

4 - Black letter at the 12 o’clock of the diamond on a red background,

0 - Black letter at the 3 o’clock of the diamond on a yellow background.

CNG – Black letter at the 6 o’clock of the diamond on a white background)

D. NFPA 52 Signs: 1. Size: 14 inches wide by 10 inches high, Unless otherwise scheduled. 2. Material: Porcelain Enamel, 18-gauge. 3. Text, format, and color:

a. Conforming to NFPA 52 b. Text as scheduled below.

4. Provide eyelet holes at each corner for mounting. 5. Schedule of signs required:

Quantity Text

3 STOP MOTOR – FLAMMABLE GAS NO SMOKING – ODORIZED GAS

(Signs with red letters at least 4” high on white background)

2 NATURAL GAS VEHICLE FUEL CYLINDERS SHALL BE INSPECTED AT INTERVALS

NOT EXCEEDING 3 YEARS TO ENSURE SAFE OPERATION OF THE VEHICLE.

(Signs with red letters at least 2” high on white background) 2 NATURAL GAS VEHICLE FUEL CYLINDERS

PAST THEIR END-OF-LIFE DATE SHALL NOT BE REFUELED AND SHALL BE REMOVED FROM SERVICE. (Signs with red letters at least 2” high on white background)



Quantity Text

1 CNG EMERGENCY VALVE; PUSH (Sign with white letters at least 2” high on red background)

1 4500 / PSI (Size: 10” w x 7” h, A rectangular sign divided by a diagonal line, to be mounted on a post next to the Fuel Dispenser. Upper triangle with 1” blue letters on white background and lower triangle with 1”

white letters on a light green back ground. )

E. Caution sign colors: 1. Background: Yellow. 2. Heading: Yellow lettering on black rectangular panel. 3. Message: Black lettering on yellow. 4. Size: As scheduled.

F. Safety instruction signs: 1. Background: White. 2. Heading: White lettering on green rectangular panel. 3. Message: Black lettering. 4. Size: As scheduled.

G. Warning sign colors: 1. Background: Orange. 2. Heading: White lettering on orange diamond on back rectangular panel. 3. Message: Black lettering on orange. 4. Size: As scheduled.

H. Notice information signs: 1. Background: White. 2. Heading: White lettering on blue rectangular panel. 3. Message: Black lettering. 4. Size: As scheduled.

I. Fasteners: Round head stainless steel bolts or screws.

J. See schedule A for specific sign size, location, text, and quantity.

2.02 EXTERIOR INFORMATION SIGNS

A. Able to withstand 100 miles per hour wind load without damage:

: 1. Manufacturers: One of the following or equal:

a. Best Manufacturing Sign Systems, Montrose, Co; equivalent product. b. Andco Industries Corp., Greensboro, NC; equivalent product. c. Vomar Products, Inc., Sepulveda, CA; equivalent product.

B. Sign panel: Nominal 3 inches thick, consisting of 1/8-inch thick fiberglass material with integral returns fully encapsulating wood and foam core, 1/8-inch radius edges and corners, size as indicated on the drawings.

C. Text: Helvetica medium, size and wording as indicated on the Drawings.




2.03 PIPE MARKERS

A. Seton Nameplate Company; SetMark, W.H. Brady Company; Piper Marker System 1; or equal.

B. Pipe Markers conforming to ANSI A13.1. See paragraph 3.03 for required locations.

C. Material: Acrylic plastic snap-around type or pressure sensitive vinyl, temperature tolerance range of -40°F to 250°F, non-fade, colored fields, lengths as shown below.

D. Text: Non-fade ink, lettering size, as shown below:

Outside Diameter of Pipe (Inches)

Length of Color Field (Inches)

Size of Letters (Inches)

3/4 to 1-1/4 8 1/2

1-1/2 to 2 8 3/4

2-1/2 to 6 12 1-1/4

8 to 10 24 2-1/2

Over 10 36 3-1/2

E. Provide directional arrows to indicate flow direction. See paragraph 3.03.

F. Pipe Marker Schedule (Colors to be confirmed with City prior to fabrication):

Text Field Color Letter Color

AIR Blue White

COMPRESSED NATURAL GAS Yellow Black

DRAIN Green White

DIGESTER GAS Yellow Black

NATURAL GAS Yellow Black

OFF GAS (WASTE GAS) Yellow Black

PRODUCT GAS (BIOMETHANE) Yellow Black

REFRIGERATED LIQUID Green White

UTILITY WATER Green White

WASTE GAS Green Black

PART 3 - EXECUTION

3.01 SIGN INSTALLATION

A. Location of signs shall be determined by on-site conditions but shall be visible from each point of transfer.



B. Install signs after painting surfaces to receive signs. Follow manufacturer's written installation instructions.

C. Use fasteners as follows: 1. To concrete and masonry materials: 4-1/4-inches diameter expansion

anchors. 2. To sheet metal (gauges 28 to 6) #10 sheet metal screws. 3. To gypsum board: Adhesive backing tape. 4. To chain link fencing: Wire ties at each corner. 5. To plywood backing boards: #10 wood screws. 6. To machinery: Fasteners as suitable.

D. Set sign posts in concrete.

3.02 TAGS

A. Do Not Drink Water Tags: Tie to faucets of non-potable water hose bibs as directed by Engineer.

B. All Other Tags: Deliver to the Owner in properly identified boxes or envelopes.

3.03 PIPE MARKERS

A. Pipe Markers shall be applied where piping enters or leaves the wall or floor of a structure, adjacent to tanks or other hydraulic containments, at each valve, at each piping change in direction, and shall be applied along piping runs not exceeding 16 feet on center.

B. Directional Arrows: Point in the direction of flow.

C. Locate pipe markers for easy reading. Where pipes are located above normal line of vision, the lettering and directional arrows shall be placed below the horizontal centerline of the pipe. Where pipes are below normal line of vision, lettering and directional arrows shall be above the horizontal centerline of the pipe.

END OF SECTION




PAGE INTENTIONALLY

LEFT BLANK


11001 - 1 General Equipment and Mechanical Requirements

CNG Fueling Station

SECTION 11001

GENERAL EQUIPMENT AND MECHANICAL REQUIREMENTS

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: The general requirements for all of the Equipment and Mechanical work in the scope of the Project, included in Divisions 01, 05, 11, 13, 15, and17, and elsewhere wherever specifically mentioned in these Specifications.

B. Related Sections: 1. Section 05090: Metal Fastenings 2. Section 05500: Metal Fabrications 3. Section 09960: High Performance Coatings 4. Section 11002: Electric Motor Drives 5. Section 17010: Instrumentation and Controls, General Requirements

C. Direct the attention of all subcontractors and suppliers of equipment and related appurtenances for the work to the applicable provisions in the Contract Documents wherever they may occur.

1.02 REFERENCES

A. American Gear Manufacturers Association (AGMA).

B. American Institute of Steel Construction (AISC).

C. California Code of Regulations, Title 8 Industrial Relations (CAL/OSHA).

D. Hydraulic Institute.

E. National Electrical Manufacturers Association (NEMA).

F. Occupational Safety and Health Act (OSHA).

1.03 STANDARDS FOR THE WORK

A. Complete Systems: Provide pipe, fittings, wiring and supports to produce complete, operable systems with all elements properly interconnected. If a specific dimensioned location is not shown for interconnections or smaller system elements, select appropriate locations and show them on Shop Drawing submittals for review.

B. Provide equipment and material new and without imperfections. Erect in a neat and workmanlike manner; aligned, leveled, cleaned and adjusted for satisfactory operation; installed in accordance with the recommendations of the manufacturers and the best standard practices for this type of work so that connecting and disconnecting of piping and accessories can be readily made and so that all parts are easily accessible for inspection, operation, maintenance and repair. Locate oil and lubrication fittings clear of and away from guards, base, and equipment and within reach from the operating floor. Coordinate location of all motor connections

General Equipment and Mechanical Requirements CNG Fueling Station



in order to properly orient encased electrical conduits. In order to meet these requirements with equipment as furnished, minor deviation from the Drawings may be made as favorably reviewed by the City Representative.

C. The recommendations and instructions of the manufacturers of products used in the work are hereby made part of these Specifications, except as they may be superseded by other requirements of these Specifications.

1.04 SUBMITTALS


B. Shop Drawings: Submit Shop Drawings to the City Representative and receive favorable review prior to fabrication, construction or delivery to the project site in accordance with Section 01330 of these Specifications. Show sizes and arrangement of equipment, foundations and anchor bolts required, performance characteristics, fan curves and pump curves, control diagrams, wiring diagrams, motor data sheets, methods of assembly, pipe hanging details, ductwork layouts and connections to other work. Date and sign drawings as certified for use in construction of this project. The arrangement of mechanical equipment and appurtenant piping shown on the Drawings may be varied as necessary to fit the favorably reviewed certified manufacturer's installation drawings. However, manufacturers' drawings shall not deviate in substance from the Contract Drawings and Specifications as to location, size, type and design of equipment. The following minimum requirements shall accompany all equipment submissions: 1. Overall dimensions. 2. Mounting arrangement and dimensions. 3. Description of materials. 4. Connection sizes and orientation. 5. Capacity and location of lifting eyes. 6. Motor arrangement showing location of electrical connections. 7. Rating data - Mechanical and Electrical as applicable. 8. Detail electrical wiring diagrams, showing component designation and rating. 9. Seismic design and calculations as required in Section 01612. 10. Motor data as specified in Section 11002. 11. List of special tools and/or spare parts to be furnished, if any.

C. Each piece of equipment, for which certified witnessed or non-witnessed performance tests are required, shall be accompanied by a completed form containing at least the following information: 1. City's name and location of project. 2. Contractor's name and subcontractor if applicable. 3. Name of item being submitted. 4. Specification reference by section, paragraph and page. 5. Data on item (manufacturer, general descriptive data, dimensions, size of

connections, speeds, performance curves, and serial number). A specific list of the test results plus a list, which shows the values that differ from Specifications.

6. Motor data, type, voltage, frequency, phase, full load amperes, starting method, frame size, enclosure insulation type (NEMA Code letter), dimensions, service factor, serial number.

7. Date and signature of person certifying the performance.



CNG Fueling Station

D. Instruction Manuals: Prepare and submit instruction manuals covering installation, operation and maintenance of all equipment and machinery specified in Divisions 11, 13, 15, and 17. Refer to Section 01782.

E. Manufacturers' Certificates: Where called for in the Specifications, each equipment manufacturer, or his authorized representative, shall submit an affidavit conforming to the requirements of Section 01756 .

F. Special Guarantees: Each equipment manufacture shall furnish a warranty in accordance with the General Conditions.

G. Training Materials: Furnish training materials for equipment in accordance with Section 01756.

1.05 RESPONSIBILITY AND CARE OF EQUIPMENT

A. The Contractor shall be responsible for the equipment included in this Contract until it has been finally inspected, tested and accepted in accordance with the requirements of these Specifications.

B. The Contractor shall make his own provisions for properly storing and protecting all material and equipment against theft, injury or damage from any and all causes. Damaged material and equipment shall not be used in the work.

PART 2 - PRODUCTS

2.01 DESIGN

A. General: Design all equipment for the service intended, of rugged construction, of ample strength for all stresses which may occur during fabrication, transportation, erection and during continuous or intermittent operation. Adequately stay, brace and anchor, and install equipment in a neat and workmanlike manner. Give consideration to appearance and safety, as well as utility, in the design of details. Use cathodically compatible materials of construction.

B. Seismic: Refer to Section 01612 of the Specifications for the seismic design criteria.

C. Controls: Unless noted otherwise, the design of the electric control of any equipment system and/or equipment package shall be the responsibility of the manufacturer of the equipment system and/or equipment package. The elementary control diagrams as shown on the Electrical Drawings and the diagrams shown on the Instrumentation Drawings are illustrative of control and monitoring requirements pertaining to various equipment of this project. The manufacturers shall design their own functional electric control devices and circuitry, in consultation with the specific elementary control diagrams and other project specifications, to meet the equipment control requirements. All such systems and package controls shall be furnished by the equipment manufacturer, except that controls shown in motor control centers and process controllers, remote control devices, and their interconnecting wiring shall be provided under Divisions 16 and 17.




2.02 MATERIALS AND STANDARD SPECIFICATIONS

A. Materials: Design, fabricate and assemble equipment and systems with new materials and in accordance with acceptable modern engineering and shop practices. Manufacture individual parts to standard sizes and gauges so repair parts can be installed in the field.

B. Uniformity: Unless otherwise specified, equipment or material of the same type or classification used for the same purpose shall be the product of the same manufacturer and shall be the same model.

2.03 LUBRICATION

A. Provide lubricants of types recommended by equipment manufacturers, in quantities sufficient for consumption prior to completion, testing and final acceptance.

2.04 STRUCTURAL METAL FRAMING

A. Details of fabrication shall be in accordance with Division 05.

B. Weld submerged steel surfaces which butt or bear against each other, to seal the surfaces against the penetration of the liquid. Weld all gaps between adjacent submerged steel surfaces less than 1/32-inch wide to seal the surfaces. Weld size shall be not less than the thickness of the thinnest member of the lapped or joined assembly.

2.05 EQUIPMENT BASES AND BEDPLATES

A. Mount equipment assemblies on a single heavy cast iron or welded steel bedplate unless otherwise shown or specified. Provide bases and bedplates with machined support pads, tapered dowels for alignment or mating of adjacent items, adequate openings to facilitate grouting, and openings for electrical conduits. Round or chamfer and grind smooth all corners. Continuously weld seams and contact edges between steel plates and shapes, and grind welds smooth. Do not support machinery or piping on bedplates other than that which is factory installed. Provide jacking screws in equipment bases and bedplates to aid in leveling prior to grouting. Mount all equipment bases and baseplates on reinforced concrete pads at least 3 inches high.

2.06 ANCHORS

A. Each equipment manufacturer shall furnish an anchor bolt pattern and the required anchor bolts, nuts and washers of adequate design for securing bases and bedplates to concrete bases. Provide anchor bolts of length to allow for 1-1/2-inch of grout under baseplates and adequate anchorage into structural concrete unless otherwise shown or specified.

B. Provide anchor and assembly bolts and nuts of ample size and strength for the purpose intended. All bolts shall be standard machine bolts, with cold pressed hexagon nuts. Provide suitable degauling compounds for bronze and stainless steel threaded components. Any space wholly or partially underground, or having a wall or ceiling forming part of a water channel, is classified as a moist location. Unless otherwise specified or noted on the Drawings, provide materials as follows:



CNG Fueling Station

1. Bolts and nuts in submerged locations or submerged and embedded in concrete or buried in earth, in all exterior locations, and in moist locations: Type 316 stainless steel.

2. Bolts and nuts for supports or equipment in dry locations: Galvanized steel (hot-dipped), with oversize nuts.

3. Use other bolting materials where specifically called for in the Specifications or on the Drawings.

C. Anchor all motor-driven equipment with cast-in-place anchor bolts or drilled-in anchors set with epoxy adhesive. Do not provide expansion type anchors for motor-driven equipment.

D. Anchor all non-motor-driven equipment with cast-in-place anchor bolts or drilled-in anchors set with epoxy adhesive except that, where specifically allowed by note on the Drawing, expansion type anchors may be used.

E. Refer to Section 05090 for technical specification requirements of drilled-in anchors set in epoxy adhesive and for expansion bolt anchors. Refer to Section 05090 for cast-in-place anchors.

2.07 SAFETY GUARDS

A. Cover belt or chain drives, fan blades, couplings, nip points, exposed shafts and other moving or rotating parts on all sides with safety guards conforming to all Federal, State, and local codes and regulations pertaining; conform to the most restrictive requirement. Design guards for easy installation and removal, complete with necessary supports, accessories, and fasteners, all hot-dip galvanized. Design guards in outdoor locations to prevent entrance of rain and dripping water. Provide tachometer test opening in line with ends of shafts. Typically guards shall be expanded metal on a structural steel frame except that outdoor guards may be of solid material. Provide hinged doors with latch for service and lubrication access.

B. Cover all pipes, manifolds, heaters, and other surfaces which have a surface temperature sufficient to burn human tissue with a thermal insulating material or otherwise guard against contact.

C. Guards to comply with CAL/OSHA 3940 through 3944.

2.08 LIFTING EYES

A. Supply all equipment weighing over 100 pounds with lifting eyes. Parts of equipment assemblies which are normally serviced separately, such as motors, to have lifting eyes of their own.

2.09 DRIVES

A. General: Provide all drive units with a AGMA rating and service factor suitable for 24 hours per day operation under the operating load.

B. Electric Motors: Conform to the requirements of Section 11002.

2.10 NAMEPLATES

A. Manufacturer's Nameplate: Furnish each piece of equipment and its driver with a corrosion-resistant metal nameplate fastened to the item in a readily readable position. This nameplate to contain the manufacturer's name, equipment rating,




capacity, size, model, serial number and speed. All information written or printed to be in English.

B. Direction of Rotation: Furnish each piece of rotating equipment with a direction of rotation arrow.

C. Functional Identification: Label each piece of equipment using a Phenolic label, 3/32-inch thick, matte surface, with the functional name and number of the equipment. 1. Fasten labels to the equipment, its base or other acceptable location:

a. Letters: 3/8-inch high with the border trim on all sides not less than ¼-inch.

b. Color: Bold background with white letters. City to determine background color.

c. Fasteners: Brass or stainless steel screwed into inserts, anchor shields or tapped holes in equipment or base.

2.11 PROTECTION AGAINST ELECTROLYSIS

A. Where dissimilar metals are used in conjunction with each other, provide suitable insulation between adjacent surfaces so as to eliminate direct contact and any resultant electrolysis. Connections of dissimilar piping materials shall utilize dielectric unions, flanges, couplings or bushings.

2.12 SPECIAL TOOLS

A. For each type of equipment to be furnished, provide a complete set of all special tools (including grease guns or other lubricating devices) which may be necessary for the adjustment, operation and maintenance of such equipment.

2.13 FINISHES

A. Conform to applicable requirements of Section 09960.

B. Factory Painting: On pumps, motors, drives, starters, control panels and other similar self-contained or enclosed components, apply a factory protective paint system unless otherwise noted. Paint or otherwise protect surfaces that are inaccessible after assembly by a method which provides protection for the life of the equipment.

C. Shop Priming: Except where field sandblasting is required, apply one or more shop coats of metal primer on surfaces to be finish painted at the site, of sufficient thickness to protect surfaces until finished. Primer shall be compatible with finish coat.

D. Rust Preventive: Coat machined, polished, other ferrous surfaces, and non-ferrous surfaces which are not to be painted with rust preventive compound.

2.14 NOISE AND VIBRATION

A. Mechanical and electrical equipment, as installed in this project, shall not create sound levels that are in excess of that permitted by CAL/OSHA for 8 hours per day worker exposure unless otherwise noted for the specific piece of equipment involved. If the required sound level cannot be achieved by bare equipment in its designated environment, provide sound attenuating enclosures. Sound attenuating enclosures shall have necessary ventilation to prevent equipment overheating and



CNG Fueling Station

shall be constructed for easy removal to permit maintenance. Devices necessary for day-to-day operation shall pierce the enclosure or otherwise be accessible without need to remove the enclosure.

B. Equipment which when operating has obvious excessive vibrations shall be repaired or replaced as directed by the City Representative. Baseline vibration measurements shall be made where specified.

2.15 FACTORY TESTS

A. Perform factory tests for each piece of equipment where specifically called for in the section specifying that equipment. Note that factory tests are inherent in many reference standards. The requirement for a factory test in a referenced standard is hereby made a part of these Specifications. Conduct factory tests at the same speeds and other conditions at which the equipment will operate in the field, except as noted.

B. Where specifically noted, performance tests may be witnessed by the City Representative. Inform the City Representative in sufficient time to allow arrangements to be made for witness of such tests. When non-witnessed tests are performed, supply certified results.

C. Perform factory testing of pumps in accordance with the requirements and standards of the Hydraulic Institute.

D. Tests of other equipment shall conform to the requirements set forth in these Specifications.

PART 3 - EXECUTION

3.01 EXAMINATION

A. Inspect each item of equipment for damage, defects, completeness, and correct operation before installing.

3.02 PREPARATION

A. Prior to installing equipment, ensure that the areas are clean. Maintain the areas in a broom-clean condition during installation operations. Clean, condition, and service equipment in accordance with the approved Instruction Manuals and specific recommendations of the equipment manufacturer.

3.03 INSTALLATION

A. Structural Fabrications: Conform to the AISC Code and Specification referenced in Article "Structural Steel Fabrications," and conform to Section 05500.

B. Equipment: Conform to approved Instruction Manuals. Employ skilled craftsmen experienced in installation of the types of equipment specified. Use specialized tools and equipment, such as precision machinist levels, dial indicators, gauges, and micrometers, as applicable. Produce acceptable installations free of vibration or other defects. Align and pin to common bedplate equipment and drivers connected by flexible couplings.

C. Anchor Bolts: Deliver bolts with templates or setting drawings and verify that bolts are correctly located before structural concrete is placed.




D. Base and Bedplate Grouting: Do not place grout until initial fitting and alignment of connected piping is completed. Level and align equipment on the concrete foundations, then entirely fill the space under base or bedplates with grout. Bevel exposed grout at 45-degree angle, except round exposed grout at horizontal surfaces for drainage. Trowel or point exposed grout to a smooth, dense finish and damp cure with burlap for three days. When grout is fully hardened, remove jacking screws and tighten nuts on anchor bolts. Check the installation for alignment and level, and perform approved corrective work as required to conform to the tolerances given in the applicable Instruction Manual. 1. Make an allowance of at least 1-1/2 inches for grout under the equipment

bases, whether or not shown on the Drawings. Use steel shims to level and adjust the bases. Shims may be left embedded in the grout, in which case they shall be installed neatly and so as to be as inconspicuous as possible in the completed work. Unless otherwise approved, all grout shall be a favorably reviewed non-shrink, non-metallic grout.

2. Grout: Dimensionally stable, inorganic, premixed and resistant to acids, alkalies, and salt water, and unaffected by water and oil. It shall have high strength even when used as a pourable mixture, and shall bond well with steel and cured concrete or be compatible with a suitable bonding agent which shall then be used to effect the bond. Use in strict accordance with the manufacturer's recommendations. Provide Five Star Grout as manufactured by U.S. Grout Corporation, Bonsal Construction Grout as manufactured by Bonsal Company, or equal. Submit for favorable review by the City Representative prior to use.

3. Where practicable, place the grout through the grout holes in the equipment base and work outward and under the edges of the base and across the rough top of the concrete foundation to a peripheral form so constructed as to provide a suitable chamfer around the top edge of the finished foundation.

E. Architectural Metals: Handrails, guardrails, stairs, and other architectural metals furnished as a part of equipment shall conform to the requirements of Section 05500.

3.04 EQUIPMENT STARTUP AND ADJUSTMENT

A. Arrange for an authorized factory-trained representative of the company or companies supplying the various items of equipment to check the installation and adjust and test the equipment furnished before the acceptance of the work by the City. Said representative shall be experienced and knowledgeable of the equipment being tested. Furthermore, he shall assist and instruct the operating staff in adjusting and operating the equipment during the initial plant operation period. 1. Provide initial lubrication for all equipment. 2. Test and demonstrate to the City Representative that all equipment operates

properly and specified performance has been attained. For pumps, include measurement of suction and discharge pressure at the pump and measurement of pumping rate by volumetric means or through a suitably calibrated meter for two points on the performance curve. For adjustable-speed pumps, conduct tests at a minimum of two speeds. Furnish any test equipment or measuring devices required which is not part of the permanent installation.



CNG Fueling Station

3. In addition, demonstrate that the entire facility is in full operating condition prior to the acceptance of the work. Should any equipment or part thereof fail to operate as intended, immediately remove and replace it, all at the Contractor's expense. Pay for all tests involved in this Section.

4. Pressure test equipment and connections thereto as required by these Specifications.

5. Unless specified otherwise, the authorized factory-trained representative shall furnish a minimum of 8 hours to test and start-up equipment.

3.05 PERFORMANCE TESTS

A. Upon completion of the work, and after all systems are set and balanced, conduct performance tests in accordance with Specification Section 01756 and other applicable sections of these Specifications. Submit test conditions, test data and results to the City Representative for review.

3.06 SOUND LEVEL TESTING

A. Measure the sound level developed by all mechanical and electrical equipment provided. Perform testing in all rooms and spaces containing such equipment during the final operation test program with all equipment operating. Use OSHA approved instrument and record the highest sound level developed when measured according to Cal-OSHA standards in each room and space. Deliver a copy of records to the City.

3.07 TOOLS, LOOSE PARTS, AND LUBRICANTS

A. Tools and Loose Parts Supplied: Provide an inventory of tools and loose parts required to be supplied under the project. Turn over inventory and parts to the City. The City's written acknowledgment of receipt is required for project completion. Loose parts are defined as items such as special tools, keys, safety equipment, and portable equipment.

B. Recommended Spare Parts: Furnish a complete list of recommended spare parts and supplies for each equipment furnished with current prices and a source of supply.

C. Provide a list of all recommended lubricants not listed in the O&M Manuals.

3.08 REQUIREMENTS FOR VIBRATION TESTING

A. Unless specified elsewhere all rotating mechanical equipment shall receive Level 1 Factory testing that is unwitnessed, and receive Level 2 Field testing that is witnessed.

B. Definitions: 1. Peak-to-Peak Displacement: The root mean squared average of the peak-to-

peak displacement multiplied by the square root of 2. 2. Peak Velocity: The root mean squared average of the peak velocity multiplied

by the square root of 2. 3. Peak Acceleration: The root mean squared average of the peak acceleration

multiplied by the square root of 2. 4. High Frequency Enveloping: A process to extract very low amplitude time

domain signals associated with impact or impulse events such as bearing or




gear tooth defects and display them in a frequency spectrum of acceleration versus frequency. Manufacturers: One of the following or equal: a. Rockwell Automation, Entek Group, "Spike Energy" analysis. b. CSI, "PeakVue."

5. Low Speed Equipment: Equipment or components of equipment rotating at less than 600 rpm.

6. High-Speed Equipment: Equipment and equipment components operating at or above 600 rpm.

C. Vibration Instrumentation Requirements: 1. Analyzers: Use digital type analyzers or data collectors with anti-aliasing filter,

12-bit A/D converter, fast fourier transform circuitry, phase measurement capability, time wave form data storage, high frequency enveloping capabilities, 35 frequency ranges from 21 to 1,500,000 cycles per minute, adjustable fast fourier transform resolution from 400 to 6,400 lines, storage for up to one hundred 3,200 line frequency spectra, RS232C data output port, circuitry for integration of acceleration data to velocity or double integration to displacement. Manufacturers: One of the following or equal: a. Entek-IRD, Division of Rockwell Automation, Enpac 1200 with

applicable data analysis software or Entek Model 838 analyzer with built in printer.

b. Computational Systems Inc., (CSI) Division of Emerson Electric, Model 2120A, Data Collector/analyzer with applicable analysis software.

2. Analyzer Settings: a. Units: English, inches/second, mils, and g's. b. Fast Fourier Transform Lines: Most equipment 1,600 minimum; for

motors, enough lines as required to distinguish motor current frequencies from rotational frequencies, use 3,200 lines for motors with a nominal speed of 3,600 rpm; 3,200 lines minimum for High Frequency Enveloping; 1,600 lines minimum for low speed equipment.

c. Sample Averages: Four minimum d. Maximum Frequency (Fmax): 40 times rotational frequency for rolling

element bearings, 10 times rotational frequency for sleeve bearings. e. Amplitude Range: Auto select but full scale not more than twice the

acceptance criteria or the highest peak, whichever is lower. f. Fast Fourier Transform Windowing: Hanning Window. g. High Pass Filter: Minus 3 dB at 120 cycles per minute for high-speed

equipment. Minus 3 dB at 21 cycles per minute for low speed equipment.

3. Accelerometers: a. For Low Speed Equipment: Low frequency, shear mode accelerometer,

500 millivolts per g sensitivity, 10 g range, plus/minus 5% frequency response from 0.5 hertz to 850 hertz, magnetic mount. Manufacturers: One of the following or equal:

b. Wilcoxon Research, Model 797L. c. PCB, Model 393C. d. For High Speed Equipment: General purpose accelerometer,

100 millivolts per g sensitivity, 50 g range, plus/minus 3dB frequency response range from 2-hertz to 12,000 hertz when stud-mounted, with magnetic mount holder. Manufacturers: One of the following or equal: 1) Wilcoxon Research, Model 793.



CNG Fueling Station

2) Entek-IRD Model 943.

D. Accelerometer Mounting: 1. Use magnetic mounting or stud mounting. 2. Mount on bearing housing in location with best available direct path to

bearing and shaft vibration. 3. Remove paint and mount transducer on flat metal surface or epoxy mount for

High Frequency Enveloping measurements.

E. Vibration Testing Results Presentation: 1. Provide equipment drawing with location and orientation of measurement

points indicated. 2. For each vibration measurement take and include appropriate data on

equipment operating conditions at the time vibration data is taken; for pumps, compressors, and blowers record suction pressure, discharge pressure, and flow.

3. When Vibration Spectra Data Required: a. Plot peak vibration velocity versus frequency in cycles per minute. b. Label plots showing actual shaft or part rotation frequency, bearing

inner and outer race ball pass frequencies, gear mesh frequencies and relevant equipment excitation frequencies on the plot; label probable cause of vibration peaks whether in excess of specification limits or not.

c. Label plots with equipment identification and operating conditions such as tag number, capacity, pressure, driver horsepower, and point of vibration measurement.

d. Plot motor spectra on a log amplitude scale versus frequency. 4. For low speed equipment, plot peak vibration displacement versus frequency

as well as velocity versus frequency. 5. Provide name of manufacturer and model number of the vibration

instrumentation used, including analyzer and accelerometer used together with mounting type.

3.09 VIBRATION TESTING LEVELS

A. Level 1 Quality Control Tests: 1. Level 1 Vibration Test:

a. Test Requirement: 1) Measure filtered vibration spectra versus frequency in three

perpendicular planes at each normally accessible bearing housing on the driven equipment, any gears and on the driver; one plane of measurement to be parallel to the axis of rotation of the component.

2) Vibration spectra versus frequency shall be in accordance with Article 3.10.

b. Equipment Operating Condition: Test at specified maximum speed.

B. Level 2 Quality Control Tests: 1. Level 2 Vibration Test:

a. Test Requirement: 1) Measure filtered vibration spectra versus frequency and measure

vibration phase in three perpendicular planes at each normally accessible bearing housing on the driven equipment, any gears and on the driver; one plane of measurement to be parallel to the




axis of rotation of the component; measure actual rotational speeds for each vibration spectra measured using photometric or other tachometer input connected directly to the vibration data collector.

2) Vibration spectra versus frequency shall be in accordance with Article 3.10.

b. Equipment Operating Condition: Repeat test requirements at design specified maximum speed and at minimum speed for variable speed equipment.

c. Natural Frequency Test of Field Installed Equipment: 1) Excite the installed equipment and support system in three

perpendicular planes, use same planes as operating vibration measurement planes, and determine the as-installed natural resonant frequency of the driven equipment, the driver, gears and supports.

2) Perform test at each bearing housing, each support pedestal, and for pumps on the suction and discharge piping.

3) Perform with equipment and attached piping full of intended service or process fluid.

3.10 VIBRATION ACCEPTANCE CRITERIA

A. Testing of Rotating Mechanical Equipment: Tests are to be performed by an experienced, factory trained, and independent authorized vibration analysis expert.

B. Vibration Displacement Limits: Unless otherwise specified, equipment operating at speeds 600 RPM or less is not to exhibit unfiltered readings in excess of following:

Operating Speed (rpm) Unfiltered (Overall) Peak-to-Peak Amplitude (mils)

All Rotating Equipment 0 - 300 6.5

301 - 600 4.5

Note: For all equipment, axial shaft displacements not to exceed 50% of the maximum radial shaft

displacements shown in the table relative to the casing.

C. Vibration Velocity Limits: Unless otherwise specified, equipment operating at speeds greater than 600 rpm is not to exceed the following peak velocity limits:

Item Unfiltered Overall Limit

(inches per second)Any Filtered Peak Limit

(inches per second) Motors See Applicable Motor Specification Gear Reducers, Radial Not to exceed AGMA 6000-A88 limits Other Reducers, Axial 0.10 0.10 Centrifugal Blowers 0.15 0.10 Other Equipment, Radial 0.16 0.10 Other Equipment, Axial 0.10 0.10 Other Equipment, Axial 0.10 0.10

D. Equipment Operation: Measurements are to be obtained with equipment installed and operating within capacity ranges specified and without duplicate equipment running.



CNG Fueling Station

E. Additional Criteria: 1. No narrow band spectral vibration amplitude components, whether

subrotational, higher harmonic, or synchronous multiple of running speed, are to exceed 40% of synchronous vibration amplitude component without manufacturer's detailed verification of origin and ultimate effect of such excitation.

2. The presence of discernable vibration amplitude peaks in Test Level 2 vibration spectra at bearing inner or outer race frequencies shall be cause for rejection of the equipment.

3. For motors, the following shall be cause for rejection: a. Stator eccentricity evidenced by a spectral peak at two times electrical

line frequency that is more than 40% of the peak at rotational frequency. b. Rotor eccentricity evidenced by a spectral peak at two times electrical

line frequency with spectra side bands at the pole pass frequency around the two times line frequency peak.

c. Other rotor problems evidenced by pole pass frequency side bands around operating speed harmonic peaks or two times line frequency side bands around rotor bar pass frequency or around two times the rotor bar pass frequency.

d. Phasing problems evidenced by one third line frequency side band spectral peaks around the two times electrical line frequency peak.

4. The presence of peaks in a High Frequency Enveloping spectra plot corresponding to bearing, gear or motor rotor bar frequencies or harmonics of these frequencies shall be cause for rejection of the equipment; since inadequate lubrication of some equipment may be a cause of these peaks, lubrication shall be checked, corrected as necessary and the high frequency envelope analysis repeated.

END OF SECTION




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11002 - 1 Electric Motor Drives CNG Fueling Station

SECTION 11002

ELECTRIC MOTOR DRIVES PART 1 - GENERAL 1.01 SUMMARY

A. Section Includes: Provide motors to drive equipment specified in other sections and Divisions, including, but not limited to, Divisions 11, 13, and 15. Refer to driven equipment sections for additional requirements. Requirements of the driven equipment Specifications shall take precedence over the requirements of this Section, where conflict occurs. This Section applies to all electric motors furnished for this project, unless otherwise noted.


1. Section 11001: General Equipment and Mechanical Requirements 2. Section 16010: Electrical Work 3. Section 16920: Switchboard Motor Control Center Modifications

1.02 REFERENCE STANDARDS

A. National Electrical Manufacturers Association (NEMA) Standard: 1. MG 1 Motors and Generators

B. Institute of Electrical and Electronics Engineers (IEEE) Standard: 1. 112 Test Procedure for Polyphase Induction Motors and Generators

C. Underwriters Laboratories (UL) Publication: Recognized Component Directory 1.03 SUBMITTALS

A. Make all submittals in accordance with Specification Section 01330. For each motor, include the following data in the shop drawing submittal for the driven equipment: 1. Manufacturer's name. 2. Manufacturer's type and frame designation. 3. Horsepower output. 4. Time rating. 5. Maximum ambient temperature rating. 6. Insulation system designation. 7. Rpm at full load. 8. Voltage, number of phases, frequency and full load amperes. 9. Code letter for locked rotor kVA. 10. Service factor at 40°C ambient. 11. NEMA design letter. 12. Enclosure type. 13. Lubrication requirements, including type and frequency.

Electrical Motor Drives CNG Fueling Station



14. KW input power and power factor at 75% and 100% of rated horsepower output.

15. Guaranteed minimum efficiency and nominal efficiency per MG1-12.55. 16. Nominal efficiency.

B. Provide installation, operation and maintenance instructions, and renewal parts list as required for maintenance manuals under Section 01330.

1.04 COORDINATION

A. General: Coordinate motors with driven equipment requirements. Unless otherwise specified, equipment manufacturers or suppliers shall select and provide motors for their equipment in conformance with these Specifications. Give particular attention to coordination of requirements for: 1. Power. 2. Starting torque. 3. Speed. 4. Bearing load. 5. Ambient temperature. 6. Frequency of starting. 7. Moisture exposure.

B. Suppliers of motors to be used with adjustable speed systems shall: 1. Provide all relevant motor data to the adjustable speed control manufacturer for

analysis. Provide motors in conformance with and compatible with the adjustable speed control manufacturer's equipment and requirements.

2. Provide all relevant motor data to the pump manufacturer for vibration, reed critical frequency and other required analyses.

1.05 SPECIFIC REQUIREMENTS

A. The following motor characteristics are specified with the driven equipment in all cases: 1. Speed. 2. Horsepower or supplier responsibility to determine. 3. Horizontal or vertical arrangement. 4. Indoor or outdoor location.

B. Additional motor characteristics are specified with the driven equipment only where the required motor differs from the typical characteristics described below or where additional properties or characteristics are required that are not specified in this Section.

PART 2 - PRODUCTS 2.01 GENERAL



A. Motors shall be designed, built, and installed in the driven equipment, to provide long, trouble-free life in industrial service and shall be rated in conformance with NEMA MG1. Motors rated 100 horsepower or less and rated 600V or less shall be listed in UL Recognized Component Directory or shall be listed and labeled by other organizations acceptable to the authority having code enforcement jurisdiction.

B. Unless otherwise specified with the driven equipment, provide motors with the

following typical characteristics: 1. Motors shall be single speed, and designed for continuous duty and full voltage

starting. Motors shall provide standard starting torque. 2. Voltage Ratings:

a. 1/2 horsepower or less: 115 volts, single phase, 60 Hz, capacitor start. Small fan motors may be split phase or shaded pole type if standard for the equipment.

b. Above 1/2 horsepower: 460 volts, three phase, 60 Hz, squirrel cage induction motors.

3. All motors shall have a service factor of 1.15 in an ambient temperature of 40°C. a. Exceptions: Motors, which have special enclosures or winding

configurations, may carry a Unity (1.0) Service Factor. Examples are totally enclosed, explosion proof, or submersible motors.

4. Windings shall be copper. 5. Provide ground lug inside the terminal box. 6. Provide lifting eye on each motor weighing more than 50 pounds. 7. Each motor shall be suitable for six starts per hour (5 minutes on and 5 minutes

off, continuously) when powering the specific driven equipment required for this project.

8. Each motor shall have an overall sound power level at no load not greater than given in NEMA MG1-12.49.

9. Motors, which have special operating characteristics such as multi-speed, high torque/high slip, short time intermittent ratings shall be nameplated to show how these characteristics differ from standard design.

C. Motors used with adjustable frequency drives shall have inverter duty complying with NEMA MG-1, Section IV, Part 31.

2.02 NAMEPLATE

A. Provide stainless steel nameplate for each motor, attached to the motor by stainless steel screws or drive pins. Nameplates shall indicate clearly the information required by NEMA MG1, Part 10 and Part 12.

2.03 ENCLOSURE TYPE BY LOCATION

A. Unless otherwise specified with the driven equipment, provide motors with the following typical enclosures: 1. Indoors: Motors shall be totally enclosed, fan cooled. 2. Outdoors: Vertical motors shall be weather-protected type I. Horizontal motors

shall be totally enclosed, fan cooled. All motors shall have the following features: a. Bearing protection. b. Anti-corrosion treatment of external hardware and internal metal parts.




c. Weatherproof terminal box with gaskets between the motor, terminal box and terminal box cover.

d. Guard screens on ventilation openings. e. Moderate moisture resistant insulation, specified hereinafter. f. Interior and exterior corrosion protection coatings. g. Special attention to leads into terminal box.

B. When specifically called for in the Specifications for the driven equipment or

required by Code, provide the following enclosure types: 1. Hazardous locations: Motors shall be explosion-proof and shall be UL listed for

Class I, Division 1, Groups C and D locations; motors shall bear the UL label. 2. Severe duty: Motors shall have the following features:

a. Totally enclosed, fan cooled enclosure. b. Stainless steel nameplate. c. Cast iron housing, bearing brackets and fan guard. d. Cast iron conduit box with threaded conduit entrance. e. Corrosion resistant fan. f. Corrosion resistant hardware. g. Automatic breather/drain. h. Ground lug. i. Regreasable bearings. j. Provision for excluding water and dust from bearings. k. Class F insulation. l. Service factor of 1.15. m. Epoxy coating on all external surfaces.

3. Submersible: Submersible motors shall comply with the following: a. Air filled or oil filled squirrel cage induction type. b. Service factor of 1.15 or better. c. Class F insulation, Class B temperature rise. d. Rated for 6 starts per hour. e. Listed by either UL or FM for Class 1, Division 1, Groups C and D

hazardous locations. f. Suitable for operating in free air continuously (i.e., not submerged in

sewage). g. Bearing B10 life 18,000 hours minimum. h. Tungsten carbide seals. i. Lower bearings of either the ball or roller type. j. If required by the manufacturer to not void the motor warranty, provide a

moisture detection system and a motor winding thermostat system. These systems shall be complete, including all necessary interfaces, control panels, conduits, and wires, even though these may not be shown on the Drawings.

2.04 INSULATION

A. Unless otherwise specified with the driven equipment, provide motors with Class B or F insulation, non-hygroscopic. In single phase motors 1/2 horsepower or smaller, provide Class A insulation or better.

B. Where called for in the Specifications for the driven equipment, provide the following

type of insulation:



1. Moderate Moisture Resistant: Provide extra dip and bake of epoxy or polyester varnish to resist somewhat higher than normal moisture in the atmosphere.

2.05 MOTOR HORSEPOWER

A. The maximum permissible motor loading: 1. Motors with service factor 1.15 or greater: 100% of nameplate horsepower. 2. Motors with service factor less than 1.15: 90% of nameplate horsepower.

TABLE 26 60 13-1

MOTOR NOMINAL EFFICIENCIES AT FULL LOAD

HP 900 RPM 1,200 RPM 1,800 RPM 3,600 RPM

Open Drip-Proof and Weather Protected Type 1 Motors

1 78.5 78.5 82.5 80.0

1.5 80.0 80.0 84.0 81.5

2 85.5 82.5 82.5 85.5

3 85.5 82.5 82.5 84.0

5 86.5 86.5 85.5 86.5

7.5 87.5 89.5 87.5 88.5

10 90.2 90.2 89.5 86.5

15 90.2 91.7 90.2 89.5

20 91.7 91.7 91.0 90.2

25 91.7 92.4 91.7 90.2

30 92.4 93.0 92.4 92.4

40 91.7 93.0 93.6 93.6

50 93.0 93.0 93.6 93.6

60 93.6 93.6 94.1 94.1

75 94.1 93.6 94.1 93.6

100 94.5 94.5 94.5 94.1

Total Enclosed Fan Cooled Motors

1 78.5 78.5 82.5 80.0

1.5 80.0 80.0 84.0 81.5

2 85.5 82.5 82.5 85.5

3 86.5 86.5 82.5 84.0

5 88.5 87.5 85.5 86.5

7.5 89.5 90.2 87.5 88.5

10 90.2 91.0 89.5 90.2

15 90.2 92.4 91.0 91.7

20 91.7 92.4 91.0 91.7

25 91.7 93.0 92.4 92.4

30 92.4 93.0 93.0 93.0

40 92.4 93.6 94.1 94.1

50 93.6 93.6 94.1 94.1

60 93.6 94.1 94.1 94.1

75 94.1 94.1 94.1 94.5

100 94.5 95.0 95.0 94.5




B. Probable motor horsepower ratings have been specified or shown on the Drawings.

Changes from the specified horsepower may be accepted, if necessary to assure that motors do not exceed their maximum permissible loading, as defined above, under normal operation. Motor horsepowers shall not be less than those specified in driven equipment sections. If a larger horsepower rating is required by the driven equipment, provide all changes required to motor starting and control equipment and to the conduit and wiring system without any additional cost to the City.

2.06 EFFICIENCY

A. For motors 1 Horsepower and Larger: 1. Provide premium efficiency motors unless otherwise specified. Premium

efficiency motors shall have nominal efficiencies at full load not less than those listed in Table 26 60 13-1.

2. Guaranteed minimum efficiencies of premium efficiency motors shall correspond to nominal values as tabulated in NEMA MG-1, Table 12-8.

B. Efficiencies shall be determined by using the IEEE 112, Test Method B using

segregated loss determination. C. Single-phase fractional horsepower motors 1/4 HP through 3/4 HP motors shall be

high-efficiency split-capacitor types having minimum efficiency ratings of not less than 64% and power factors of not less than 94.5%.

2.07 LOCKED ROTOR KVA - CODE LETTER

A. Provide motors with locked rotor kVA values less than or equal to those corresponding to the following:

Horsepower Code Letter

5 M

7-1/2-10 H

15 G

2.08 THERMAL PROTECTION

A. In each motor to be used with adjustable speed drives, in all motors 60 horsepower and larger, or where called for in the Specifications for the driven equipment, provide integral thermostats or other approved devices to protect the motor from overheating. Thermostats or other devices shall be normally closed and rated 125 Vac, 1 amp.

2.09 NOT USED 2.10 SPACE HEATERS

A. Where called for in the Specifications for the driven equipment, provide space heaters for motors. Heaters shall be 120 volts, single phase. Heater wattage and voltage ratings shall be indicated on motor nameplate.



2.11 FACTORY TESTS

A. Conduct factory tests on all motors in conformance with NEMA MG 1-12.55. All tests shall be made in accordance with IEEE Standard 112.

PART 3 - EXECUTION 3.01 INSTALLATION

A. Install motors in driven equipment in conformance with motor manufacturer's recommendations and requirements. Motor nameplate shall be visible when installed on the driven equipment.

3.02 WARRANTY

A. Upon completion of all installation, testing and training, the Contractor shall deliver to the City Representative a warranty in accordance with the General Conditions.

END OF SECTION




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11209 - 1 Rotary Actuators CNG Fueling Station

SECTION 11209

ROTARY ACTUATORS

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: Furnish, install, and place in satisfactory operation all electric valve actuators for the conditions and locations shown on the Drawings and described herein. 1. Actuators shall contain motor, gearing, manual override, limit switches, torque

switches, drive coupling, integral motor controls, feedback transmitter, and integral position indicator.

2. All actuators shall be from a single manufacturer.

B. Related Sections: 1. Section 11001: General Equipment and Mechanical Requirements 2. Section 11002: Electric Motor Drives 3. Section 15050: Process Piping, Valves and Accessories

1.02 REFERENCES

A. American Iron and Steel Institute (AISI)

B. American National Standards Institute (ANSI)

C. American Gear Manufacturer’s Association (AGMA)

D. American Society for Testing and Materials (ASTM)

E. American Water Works Association (AWWA) 1. C540-02 – Power-Actuating Devices for Valves and Slide Gates

F. Hydraulic Institute (HI)

G. National Electric Manufacturer’s Association (NEMA)

H. Steel Structures Painting Council (SSPC)

1.03 SUBMITTALS

A. Shop Drawings and Product Data: Submit the following as a single complete initial submittal in accordance with Section 01330: 1. Manufacturer’s Certificate of Compliance certifying compliance with the

referenced specifications and standards. 2. Certified copies of reports of factory tests specified in this Section and

required by the referenced standards. 3. Descriptive information including catalogue cuts and manufacturer’s

specifications for all components. 4. Copy of manufacturer’s standard warranty for each type of equipment

provided.

Rotary Actuators CNG Fueling Station



5. Shop drawings with performance data, descriptive literature, weights and dimensions, and other physical characteristics verifying compliance with this section, including motor starting and full-load amps, motor horse power, and motor data. When numerous options and sizes are shown, the shop drawings shall be marked to clearly indicate the size and types specific to this Section and project.

6. Electrical: a. Submit all electrical requirements for each piece of equipment including

voltage, phase, and load data. b. Provide wiring diagrams for each piece of equipment. For example,

submitting one diagram for all electric valve actuators is not acceptable. c. “Typical” diagrams are not acceptable. Manufacturer’s standard

diagrams may be submitted if they are made specific for this project by: 1) Showing all included options, special items, etc. 2) Unused options or features shall be crossed out or deleted. 3) Identifying the drawing with project name, equipment name, and

tag number, e.g., “City of Petaluma Biomass to Biofuel Project, Tag No. xx-xxxx.”

7. A material list indicating items to be furnished by the equipment manufacturer.

8. List of which components and materials shall be shipped preassembled and parts list for the other components and materials. Weights and physical dimensions shall be indicated for each part, assembly, and/or package to be shipped.

9. Manufacturer’s installation instructions and recommended testing procedures.

B. Performance Testing: Submit certified factory performance test results, which shall include test results for all specified operational settings. Receive favorable review of test results prior to shipping the equipment.

C. Manuals: Furnish manufacturer’s operation and maintenance (O&M) manuals and materials. When numerous types and sizes are shown, the manuals shall be marked to clearly indicate the sizes and types specific to the project.

D. Affidavits: Submit affidavit from the manufacturer stating that the equipment has been properly installed, adjusted, and tested and is ready for full-time operation.


A. Valve manufacturers shall be supplied by a single manufacturer who has been regularly engaged in the design and manufacture of the equipment for at least five years, and shall furnish all of the electric valve actuators. Actuators and valves shall be assembled in the factory, and they shall be tested under rated conditions and configurations. Each actuator shall be given a unique serial number and be performance tested (under simulated loads) by the actuator manufacturer prior to shipment. As a minimum, test certificates for each actuator, which include the following information, shall be provided: 1. Current at maximum torque setting 2. Torque at maximum torque setting 3. Flash test voltage 4. Actuator output speed or opening time



B. Test certificates shall record the details of the actuator specifications, such as the gear ratios for the manual and electric drives, the closing direction, and the wiring diagram code numbers.

C. The City Representative and Design Engineer shall have the option of witnessing such tests at their own expense.

D. Upon installation, actuators shall be inspected by a representative of the actuator manufacturer for structural an operational correctness. Valves shall not stick or bind in any position when being opened or closed.

1.05 PRODUCT DELIVERY, STORAGE, AND HANDLING

A. The Contractor shall be responsible for the delivery, storage and handling of products.

B. Promptly remove damaged products from the job site. Replace damaged products with undamaged products.

PART 2 - PRODUCTS

2.01 MANUFACTURER

A. The actuators shall be as manufactured by Rotork; Limitorque; or equal.

2.02 ELECTRIC ACTUATORS

A. General: Electric actuators for valve shall include the following: 1. Open-Close Service: The electric valve actuator shall include integral electric

controls for open-close service including lockable disconnecting means, overcurrent protection, reversing combination starter, limit switches, torque switch, indicating lights, open and close pushbuttons, and local-off-remote switch. Comply with AWWA C540.

2. Actuators shall receive a 480 VAC, three phase, 60 Hz power supply. 3. Valve actuators shall provide a travel time (from the full open position to the

full closed position or vice versa) between 30 and 60 seconds. 4. The valve actuator shall provide a set of contacts (normally open and

normally closed) for indication of valve “OPEN” and “CLOSED” position. These contacts will be activated at set positions when the actuators reach a certain set point.

B. Motor: The motor shall be specifically designed for actuator service. The motor will be of the induction type with Class F insulation and have a time rating of at least 15 minutes at 104ºF (40ºC) or twice the valve stroking time, whichever is longer, at an average load of at least 33 percent of the maximum valve torque. The motor shall be protected by means of thermal switches imbedded in the motor windings. Motor shall be explosion-proof and shall be UL listed for Class I, Division 1, Groups C and D locations; motors shall bear the UL label. Motors shall have space heaters as specified in Section 11002. 1. Motors will be capable of operating on 460 volt, three phase, 60 hertz power.




C. Integral Starter and Transformer: 1. The actuator starter, control transformer, and all control devices shall be

integral with the actuator and suitably housed to prevent breathing and condensation buildup.

2. The starter shall be of a solid state type and shall also incorporate an anti-hammer feature to prevent the actuator from repeatedly accepting a closed signal from a maintained control signal source.

3. Jammed actuator motor protection with logic circuit shall be provided to prevent the motor from overheating in the event of stalling against a jammed valve or gate.

4. The time allowed before disconnect shall be between 7 and 10 seconds.

D. Gearing Reduction Assembly: The gear reduction unit shall be selected by the valve manufacturer for reducing the rotational speed from actuator. For multi-turn valves, the actuator shall include a second stage gearbox that is totally enclosed, grease filled, and has a suitable torque rating for the application. For quarter-turn valves, operating time from fully open to fully closed shall be between 20 and 30 seconds. For rising stem valves and gates, the speed shall be such to operate the vertical travel of the valve or gate in increments of one-sixteenth inch. Gears shall be rated AGMA 420.04 (service factor 1.25) or AGMA 460.05 (Class II) for 24-hour service.

E. Limit Contacts: 1. Limit contacts shall be furnished at each end of travel. 2. Limit switch adjustment shall not be altered by manual operation. 3. Mechanical limit switches must be capable of quick adjustment requiring no

more than 5 turns of the limit switch adjustment spindle. 4. One set of normally open and 1 set of normally closed contacts will be

furnished at each end of travel for remote monitoring. 5. Contacts shall be capable of maintaining state without an external power

supply.

F. Torque Sensing: Over torque protection and contacts shall be furnished at each end of travel. Torque contacts will trip when the load exceeds the torque switch setting. The torque switch adjustment device must be calibrated directly in engineering units or torque.

G. Actuator Enclosure: 1. Unless otherwise indicated, actuators shall be NEMA 4X. Actuators shall

have an inner watertight and dustproof ‘O’ ring seal between the terminal compartment and the internal electrical elements of the actuator fully protecting the motor and all other internal electrical elements of the actuator from ingress of moisture and dust when the terminal cover is removed on site for cabling.

2. Actuators located within 5 feet of a digester wall or potential digester gas leakage source shall be NEMA 7 rated to provide explosion-proof protection per NFPA 820 Class1, Division 1, Group D.

3. Actuators located between 5 feet and 10 feet from the digester wall or potential digester gas leakage source shall be NEMA 4X rated to provide protection per NFPA 820 Class1, Division 2, Group D.

4. The terminal compartment shall be separately sealed to prevent moisture ingress.



5. All external fasteners on the electric actuator will be stainless steel. Fasteners on limit switch and terminal compartments shall be captured to prevent loss while covers are removed.

H. Wiring: All external control and power wiring shall be securely terminated inside a separately sealed terminal compartment.

2.03 CONTROL

A. Local/Remote Control Configuration: 1. The actuator shall be furnished with local, OPEN – CLOSE – STOP,

momentary pushbuttons integrally mounted at the actuator. 2. A LOCAL – STOP – REMOTE padlockable switch shall be provided to select

the source of control in the LOCAL position. 3. Provide OPENED (green) & CLOSED (red) pilot lights. Pilot lights shall be

high intensity LED type or equal with a minimum 75,000 hour life. Both lights shall be energized when the valve is in an intermediate position.

B. Actuator shall provide the following inputs and outputs. Discrete inputs and outputs shall be rated for 120 VAC operations. Provide analog inputs and outputs for actuators with modulating service 1. Discrete (contact closure) inputs from PLC, operator in “remote” switch

position: a. OPEN b. CLOSE c. STOP

2. Discrete outputs (dry contacts to PLC): a. Actuator NOT full opened position (contact opens when valve is fully

opened) b. Actuator NOT full close position (contact opens when valve is fully

closed) c. Remote switch position

3. For Modulating Service: a. Local indication of valve position, 0-100% open b. Contacts for remote indication of valve position, 4-20 mA signal c. Contacts to receive a remote 4-20 mA signal to position the valve

C. Manual Operation 1. Manual override shall be achieved using the padlockable declutch lever and

handwheel. If valve is located more than 7 feet above grade, furnish a chain operator or equal so that the valve can be manually operated while standing at grade.

2. In the event of emergency, it shall be possible to disengage the electric drive with the declutch lever.

3. This disengagement and subsequent reengagement shall not cause any damage to the valve or operator, even with the motor is running.

4. Manual operation will be via power bearing to minimize required rimpull so a maximum of 80 pounds of effort will be required and facilitate easy changeover from motor to manual operation when actuator is under load.

5. Return from manual to electric mode of operation will be automatic upon motor operation.

6. A seized or inoperable motor shall not prevent manual operation.




PART 3 - EXECUTION

3.01 ASSEMBLY

A. The valve manufacturers shall furnish all of the electric valve actuators. Actuators and valves shall be assembled in the factory, and they shall be tested under rated conditions and configuration. In so far as practicable, these valves shall be shipped to the Contractor in the assembled condition. If the valve and actuators are separated for shipment and reassembled onsite, then the actuators must be designated for specific valves so that the same actuator-valve combination will be installed at the site.

3.02 INSTALLATION

A. Install the valves and electric valve actuators according to the manufacturer’s recommendation.

B. Obtain the services of the actuator manufacturer’s factory service representative to check the installation of the equipment and make any field adjustments necessary to ensure proper operation. The service representative shall certify to the City Representative in writing that the equipment has been satisfactorily installed and adjusted for continuous operation.

3.03 FIELD SERVICES

A. The Contractor shall provide the services of a qualified representative of the manufacturer to perform the following tasks: 1. Inspect the installation of the equipment. 2. Place the equipment in operation and make any necessary adjustments. 3. Perform tests specified in this Section and recommended by equipment

manufacturer. 4. Furnish certificate as specified in Section 01756. 5. Instruct City personnel in the proper operation and maintenance (O&M) of the

equipment (training) as specified in Section 01756.

B. If equipment is not completed for proper start-up and training procedures, the representative shall reschedule another visit at no additional cost to the City. Training will not be permitted without proper start-up and operation of the equipment. Training shall be performed separate and distinct from start-up and testing tasks. An abstract or outline of the start-up, testing, and training procedures shall be provided to the City Representative at least five (5) days prior to the schedule visit. Manufacturer’s operation and maintenance manuals and materials and audio-video cassette, when included under submittal requirements, shall be incorporated in the training procedures, with emphasis on items or materials or greatest importance.

C. A typed, bound report, covering the manufacturer’s representative’s findings shall be submitted to the City Representative for review and approval. The report shall (1) describe the start-up procedures taken; (2) include any inspections performed; (3) outline in detail any deficiencies observed along with the corrective measures taken; and (4) include the results of all field test, including necessary graphs, charts, tables, etc., specified in this Section or required by the referenced standards. The report shall certify that the equipment is properly installed and functioning for the purpose intended.



D. The Contractor shall bear all expenses associated with the start-up testing, and training procedures and report described above, including labor, transportation, lodging, and material costs.

3.04 FIELD TESTING

A. Field test all electric actuators. See Section 11001 for additional requirements on performance tests.

3.05 WARRANTY

A. Upon completion of all installation, testing and training, the Contractor shall deliver to the City Representative a warranty in accordance with the Genera Conditions. This warranty shall be held in effect regardless of pre-commissioning storage conditions in a typical indoor or outdoor environment as long as the actuators are not disassembled or physically abused. This warranty shall be enforced even if special storage procedures (such as the use of plastic bags, dessicants, and the energizing of heaters) are not utilized.

END OF SECTION




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11300 - 1 Gas Treatment System CNG Fueling Station

SECTION 11300 GAS TREATMENT SYSTEM

PART 1 GENERAL 1.1 GAS TREATMENT SYSTEM

A. The Gas Treatment System and appurtenances shall be furnished

by the Owner and installed by the Contractor as specified herein. B. The Gas Treatment System shall be the BioCNG 100 system and

appurtenances, and shall be furnished by Unison Solutions. The technical proposal for this system is included at the end of this specification section proposal (18 pages). This includes the following major conditions and services:

1. Major components furnished by Unison include the following:

a. Gas treatment skid b. Gas treatment control panel c. Transformer TX-21 d. Chiller and appurtenances e. H2S Removal Vessel

2. Associated special services from the manufacturer to be arranged and paid for by Owner: a. Installation assistance. b. Certification of proper installation. c. Functional testing assistance. d. Performance testing assistance. e. Training of Owner’s personnel.

C. The Gas Treatment System and appurtenances shall be delivered

on site by June 30, 2018. The exact date of the delivery shall be determined as described in Paragraph 1.6 below.

1.2 INFORMATION FURNISHED BY OWNER

A. Shop drawings related to Gas Treatment System will be made available for

Contractor’s use in performing the work under this section.

B. Manufacturer’s installation, operation, and maintenance instructions for Gas Treatment System will be made available.

1.3 SUBMITTALS

A. Submittals:

Gas Treatment System CNG Fueling Station



1. Shop Drawings: a. Show layout, location, and identification of materials provided by

Contractor for installation of Owner-furnished products. b. Include pipe, fittings, valves, specialties, hangers,

supports, equipment, and required specialties. c. Accurately show openings in floors, walls, and other parts of

structures. d. Provide electrical and instrumentation diagrams to

indicate connecting and interconnecting electrical and control work.

e. Submit complete list of materials to be furnished, and include data necessary to allow Owner to determine their fitness for the work.

1.4 TRANSFER OF PRODUCTS

A. Unless indicated otherwise, items will be furnished f.o.b. the Project Site.

1. Equipment or facility necessary for receipt and unloading of product: An

area will be designated at the Wastewater Treatment plant for the equipment. Contractor shall provide the necessary equipment and materials for unloading the products as recommended by the manufacturer. If needed, the Contractor shall store the system prior to installation in accordance with the manufacturer recommendations

B. Upon delivery, conduct with Owner or Engineer, a joint inspection for the

purpose of identifying product, general verification of quantities, and observation of apparent condition. Such inspection will not be construed as final or as receipt of any product that, as a result of subsequent inspections and tests, are determined to be nonconforming.

C. Damaged or incomplete products to be returned for replacement will not be

unloaded, except as necessary to expedite return shipment. Owner will submit claims for transportation damage and expedite replacement of damaged, defective, or deficient items.

D. Indicate signed acceptance of delivery on a copy of the invoice.

E. If Contractor is not prepared to accept delivery of Gas Treatment System by

either the specified Estimated Date of Arrival or such Owner-confirmed delivery date, as specified herein, associated costs incurred by Owner shall be borne by Contractor. Such costs may include, but not be limited to, demurrage, interest, insurance costs, additional administrative and engineering costs, additional factory and field technical support, additional storage and reshipping costs, cost escalation, and extended warranty costs due.



1.5 UNLOADING, STORAGE AND MAINTENANCE

A. Subsequent to transfer, Contractor shall have complete responsibility for unloading Owner-furnished products. Unload product in accordance with manufacturers’ instructions, or as specified.

B. Store, protect, and maintain product to prevent damage until final

acceptance of completed work. Damage to or loss of products after date of transfer to Contractor shall be repaired to original condition, or replaced with new identical products, at the discretion of Engineer.

C. Maintain complete inventory of all Gas Treatment System after their

transfer to Contractor.

1.6 SCHEDULING AND SEQUENCING

A. Include sequencing constraints specified herein as part of Progress Schedule.

B. Owner will keep Contractor informed of probable delivery date changes.

C. Owner will confirm delivery date with Contractor seven (7) calendar days prior to scheduled delivery, and within 24 hours of expected delivery time.

D. Where a preinstallation meeting is required by this Section, provide a

minimum of five (5) calendar days’ advance written notice to Owner of the proposed date for starting installation.

E. Provide a minimum of seven (7) calendar days’ notice to Owner that Owner-

furnished product is ready for all special services listed herein to be furnished by Owner through its contract with seller. Contractor shall bear the cost of all damages assessed to Owner by seller resulting from delays caused by Contractor.

1.7 EXTRA MATERIALS

A. Unless otherwise specified, Owner will take acceptance of, and be

responsible for storing associated extra materials and special tools upon delivery.

1.8 PREINSTALLATION MEETING

A. Arrange and attend a preinstallation meeting with the Engineer, Unison

Solutions, and Owner to review general procedures, erection and installation instructions, and installation sequence.

B. Additional meetings prior to installation may be required, as determined by

Owner, to transmit Owner’s installation instructions to Contractor.




PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION

3.1 INSTALLATION

A. Install products in conformance with Owner-furnished product shop drawings and installation instructions.

B. Provide all interconnecting structures, equipment, piping, electrical

and instrumentation work, finish painting, and appurtenances to achieve a complete and functional system.

C. Provide foundation pads for Gas Treatment System, Gas Treatment Control Panel, H2S Removal Vessel, Chiller, and other appurtenant items as shown on the Drawings. Verify exact dimensions and configuration of all pads, including penetrations, with Owner- furnished product shop drawings.

D. Anchor Bolts:

1. Provide anchor bolts, fasteners, washers, and templates needed

for installation of the equipment indicated in Paragraph 3.1C. 2. Size and locate anchor bolts in accordance with Owner-

furnished product shop drawings and installation instructions.

E. Mechanical and electrical equipment shall be properly aligned, plumb and level, with no stresses on connecting piping or conduit.

F. Verify direction of motor rotation before starting equipment drives.

G. Verify operability and safety of electrical system needed to operate

equipment. Check electrical system for continuity, phasing, grounding, and proper functions.

3.2 FIELD FINISHING

A. Products will be delivered with prime and finish coat(s) applied.

1. Finish coats are specified in the Unison Solutions’ submittal. 2. Touch up or repair damage to coatings resulting from

unloading, storage, installation, testing, and startup. 3. If finish coats are damaged extensively after transfer, completely repaint. 4. Touch up, repair, or complete repainting shall match color of original

paint, and shall be fully compatible with applied primers and finish.



3.3 PRODUCT PROTECTION

A. Immediately after installation, lubricate components in accordance with manufacturer’s instructions.

B. Follow manufacturer’s instructions for protection and maintenance during

storage, after installation but prior to testing and startup, and after startup but prior to acceptance.

C. Furnish incidental supplies including lubricants, cleaning fluids, and similar

products as needed for protecting and maintaining the Owner-furnished products.

3.4 TESTS AND INSPECTION

A. Perform tests and inspections of installed products in accordance with requirements shown herein, Section 01756 Commissioning, and manufacturer’s instructions.

3.5 CONTRACTOR TESTING AND START UP SERVICES

A. Contractor shall provide the services of all electrical, instrumentation, and mechanical staff/subcontractors as needed to assist with the testing and start-up of the Gas Treatment System.

END OF SECTION




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Page 1 of 18

5451 Chavenelle Road, Dubuque, Iowa 52002 [O] 563.585.0967 www.unisonsolutions.com Design and content included in this document is proprietary and remains the property of Unison Solutions, Inc.

Leaders in Biogas Technology

PROPOSAL

BioCNG 100 BIOGAS CONDITIONING & UPGRADING SYSTEM Date: 6/15/2017 Expires: 8/15/2017 City of Petaluma Attn: Jason Beatty Proposal Number: BC-217-2578.4 Project Name: Petaluma BioCNG 100 Unison Solutions, Inc. is pleased to provide this proposal for the Petaluma BioCNG Project. This proposal includes all of the CAD design services, technician labor, fabrication and materials to construct a BioCNG 100 Biogas Upgrading System. Thank you for giving Unison Solutions the opportunity to provide you with the enclosed proposal. If you have questions or require additional information, please contact me at your convenience. Sincerely, Adam Klaas Unison Solutions, Inc. Phone: 563-585-0697 Cell: 563-542-3081

Page 2 of 18


EQUIPMENT/SUB-SYSTEMS

HYDROGEN SULFIDE REMOVAL SYSTEM

- Hydrogen Sulfide Removal Media Vessel - Work Platform and Ladder - Initial Charge of H2S Removal Media

GAS COMPRESSION, MOISTURE/SILOXANE/VOC REMOVAL SYSTEM

- Gas Compressor Inlet Moisture/Particulate Filter - Pre-cooler - Gas Compressor - Oil/Gas Separator - Oil Cooler - Oil Particulate Filter - Gas to Gas Heat Exchanger - Gas to Glycol Heat Exchanger - Moisture Separator - Gas Recirculation - Siloxane Removal Vessels - Work Platform and Ladder - Initial charge of Siloxane Removal Media - Siloxane Removal Final Particulate Filter - Skid Base

CO2 REMOVAL SYSTEM

- Single Pass CO2 Removal System - Product Gas Flow Meter - Product Gas Odorizer

GLYCOL CHILLER

- Glycol Chiller - Initial fill of Propylene Glycol/Water Mixture

CONTROL SYSTEM

- Gas Conditioning System Control Panel - Transformer

BioCNG GAS ANALYZER

- Gas Analysis Panel - Cal Gas - Cal Gas Regulator

Page 3 of 18


DESIGN CONDITIONS

SITE INFORMATION

- Minimum Ambient Temperature 35°F - Maximum Ambient Temperature 100°F - Site Elevation 25’ AMSL

SYSTEM REQUIREMENTS

- Gas Flow 100 scfm

INLET GAS CONDITIONS

- Inlet Gas Pressure 0-15“WC - Inlet Gas Temperature 70-100°F - Relative Humidity 100% - Methane (CH4) 58-65% - Carbon Dioxide (CO2) 35-42% - Nitrogen (N2) <0.5% - Oxygen (O2) <0.2% - Hydrogen Sulfide (H2S) 87 ppmv* - VOCs & Siloxanes 730 ppbv*

*Per 3/1/2016 Gas Analysis: ALS Project ID: P1600954B This is the latest gas analysis that Unison has on file.

DISCHARGE GAS CONDITIONS

- Discharge Gas Pressure 115 psig - Discharge Gas Temperature 80°F - Dew Point Temperature 40°F - Maximum Hydrogen Sulfide <5 ppmv - Maximum VOCs & Siloxane <100 ppbv - Particulate Removal 99% removal of >0.5 micron Product gas quality will meet SAE-J1616 fuel specifications with proper system maintenance and monitoring of system gas quality to determine media bed condition.

SITE REQUIREMENTS

ELECTRICAL CLASSIFICATION

- NEC Class I, Division 1 Group D Areas - Hydrogen Sulfide Removal System - Gas Compression/Moisture Removal System - Siloxane Removal System - CO2 Removal System

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- Unclassified Electrical Areas - Glycol Chiller - Gas Conditioning System Control Panel - Transformer - Gas Analysis Panel

EQUIPMENT MOUNTING

- Skid Mounted

- Gas Compression/Moisture Removal System - Siloxane Removal System - CO2 Removal System

- Standalone

- Hydrogen Sulfide Removal System - Glycol Chiller - Gas Conditioning System Control Panel - Transformer - Gas Analysis Panel

EQUIPMENT/SUB-SYSTEM DETAILS

HYDROGEN SULFIDE REMOVAL SYSTEM - (1) Hydrogen Sulfide Removal Media Vessel

- 8’Ø x 10’ straight side - Rated for 5psig pressure and 1psig vacuum - Materials of construction shall be 304L stainless steel - 150# ANSI B16.5 side inlet and outlet connections - Flanged and dished top and bottom heads - Vessel shall be free-standing on four 304L stainless steel legs - Vessel equipped with a top manway - Vessel equipped with a side manway - Internal supports and grating for media - Pressure relief valves included - Two top vents with stainless steel ball valves - Bottom manual condensate drain with stainless steel ball valves

- Work Platform and Ladder

- Work platform shall be welded carbon steel construction with satin black powder coat finish

- Ladder shall be aluminum construction - Initial Charge of H2S Removal Media

Page 5 of 18


- The initial charge of media for the Hydrogen Sulfide Removal Media Vessel will be provided.

- Media to be loaded into Hydrogen Sulfide Removal Vessel by the INSTALLATION CONTRACTOR

GAS COMPRESSION, MOISTURE/SILOXANE/VOC REMOVAL SYSTEM

- Gas Compressor Inlet Moisture/Particulate Filter

- Mounted upstream of the Gas Compressor - 99% removal of 3micron and larger particulates and liquid droplets - Materials of construction shall be 304L stainless steel - 150# ANSI B16.5 side inlet and outlet connections - Cleanable polypropylene structured mesh element - Differential pressure gauge across the filter element - Float operated gauge for liquid level indication - Level switches above the condensate drain to warn of failure - Bottom drain with strainer, level controlled condensate pump, check valve, manual bypass and piping

- Pre-cooler

- Within the heat exchanger the gas will be cooled to 70°F - Aluminum bar and plate core - Materials of construction shall be aluminum core in a 304L stainless steel shell - 150# ANSI B16.5 inlet and outlet connections

- Gas Compressor

- One Oil Flooded Twin Screw Compressor rated for 100scfm - Direct drive 60Hp, 480V/3Ph/60Hz electric motor - Motor will be controlled by a MS/OL - All gas and oil components other than the compressor head shall be constructed of stainless steel and/or aluminum.

- Gas inlet and discharge flex connectors - Gas inlet check valve - Discharge pressure safety valve - Oil handling system will include an oil handling reservoir, coalescing filter, pressure safety valve, oil cooler, three way thermal bypass valve and an oil particulate filter.

- Initial fill of oil for the Gas Compressor system will be provided - Gas Compressor shall have a hydrogen sulfide tolerance of 40,000 ppmv

- Oil/Gas Separator

- ASME Section VIII, Division 1 code stamped - Materials of construction shall be 304L stainless steel - 150# ANSI B16.5 inlet and outlet connections - Discharge check valve

Page 6 of 18


- Oil Cooler

- Bar/Plate Air to Oil type heat exchanger - Materials of construction shall be aluminum - 150# ANSI B16.5 inlet and outlet connections - 480V/3Ph/60Hz EXP electric motor

- Oil Particulate Filter

- ASME Section VIII, Division 1 code stamped - Materials of construction shall be 304L stainless steel - 150# ANSI B16.5 inlet and outlet connections - Removable element for 5 micron filtration

- Gas to Gas Heat Exchanger

- Brazed plate - Materials of construction shall be 304L stainless steel body with nickel/chrome brazing

- 150# ANSI B16.5 inlet and outlet connections - Gas to Glycol Heat Exchanger

- Brazed plate - Materials of construction shall be 304L stainless steel body with nickel/chrome brazing

- 150# ANSI B16.5 inlet and outlet connections - Moisture Separator

- Uni-Flow Model - ASME Section VIII, Division 1 code stamped - Materials of construction shall be 304L stainless steel - 150# ANSI B16.5 inlet and outlet connections - Centrifugal style with no element to be cleaned or changed - Integral level switched for drain control - Automated bottom drain with strainer, solenoid valve, check valve, manual bypass and piping

- Gas Recirculation

- Backpressure regulator shall be provided to allow excess gas to flow from the discharge of the system back to the inlet of the Gas Compressor.

- (4) Siloxane Removal Media Vessels

- 18”Ø x 8’ straight side

Page 7 of 18


- Materials of construction shall be 304L stainless steel - 150# ANSI B16.5 inlet and outlet connections - Flat bottom with flanged top head - Flanged access nozzle on top of each vessel - Internal septas for even gas distribution through media - Pressure relief valves included - Bottom manual condensate drain with stainless steel ball valves - Test/purge ports with ball valves on the inlet and outlet of each Siloxane Removal Media Vessel

- Series piping and valves between Siloxane Removal Media Vessels will be provided

- Initial charge of Siloxane Removal Media

- The initial charge of siloxane removal media for each Siloxane Removal Media Vessel will be provided.

- The media shall be specifically engineered for removal of siloxanes and similar contaminants from landfill and digester gas sources.

- Siloxane media to be loaded into the Siloxane Removal Media Vessels by the city hired INSTALLATION CONTRACTOR.

- Siloxane Removal Final Particulate Filter

- Mounted downstream of the Siloxane Removal Vessels - 99% removal of 0.5 micron and larger particulate - Materials of construction shall be 304L stainless steel for filter housing and cartridge style element

- 150# ANSI B16.5 side inlet and outlet connections

Single Pass CO2 REMOVAL SYSTEM

- Single Pass CO2 Removal System

- Mounted downstream of the Siloxane/VOC Removal System - Materials of construction shall be 304L stainless steel for filter housing and cartridge style membrane element

- Modulating valves for pressure control - Off Gas Line to the Flare (Flare supplied by others) - Product gas flow meter - Endress & Hauser Model 65I Thermal Mass - Gas Odorizer - Gas Analyzer - Three Gas Analyzer (CH4, CO2, O2) - Siemens Model Ultramat 23 - All gas analyzer outputs will be available to Plant SCADA over Ethernet - NEMA 4 Cabinet with Air Conditioning

Page 8 of 18


- Skid Base

- Welded carbon steel construction with satin black powder-coat finish - All components mounted, piped and wired on skid base - 24V, 120V, & 480V electrical components wired to one of three junction boxes on edge of skid

- INSTALLATION CONTRACTOR to provide conduit and wiring to 480V components to the skid base junction boxes

- Conduit shall be rigid aluminum - Insulated condensate drains piped to edge of the skid base. Drains to be

routed to floor drain by the city hired INSTALLATION CONTRACTOR. GLYCOL CHILLER

- Glycol Chiller

- Manufactured by Advantage Engineering - Sized for the process heat load - Suitable for outdoor installation - Refrigeration System

- One refrigeration circuit - One compressor sized for 100% capacity - High efficiency condenser with copper tubes and aluminum fins - Condenser screen guard with air filter - Refrigerant piped and charged at factory with R410a - Low ambient head pressure controls down to -20°F - Heresite coated condenser - Heresite coated exposed copper lines - Brazed plate evaporator with stainless steel plates and copper brazing material

- Evaporator basket strainer with isolation valves - Refrigeration circuit has filter drier, sight glass with moisture indicator, liquid line solenoid valve, liquid receiver and thermal expansion valve

- R410a refrigerant - Glycol Chiller will be factory tested and shipped with complete refrigerant charge

- Glycol Circulation - One glycol circulation pump sized for 100% capacity - Pump motor is TEFC

- Pump discharge pressure gauge - Pump discharge check valve and electric return line shut off valve

- Manual low flow bypass valve - Glycol reservoir is insulated sealed-vented polyethylene - Level sight tube, drain valve and removable screw cover - Glycol piping is copper with anti-corrosion coating - Armaflex insulation - Glycol Chiller to utilize propylene glycol/water mix

Page 9 of 18


- Initial fill of Propylene glycol will be provided - Support Structure

- Galvanized steel member frame - All components mounted, piped and wired on skid

- Glycol Chiller Control Panel - UL Type 4 - UL 508A Listed Industrial Control Panel - Painted carbon steel - 480V/3Ph/60Hz feed will be required - 480V disconnect - Microprocessor based controller

CONTROL SYSTEM

- Gas Conditioning System Control Panel

- Enclosure

- UL Type 4 - UL 508A Listed Industrial Control Panel - Painted Carbon Steel - Outdoor location, out of direct sunlight

- Thermal Management - Heater - Air conditioner

- Power Distribution - Fused Disconnect - 480V/3Ph/60Hz feed required - 35kA Short Circuit Current Rating - Over current and branch circuit protection via fuses - 480VAC field wiring to terminate at the component or terminal strips inside control panel

- Surge Suppression - 480VAC Transient Voltage Surge Suppressor - 120VAC Surge Filter

- Motor Control - (1) FVNR motor starter overload for Gas Compressor Motor - (1) FVNR motor starter overload for Oil Cooler Motor - (1) FVNR motor starter overload for Condensate Pump

- Programmable Logic Controller - Allen Bradley - Compact Logix PLC and I/O - Native Allen Bradley Ethernet IP data network - Includes hardware and software to ensure communication capability with existing Modicon SCADA network via Ethernet communication protocol

- Human Machine Interface (Touch Screen) - Proface PFXGP4601TAD - TFT Color LCD Display

Page 10 of 18


- 12” diagonal - 800 x 600 pixels

- Instrument wiring to terminate at terminal strips inside Control Panel - Transformer

- 3 kVA - 480VAC to 120VAC - NEMA 3R; Painted carbon steel

INSTRUMENTATION

- All instrumentation provided will be designed for gas service and rated for use in a NEC Class I, Division 1 Group D area.

- Hydrogen Sulfide Removal System Instrumentation - Inlet Pressure Transmitter - Endress and Hauser PMP 75 pressure indicating transmitter - Inlet Resistive Temperature Detector (RTD) 3 Wire-100Ω

- Gas Compression/Moisture, Siloxane, & CO2 Removal System Instrumentation - Inlet Pressure Transmitter

- Endress and Hauser PMP 75 pressure indicating transmitter - Level Switches at each Condensate Drain - Level Indicators at each Condensate Drain - RTD’s (3 Wire-100Ω) at each Temperature Change Point - RTD (3 Wire-100Ω) to Monitor Glycol Temperature - Bi-metal Thermometers at each Temperature Change Point - Gas Compressor Discharge Pressure Transmitter - CO2 Removal Inlet & Discharge Pressure Transmitters - Product Gas Delivery Pressure Transmitter - Product Gas Analyzer - Product Gas Flow Meter

PIPING

- Pipe will be SA-312 TP304/304L Weld Pipe, minimum Schedule 10S. Threaded pipe shall be minimum Schedule 40S.

- Flange connections will be ANSI B16.5, SA-182 F304/304L Class 150. - Pipe welding will follow ASME B31.3 Process Piping. Welded pipe will be visually inspected and pressure tested.

- Gaskets will be 1/16” nitrile bound non-asbestos ring gaskets.

VALVES

- Ball Valves - Stainless steel with PTFE or RTFE seat. - Valves will be full port.

- Butterfly Valves - Lug style iron body with stainless steel disc and stem and FKM seat.

- Check Valves - Will be one of 2 styles; ball or dual-door.

Page 11 of 18


- Ball check valves shall be stainless steel with RTFE ball. - Dual-door check valves shall be wafer style body, material shall be aluminum and/or stainless steel with an FKM seat.

- Globe Valves - Stainless steel with PTFE packing

FASTENERS

- Fasteners on biogas piping shall be F593 304 stainless steel

SUBMITTALS

- Quantity: (4) copies of 3 ring binders and (4) electronic CD copy - Shop Drawings and Product Data will be provided in sufficient detail to confirm compliance with the requirements for the project. Shop Drawings and Product Data will be provided in a complete submittal package.

- Shop Drawings - Supplied per Special Conditions, Section C, paragraph 11

- Installation drawings and specifically prepared technical data, including design capacities will be provided.

- Specifically prepared wiring diagrams unless standard wiring diagrams are submitted with product data will be provided.

- Written description of operation will be provided. - Product Data - Catalog cuts and product specifications for each product specified will be provided.

- Standard wiring diagrams unless wiring diagrams are specifically prepared and submitted with Shop Drawings will be provided.

FACTORY TESTING

- The System will be tested on ambient air at Unison’s facility prior to shipment. - The CUSTOMER is allowed to witness the testing and Unison will inform the customer (2) weeks prior to anticipated testing date so customer can make travel arrangements.

OPERATION & MAINTENANCE MANUALS

- Quantity: Three (4) copies of 3 ring binders and three (3) electronic CD copy - O&M Manuals shall comply with Specification Section 01782 - After shipment the BioCNG Gas Upgrading System will be provided with a specifically prepared Operation & Maintenance Manuals. The information provided includes a system overview, operator interface, start-up/shut down procedures, communications, alarms procedures, maintenance overview, mechanical component spec sheets and electrical component spec sheets.

MANUFACTURER’S FIELD SERVICES

START-UP SERVICES

Page 12 of 18


- Includes fifteen (15) non-consecutive, 8 hour days, three trips for one Unison Technician onsite with travel and expenses included.

ELECTRICAL PARASITIC

- Electrical Parasitic

- Condensate Pump = 1 kW - Gas Compressor Motor = 61 kW - Oil Cooler Motor = 1 kW - Glycol Chiller = 24 kW - Controls & Auxiliary Equipment = 4 kW Total = 91 kW (Full Load) Total = 73 kW (Average Run Load)

DELIVERY SCHEDULE

Delivery Schedule for Biogas Treatment Equipment Weeks After

Receipt of PO

Submit shop drawings 5

Review of shop drawings by City 6

Site delivery of Biogas Treatment System 30

Installation of Biogas Treatment System (by Contractor) 32

Testing, Training and Start-up (estimated) 36

GAS TESTING AND ANALYSIS SERVICES

- It will be the responsibility of End User to take the following gas samples and ship the samples to the 3rd party laboratory designated by Unison Solutions. Unison Solutions will provide all materials to take and ship the gas sample(s). Our personnel will work directly with the lab to facilitate the testing required and address any issues that may arise with the biogas samples. Lab analysis and results will be provided and paid for by Unison, along with a summary of all testing done to date and any anomalies in the results. Unison will provide recommendations based on the results of the gas analysis to ensure the Biogas Conditioning Equipment is operating as efficiently as possible to lower O&M costs on the system. No online meter is commercially available for real-time siloxane testing. Additional testing is available at Unison Solutions standard rates.

BIOGAS SAMPLING MATERIALS: GENERAL DESCRIPTION Unison will provide the Gas Testing Kit:

- Instructions - Tedlar Bag (1 per sample port) - Plastic Barb Fitting - Flexible Tubing - Chain of Custody Form - Shipping Kit (UN approved metal can, packing material, box, labels)

Page 13 of 18


- The End User will be responsible for providing personnel to take and ship the gas sample(s). - Gas sampling instructions will be included in each kit. We ask that the gas sample be taken

Monday-Wednesday, and shipped FedEx-Ground to the address included with the sample kit. Shipping costs to the lab are the responsibility of the End User.

Year 1 (per year) Major

Components Siloxanes H2S Only VOC Test Kit

Raw gas - Start up 1 1 1 1 1

Raw gas - Quarterly 4 4 4

After Siloxane Vessels 12 6 12

After H2S vessel - Monthly 12 12

Product – After CNG Dryer 2 2 2 2

Years 2-5 (per year) Major

Components Siloxanes H2S only VOC Test kit

Raw gas/year 2 2 2

After vessels/year 4 4 4

After H2S vessel/year 4 4

Product (After dryer)/year 1 1 1 1

PRICING SUMMARY

- Price includes all labor and expenses associated with the fabrication of the system. - Prices do not reflect any taxes that may be applicable and are valid for 30 days. - Price is FCA; Factory, Dubuque, IA 52002, per Incoterms 2010. Shipping costs not included, see

estimate below

- Price does not include Start-up and Commissioning. Costs are shown below

BioCNG 100 Biogas Upgrading System .............................................................................. $661,000.00 NEMA 4X 304SS BioCNG and Chiller Control Panel Adder ................................................. $11,750.00 Compressor Turndown Adder ............................................................................................... $9,600.00 Addition I/O Adder for Flare .................................................................................................. $4,165.00 Seismic Calculations .............................................................................................................. $5,000.00 Siloxane Removal System Work Platform ............................................................................ $7,600.00 316 Stainless Steel H2S Removal System Adder ................................................................... $6,255.00 Gas Testing and Analysis Services (5 year plan) ................................................................. $57,150.00

Page 14 of 18


Petaluma CA Sales Tax (8.125%) ........................................................................................... $55,316.63 Shipping ESTIMATE to Petaluma CA ..................................................................................... $24,500.00

Cost is an estimate and is subject to change without notice. It does not include any special packaging or permitting that may be required and is dependent on the final equipment dimensions and weights.

Start-up and Commissioning Services ESTIMATE ................................................................. $31,650.00

Price includes Fifteen (15) non-consecutive, 8 hour days, 3 trips, for one Unison Technician onsite with travel and expenses included. Additional days may be necessary to complete start-up and commissioning, they will be billed to the Buyer/Owner/End User at the cost of $1,200 per day, per technician, plus travel & expenses.

PAYMENT SCHEDULE

- 10% upon favorable review of submittals - 10% upon confirmation of purchasing of material to construct equipment - 60% + Sales Tax + Shipping Costs upon receipt and acceptance of delivery of equipment and appurtenances - 10% upon set-up of the equipment as specified - 10% upon successful start-up and training of City staff or within one year of setting on site if

delay in successful start-up is not the fault of the Supplier - Net 30 days on all payments

Note: Percentages are of total quotation without Sales Tax and Shipping PROVIDED BY OTHERS

- VPN connection for remote access to Unison supplied equipment for troubleshooting and remote assistance.

PRICE DOES NOT INCLUDE

- Shipping of equipment to jobsite, in equipment pricing - Start-up and commissioning services, in equipment pricing - Any maintenance work after start-up - H2S or Siloxane/VOC removal media after initial fill - Performance guarantee or service/maintenance contract - Any gas testing or analyses - Permitting for the installation of the equipment or air permits - Freeze protection; including insulation and/or heat trace and heat trace power - Pipe stands for field piping

ASSUMPTIONS

VESSELS & MEDIA

Page 15 of 18


- H2S and VOC’s present in the gas will foul Siloxane media, additional gas testing will be necessary to finalize all vessel and media requirements, budget pricing is dependent on gas data given at the time of the proposal.

- Any assumption of media life that has been given is an estimate; additional gas testing will be required at the Buyer/Owner/End Users expense.

- Vessel sizes are estimates only, gas testing will be necessary to finalize all vessel sizing. MECHANICAL

- Flare is supplied by OTHERS - If an existing flare is being used, it is assumed this flare is in good working order, with all safety and control equipment.

- Foundations and/or maintenance pads are designed by OTHERS to properly support the equipment.

ELECTRICAL

- 480V/3Ph/60Hz is available - No historical data acquisition is included in this proposal

INSTALLATION CONTRACTOR RESPONSIBILITIES

- Installation responsibilities are broken out below into three categories to outline the work; these responsibilities by no means fall on any single contractor or individual. It is the responsibility of the Buyer/Owner/End User to ensure all these conditions are adhered to, as necessary. It is responsibility of the Buyer/Owner/End User to install all equipment in compliance with local and national codes applicable to the installation site.

BUYER/OWNER/END USER RESPONSIBILITIES

- All foundations and/or maintenance pads as necessary for equipment - Provide and seal all roof and building penetrations as necessary - Provide all anchor bolts, temporary lift equipment, power, labor, and all other incidentals required for proper installation of the equipment shown on the drawings that will be provided by Unison Solutions, Inc.

- All rigging and setting of equipment at job site - Proper storage of the equipment and media prior to installation - Provide installation of Equipment/Sub-systems per the Unison Solutions Installation Guide

- Load initial charge of Hydrogen Sulfide Media and Siloxane/VOC Media into the vessels

MECHANICAL CONTRACTOR RESPONSIBILITIES

- Provide all field piping between the Equipment/Sub-systems, including but not limited to:

- Hydrogen Sulfide Removal System - Gas Compression/Moisture/Siloxane/VOC/CO2 Removal System - Glycol Chiller

Page 16 of 18


- Gas Analyzer - Provide pipe supports as necessary. Piping shall be self-supporting, and not supported off of the Unison supplied equipment.

- Install all field located or shipped loose devices - Provide all Heat Trace and/or Insulation as necessary to provide proper freeze protection as defined by Unison Solutions.

ELECTRICAL CONTRACTOR RESPONSIBILITIES

- Provide 480V/3Ph/60Hz feed to the Gas Conditioning System Control Panel - Provide all field wiring and conduits between the Equipment/Sub-systems to the Gas Conditioning Control Panel and associated equipment. This includes but not limited to:

- Hydrogen Sulfide Removal System - Gas Compression/Moisture/Siloxane/VOC/CO2 Removal System Removal - Glycol Chiller - Gas Conditioning System Control Panel - Transformer - Gas Analyzer

- Provide local disconnects as necessary - Provide all Hazardous location conduits & wiring systems per Article 500 of the NEC - Provide conduit seals entering and/or leaving the Class I, Division 1 Electrical Area. Conduit seals will need to be filled during Start-up and Commissioning after verification of field wiring by Unison’s Start-up Technician. Conduit seals are to be filled prior to the introduction of gas to the equipment.

- Provide heat trace power from local lighting panel, as necessary. WARRANTY

- Unison Solutions, Inc. will warrant all workmanship and materials in conformance with the attached Warranty Statement. Warranty is valid for 18 months from the time the equipment is shipped from Unison’s factory or 12 months from the date of startup, whichever occurs first.

- This proposal is for equipment only and does not include any system engineering and design services expressed or implied.

- Unison Solutions, Inc. will not release the PLC program for this system. This is considered proprietary and the intellectual property of Unison Solutions, Inc. Unison will however work directly with the City’s SCADA System consultant to ensure that the Biogas Conditioning and Upgrading System can be monitored and controlled via the plants existing SCADA.

Page 17 of 18


APPENDIX A: Optional Services Secondary Training on Equipment ....................................................................................... $10,500.00 H2S Media Removal and Replacement Services ................................................................. $42,000.00*† Siloxane Media Removal and Replacement Services ......................................................... $10,950.00*† *Cost is per change out †See below for detailed description of services Payment Schedule - 100% due upon completion of task - Net 30 days

TIME & MATERIAL RATES (2017) PRICE

Engineering/Programming $175/hr *

Service Technicianᶲ $150/hr *

Tech Support (Phone) $150/hr *

Materials + 30%

Expenses Cost

* Overtime will be billed at 1½ time the labor rate after 8 hours. Weekends and/or Holidays may be subject to additional fees. Rates subject to yearly increase.

ᶲEffective July 1, 2017 there will be an increase of $2.51/hr, Effective July 1, 2018 there will be an increase of $2.61/hr to be allocated to wages and/or fringes to meet prevailing wage requirements

- PAYMENT TERMS: 100% upon completion – Net 30 days

Media Replacement Services

H2S/VOC Media Replacement

Siloxane Media Replacement

Media: Loading: 11,000 lbs - UNI-H2S

Media: Loading:

220 lbs – UNI-CVOC 385 lbs - UNI-CC5V 660 lbs - UNI-CL3E

Raw H2S: 87ppmv

Raw Gas VOCs: See Report

Estimated days to Change Out:

Approximately 4 Years†

Estimated days to Change Out:

Approximately 150 days†

H2S Media Change Out Services Siloxane Media Change Out Services

Shipping new media to the site

Shipping new media to the site

Removal of Spent Media

Removal & Disposal of Spent Media

Install New Foam Pad

Load of New Media

Loading of New Media

Industrial Grade Nitrogen Purge


11381 - 1 Digester Gas Equipment CNG Fueling Station

SECTION 11381

DIGESTER GAS PROCESSING EQUIPMENT

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: 1. Flame Trap Assembly 2. Drip Trap

B. Related Sections: 1. Section 11001: General Equipment and Mechanical Requirements 2. Section 11700: Waste Gas Burner 3. Section 15050: Process Piping, Valves and Accessories

1.02 REFERENCES

A. American National Standards Institute (ANSI) 1. B31.2 – Industrial Gas and Air Piping Systems

B. Underwriters Laboratories (UL)

1.03 SUBMITTALS

A. Shop Drawings and Product Data: Submit the following as a single complete initial submittal in accordance with Section 01330: 1. Descriptive information including catalogue cuts and manufacturer’s

specifications for all components. 2. Shop drawings with performance data, descriptive literature, weights and

dimensions, and other physical characteristics verifying compliance with this section. When numerous options and sizes are shown, the shop drawings shall be marked to clearly indicate the size and types specific to this Section and project.

B. Manuals: The contractor shall furnish manufacturer’s installation, lubrication, operation and maintenance manuals, bulletins, and spare parts list. When numerous types and sizes are shown, the manuals shall be marked to clearly indicate the sizes and types specific to the project.


A. All equipment furnished under this Section shall be by a single manufacturer who has been regularly engaged in the design and manufacture of the equipment for at least five years. Demonstrate to the satisfaction of the City Representative that the quality is equal to equipment made by those manufacturers specifically named herein.

Digester Gas Equipment CNG Fueling Station



PART 2 - PRODUCTS

2.01 DIGESTER GAS SAFETY EQUIPMENT

A. General: Furnish and install equipment suitable for use with gas from sewage sludge digestion tanks. All devices shall be of corrosion-resistant material and shall have gas-tight and non-sparking features in conformance with requirements of UL. Assembly bolts and nuts on all aluminum equipment and anchors bolts and nuts shall be type 316 stainless steel. Screwed connections shall be National Pipe Thread and flanged connection shall be 125 lb. standard flanges matching the dimensions of ANSI B16.1, latest edition. Equipment shall be furnished in the quantities as shown on the Drawings.

B. FLAME TRAP ASSEMBLY

The flame trap assembly shall have a flame arrester and thermal shut off valve components. Stand-alone flame arrestors in this project shall also be as specified below.

1. FLAME ARRESTER:

a. The Contractor shall provide flame arresters in the gas piping as shown on the Drawings to prevent the passage of flame by means of a removable flame-arresting bank arranged for easy removal for cleaning, inspection and the replacement.

b. Flame arresters shall be Varec Biogas 5000/5010 Series, Groth Model 7618/7628 or equal.

c. Flame arresters shall be provided with Factory Mutual approved elements.

d. Net free area through the bank assembly shall be not less than three times the corresponding size standard pipe. The entire bank assembly shall slide out of the arrester housing to facilitate inspection and cleaning. Removing or replacing the bank assembly shall not require support for alignment; jack screws for extending the housing and shall not place a strain on the connecting piping.

e. The bank frame shall be extensible and shall be filled with corrugated rectangular shaped bank sheets. Sheets shall be arranged for individual removal.

f. Flame arresters for vertical installation shall be self-draining. Flame arresters for horizontal service shall include an offset housing with a 1/2" NPT drip trap connection at the low point.

g. Housing construction shall be 356-T6 low copper cast aluminum. Bank assembly shall include a low copper aluminum frame and low copper aluminum bank sheets.

h. Flame arrester shall be leak proof to 10 psig. i. Drain piping with drip traps shall be provided from the inverts of all

horizontally installed frame arresters which do not completely drain to adjacent piping.

j. Flame arresters shall be provided in accordance with the following minimum free air capacity (FAC = 60°F at 14.7 psia) and maximum pressure drop requirements.



Size (Inches) Minimum FAC (SCFH) Maximum ∆P (inches W.C.)

4 15,000 1.06 30,000 1.08 50,000 1.0

2. THERMAL SHUTOFF VALVE

a. The Contractor shall provide thermal shutoff valves in the gas piping as shown on the Drawings.

b. Thermal shutoff valves shall be Varec Biogas 430 Series, Groth Model 8530, or equal.

c. Thermal shutoff valves shall include a fusible element designed to close the valve within 15 seconds upon reaching a temperature of 260°F (minimum). The fusible element shall control a spring-loaded pallet. An isolated sight glass shall be provided so that pallet position can be determined without having to remove the valve from service. The fuse plug shall be gas tight and shall be removable for replacement of the fusible element.

d. Construction shall be 356-T6 low copper cast aluminum body and cover. The inner valve shall include a low copper aluminum pallet assembly with 304 stainless steel compression spring. Sight glass shall be acrylic with neoprene gaskets.

e. Thermal shutoff valves shall be designed to withstand a working pressure of 5 psig without leaking.

f. Thermal shutoff valves shall be provided in accordance with the following minimum free air capacity (FAC = 60°F at 14.7 psia) and maximum pressure drop requirements.

Size (Inches) Minimum FAC (SCFH) Maximum ∆P (inches W.C.)

4 7,500 1.06 20,000 1.08 35,000 1.0

C. Manual Drip Trap: a. Provide a manual drip trap at each low point on the piping system as

shown on the Drawings. b. Provide reservoir with minimum 6 quart capacity. c. Drip trap shall be constructed of corrosion resistant cast aluminum with

316 stainless steel internal components. d. Traps shall be designed to manually operate a lever to drain

condensate without releasing pressurized gas. e. Traps shall have 1-inch screwed inlet and outlet connections f. Condensate from drip traps shall be piped to the nearest drain. g. Provide drain plug to permit manual draining of the reservior h. Furnish and install an isolation valve between the drip trap and the gas

piping system so that the drip trap can be removed without venting gas. i. Traps shall be Biogas 246 Series by Varec, Inc., or equal.

D. Automatic Drip Trap:




a. Provide an automatic drip trap at each low point on the piping system as shown on the Drawings.

b. Provide reservoir with minimum 2 quart capacity. c. Drip trap shall be constructed of corrosion resistant cast aluminum with

316 stainless steel internal components. d. Traps shall be designed to automatically remove condensate by using a

float operated needle valve to allow draining without releasing pressurized gas.

e. Traps shall have 1-inch screwed inlet and outlet connections f. Condensate from drip traps shall be piped to the nearest drain. g. Provide drain plug to permit manual draining of the reservior h. Furnish and install an isolation valve between the drip trap and the gas

piping system so that the drip trap can be removed without venting gas. i. Traps shall be Biogas 245 Series by Varec, Inc., or equal.

PART 3 - EXECUTION

3.01 INSTALLATION

A. Installation of equipment shall be in strict conformance with the written instructions of the manufacturer. Drip trap outlets shall be piped to discharge to the closest drain as shown in the Drawings.

B. Field service and affidavit certificate per Section 01756.

3.02 FIELD TESTING AND START-UP

A. After the installation of this equipment is complete the Contractor shall test all digester gas equipment and gas piping for gas tightness to a pressure of 10 psi for duration of 4 hours. All connections shall be checked for leaks by means of a soap suds solution. The system shall have no leaks. All leaks shall be corrected.

B. After the successful pressure test, demonstrate that the equipment functions properly and meets the performance requirements of this specification section.

C. Start-up shall be per Section 11001.

D. Provide a minimum of 8 hours of field service by the authorized factory trained representative for testing and start-up.

3.03 FIELD PAINTING

A. All equipment and appurtenances shall receive a final color coat in the field in accordance with Section 09960.

3.04 TRAINING

A. As specified in Section 01756.

3.05 WARRANTY




END OF SECTION




PAGE INTENTIONALLY

LEFT BLANK


11700 - 1 Waste Gas Burner CNG Fueling Station

SECTION 11700

WASTE GAS BURNER

PART 1 - GENERAL

1.01 SUMMARY

A. Scope: 1. This section specifies a low-emission, natural draft, waste gas burner that shall

be capable of combustion of low methane content gas that is produced as an off-gas from a gas treatment process to remove carbon dioxide from digester gas. In addition, the waste gas burner designed for the combustion of digester gas produced by the anaerobic digestion of municipal wastewater sludge. Digester gas may be added in the future. The waste gas burner shall have a pilot system capable of utilizing digester gas or natural gas. Emission testing includes procurement of a third-party lab.

2. The Contractor shall purchase the Waste Gas Burner from Varec. The quoted price from Varec is $218,449 for the work described in this specification section. This price includes freight to the jobsite, but does not include the cost to unload the equipment from the truck.

B. Definitions: Terminology used in this specification conforms to the following definitions: 1. Standard Cubic Feet Per Minute (scfm): The volumetric flow rate in cubic feet

per minute at 60 degrees F., 14.69 pounds per square inch absolute pressure. 2. Natural-draft waste gas burners: Waste gas burners using naturally aspirated

combustion air to provide the air-gas mixture required for combustion. Combustion air is provided without the use of blowers or motorized damper louvers. Cooling air is naturally induced into the stack to eliminate the need for refractory lining or insulation.

C. Related Sections: 1. Section 05090: Metal Fastenings 2. Section 09960: Protective Coatings 3. Section 11001: General Equipment and Mechanical Requirements 4. Section 11381: Digester Gas Processing Equipment 5. Section 15050: Process Piping Valves and Accessories 6. Section 16010: Electrical Work


A. Reference Standards: 1. This Section incorporates by reference the latest revisions of the following

documents. They are part of this Section insofar as specified and modified herein. In the event of conflict between the requirements of this Section and those of the listed documents, the requirements of this Section shall prevail.

2. Unless otherwise specified, references to documents shall mean the documents in effect on the effective date of the Agreement. If referenced documents have

Waste Gas Burner CNG Fueling Station



been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued.

B. References 1. ASTM ASTM International 2. ASTM A36/A36M Standard Specification for Carbon Structural Steel 3. NEC National Electric Code 4. NEMA 250-85 Enclosures for Electrical Equipment 5. NFPA 54 National Fuel Gas Code 6. NFPA 820 Standard for Fire Protection in Wastewater Treatment and

Collection Facilities 7. UL 508 The Underwriters’ Laboratories, Inc. (UL) Safety Standard for

Industrial Control Equipment 8. UL 698 The Underwriters’ Laboratories, Inc. (UL) Industrial Control

Equipment for Use in Hazardous (Classified) Locations 9. UL 1203 The Underwriters’ Laboratories, Inc. (UL) Explosion-Proof and

Dust-Ignition-Proof Electrical Equipment for Use in Hazardous (Classified) Locations

10. 40 CFR Part 60 Standards of Performance for New Stationary Sources (NSPS)

C. Unit Responsibility: Assign unit responsibility to the low-emission waste gas burner manufacturer for the combined equipment consisting of the waste gas burner and all associated controls specified in this Section.

D. Manufacturer Qualifications: The manufacturer shall have a minimum of five installations of low-emissions waste gas burners being used in digester gas service in the United States. Each installation shall have been operating successfully for at least 3 years. Successful operation shall be defined as continuously available for operation for a period not less than 365 continuous days without interruption due to equipment or component failure. The manufacturer shall provide descriptions and complete contact information, with phone numbers, for the five projects that meet this requirement.

1.03 SUBMITTALS


B. Action Submittal Items: 1. Drawings showing general dimensions and confirming the size/capacity of

equipment, dimensions of skid and equipment, anchor bolt plan including bolt diameter, embedment and projection requirements, and piping connections.

2. Grounding rod location and installation detail for lightning protection. 3. Manufacturer’s data including materials of construction, construction details of

equipment, wiring diagrams, and weight of equipment. 4. Shop and field painting systems, including technical literature and specifications. 5. Equipment control panel wiring diagrams identifying internal and face-mounted

components and connections, and wiring diagrams and plans showing field wiring requirements between the panel(s) and the electrical equipment.

6. Manufacturer’s installation instructions.



7. Project descriptions and complete contact information of five projects demonstrating compliance with the requirements specified in this Section.

8. Warranty in accordance with the General Conditions. 9. Manufacturer’s operation and maintenance information in accordance with

Section 01782. 10. Signed and sealed structural calculations and seismic anchorage certification

and related sketch. Calculations shall conform to the requirements of Section 01612.

1.04 PERFORMANCE REQUIREMENTS

A. Service Conditions: The equipment specified in this Section shall be suitable for continuous duty under all weather conditions.

B. The emissions from the waste gas burner shall comply with the requirements of the Bay Area Air Quality Management District (BAAQMD), or with the emission requirements listed in Paragraph 1.04H below, whichever is more stringent.

C. Maximum equipment height shall be 25 feet.

D. The gas feed to the waste gas burner will consist of the off-gas from the gas treatment system. (In the future, digester gas may be added as a gas feed as described below.) When the gas treatment system is operating, the off-gas feed to the waste gas burner will range from 30-60 scfm and contain a low methane content. When the gas treatment system is not operating, there will be no gas flow to the waste gas burner. When the gas treatment system is in its start-up sequence, the off-gas flow will be predominantly digester gas with a flow of 100 scfm. The City’s goal is to operate the gas treatment system as continuously as possible.

E. In the future, digester gas may be added as a gas feed. If digester gas is added to the waste gas burner in the future, then the gas feed to the waste gas burner may consist of off-gas alone, digester gas alone, or a blend of both gas flows.

F. The off-gas composition and properties are defined as follows when the gas treatment system is operating:

Description Value

Total Polluting Components as H2S 0-100 ppm All combustibles as Methane 25 to 60%

CO2 40 to 75% Specific Gravity 0.80 to 1.0 Heating value 250 to 650 BTU/SCF

Relative humidity 0-50% Gas temperature Ambient




G. The future digester gas composition and properties are defined as follows:

Description Value Total Polluting Components as H2S 100 to 1,500 ppm

All combustibles as Methane 50 to 70% CO2 30 to 50%

Specific Gravity 0.80 to 1.0 Heating value 550 to 650 BTU/SCF

Relative humidity 100% Gas temperature Ambient

H. Design Requirements (Off-gas):

Description Waste Gas

Burner Normal operating pressure range, inches w.c.(a) 6 to 12

Gas flows in normal operating pressure rangeMaximum per unit, scfm 150

Typical operating range, scfm 40-100 Minimum per unit, scfm 0

Minimum methane destruction efficiency, percent 99Maximum burner noise at 10 feet from outer surface of flare at maximum gas flow, dBA

85

Maximum air emission rates at all gas flowsNOx, lbs/MMBtu input 0.06CO, lbs/MMBtu input 0.20

VOCs, lb/MMBtu input 0.08

Note:

(a) Operating pressure shall be adjustable between 6 and 12 inches w.c using a pressure regulating valve.

1.05 SEISMIC ANCHORAGE AND STRUCTURAL REQUIREMENTS

A. The waste gas burner shall be permanently anchored and braced to the concrete slab shown on the Drawings to resist seismic forces in accordance with Section 01612.

PART 2 -PRODUCTS

2.01 MANUFACTURERS/PRODUCTS

A. Contractor shall purchase the Varec Biogas Model 244E enclosed waste gas burner as specified in Section 1.01A above.

2.02 MATERIALS

A. Materials for components shall be as follows:



1. Waste Gas Burner Inlet Manifold: ASTM A36, carbon steel 2. Burners: Type 347 SS with Type 316 SS fittings 3. Pedestal: ASTM A36, carbon steel 4. Combustion Stack Assembly: 11 Ga. 2B Type 304 SS with Sch. 40 support

pipe rings 5. Weather Hood and Control Panel Stand: Type 304 SS with Type 316 SS pipe

fittings 6. Waste Gas Supply Piping: ASTM A778, Type 304 SS, Sch. 5 with flanged

connections 7. Pilot Gas Piping and Tubing: ASTM A312, Type 304 SS, Schedule 40S

B. Materials specified are considered the minimum acceptable for the purposes of durability, strength, and resistance to erosion and corrosion.

2.03 EQUIPMENT FEATURES

A. Combustion Stack Assembly and Burners: 1. Combustion stack assembly shall mount on the burner base and shall be self-

supporting, without the use of anchor lugs and guy wires. The stack shall be electrically grounded for lightning strike protection.

2. Combustion stack assembly shall be designed and constructed to allow combustion air to be naturally aspirated with the specified range and mixture of the off gas and/or digester gas to obtain proper air-gas mixture. This shall be done without the use of motorized dampers, blowers or like devices.

3. The combustion stack assembly shall be able to use digester gas and natural gas as the pilot gas. The switch between the digester gas and natural gas pilot gases shall be done manually.

4. Lifting lugs shall be provided on stack assembly for installation purposes. 5. The burner shall have no visible flame and be designed to combust the off gas

and digester gas efficiently without limiting the gas flow range. 6. The burners shall be made with minimum thickness of 10 gauge. The main

manifold in the base of the flare shall be accessible to allow the removal and replacement of the flare nozzles and for maintenance of the piping. Flare shall also have a sectional manifold to to accommodate removal and repair of individual headers.

7. Sample ports shall be located a distance equal to ½ the flare diameter from the top of the flare. Two 2-inch-diameter ports, located at 180-degree intervals, shall be used.

B. Stack Burner Base and Pedestal: 1. Burner base and pedestal shall be coated for corrosion resistance, in accordance

with Section 09960. 2. Burner base and pedestal shall be designed to secure the stack firmly to the skid

with bolt holes and anchor bolts.

C. Waste Gas Burner Inlet Manifold: 1. The waste gas burner inlet manifold shall divert the off gas and/or digester gas

into the combustion chamber to the orifice burners. 2. Each line from the waste gas burner inlet manifold to the combustion chamber

orifice burners shall have an isolation ball valve. Isolation valves to the upper and middle burner rings shall be provided with electric motor actuators. These valves shall be capable of open/close operation and shall be used to control the turndown of the waste gas burner. Each valve actuator shall contain contacts to




allow the valve to be opened and closed by commands from the Waste Gas Burner Control Panel based on inlet pressure to the waste gas burner . Valves shall be stainless steel ball valves designed for the service with PTFE seats and seals.

3. The waste gas inlet manifold shall be coated for corrosion resistance, in accordance with Section 09960.

4. Waste gas inlet manifold shall have a 1-inch NPT drain connection and automatic drip trap for condensate removal.

D. Flame Trap Assembly: 1. The waste gas burner shall be provided with a flame trap and thermal shut off

valve, installed on the gas header to the burner and no more than 15 feet from the burner. Flame trap and thermal shut off valve shall be in accordance with Specification Section 11381.

E. Pilot Gas Supply: 1. A continuous flame nozzle shall be mounted integral to the burner and shall have

a long profile flame. Pilot shall be inclined 45 degrees off vertical. The pilot flame shall extend through waste gas/digester gas flow profile to ensure ignition of waste gas/digester gas regardless of the flow rate. The unprotected pilot shall withstand winds up to 110 mph (177 km/h) without the use of downdraft protectors, vortex vanes or other flow restricting devices. The pilot shall burn at an elevated temperature to assist in the conversion of hydrogen sulfide and subsequently, odor control.

2. The waste gas burner shall operate using either digester gas or natural gas as follows: a. Digester gas as pilot fuel, 55 SCFH at 4” WC minimum to 12” WC

maximum. Digester gas is the preferred fuel. b. Natural gas, 55 SCFH at 0.36 PSIG minimum to 10 PSIG maximum.

Natural gas shall be regulated down to operate as required with the low pressure pilot system.

3. The waste gas burner shall be equipped with manual valves to select the pilot gas type: digester gas or natural gas. Pilot gas only runs continuously when there is a demand to flare or to combust waste gas, otherwise the burner remains on standby and does not continuously use pilot gas.

4. The pilot gas and air shall be mixed and ignited at ground level, remote from the burner stack. Specifically, no component of the ignition system shall be mounted to the burner stack or shroud; nor shall heat shields be substituted in an attempt to protect such devices from the heat of combustion.

F. Pilot Gas Control Components: 1. The waste gas burner shall be provided with a pilot gas control package. The

pilot gas control components shall be mounted on a control panel stand. The control panel shall also be mounted on the same plate.

2. The pilot gas piping from the pilot gas control components panel to the waste gas burner shall be provided as part of the waste gas burner package. The pilot gas piping and venturi shall be at an incline to maximize air-gas mixing.

3. One pilot train shall be provided that can utilize either natural or digester gas as pilot fuel. The pilot gas train shall be designed as part of the waste gas burner and set for natural gas as the pilot fuel. a. The pilot shall provide a 1-inch pipe connection from the digester gas supply

pipe to the pilot train. A pressure regulating valve designed for the gas



service shall be provided. Pressure gauges shall be provided directly upstream and downstream of the pressure regulating valve.

b. A 1-inch FNTP pipe connection shall be provided to connect the natural gas line to the pilot train. A pressure regulating valve designed for the gas service shall be provided. Pressure gauges shall be provided directly upstream and downstream of the pressure regulating valve.

4. The pilot gas control components shall include the following: a. Solenoid valves with aluminum construction and stainless steel inserts.

Solenoid valves shall be rated for service in a Class 1, Division 1 classified area.

b. Pressure gauges, 0 to 30” WC range on the digester gas pilot connection and on the natural gas pilot connection.

c. Pressure regulator on the natural gas connection to reduce the feed pressure from 5 psig to 10-12 inches w.c.

d. Isolation valves designed for the gas service. e. The pilot system shall have 1-inch and 2-inch 347 stainless steel aspirating

venturi. f. All tubing and fittings shall be stainless steel construction.

5. The pilot train outlet connections to the flare shall be a 2-inch NPT to the continuous flame line and 1-inch NPT to the flame retention line. The pilot gas and air shall be mixed and ignited remote from the burners of the combustion stack assembly. Specifically, no component of the ignition system shall be mounted to the burner stack assembly.

G. Pilot Flame Checks: 1. The waste gas burner ignition system shall be provided with a flame check sized

per manufacturer’s recommendation. Housing shall be of “pipe union” design to permit easy disassembly for inspection and cleaning. Element shall be replaceable and be made of compressed 316 SS woven wire. Housing shall be constructed of low copper cast aluminum. Maximum working pressure shall be 25 psig (172 kPa). The flame check shall meet the following design requirements: a. Flame check shall be designed to permit easy disassembly for inspection and

cleaning. b. Element shall be replaceable and be made of compressed 316 stainless steel

woven wire. c. Housing shall be constructed of low copper cast aluminum.

H. Pressure Indicator Transmitter:

a. Furnish a pressure indicator transmitter to measure the inlet gas pressure to the waste gas burner.

b. Pressure signal shall be an analog input to the Waste Gas Burner Control Panel. The pressure signal shall be used by the Waste Gas Burner Control Panel to open and close the upper and middle burner manifold valves.

c. Pressure indicator transmitter shall be in accordance with Specification Section 17150.

I. Condensate Control: 1. Provide a low-pressure automatic drip trap on the drain port of the flame trap

assembly, waste gas burner inlet manifold, and any other low points as part of




the waste gas burner components. Drip trap shall be as specified in Specification Section 11381.

J. Control Devices and Panels: 1. A Waste Gas Burner Control Panel shall be provided and mounted on a stand

near the waste gas burner. Provide separate single connection points for power and control connections. The manufacturer shall be responsible for all other power and control components associated with the burner’s electrical connections.

2. All control devices, panels, and junction boxes shall be listed by Underwriters Laboratories, Inc. All components shall meet the requirements for outdoor electrical installations, as specified in Divisions 16 and 17, and shall comply with UL 1203, UL 698, NFPA 54, NFPA 820, and the NEC.

3. The panel enclosure and device enclosures shall be corrosion resistant and meet the requirements of NEC Article 500, for a Class I, Division 1, Group D environment. Enclosures shall be NEMA7.

4. The panel shall be operated by 120 Vac, single phase, 60 Hz. The control system shall have the capability for repeated ignition cycles.

5. As a minimum, the control panel shall include the following: a. Three-position selector switch for STANDBY/AUTO/MANUAL modes b. Pilot flame monitoring c. Status lights for “Pilot On”, “Pilot Off”, “Spark”, and “Ignition Retention Valve

Open” located on the panel door d. Adjustable thermocouple set point e. Heater and thermostat f. Manual ignition button g. Single pole double throw (SPDT) contacts for remote indication of Pilot On,

Waste Gas Burner Running, “In Manual” (or Hand) mode, “In Auto” mode, and Pilot Light Failure

h. Power on-off switch i. Operating lights for power-on, ignition on, pilot on, digester gas on, and flare

failure j. Control circuit breaker k. Name plates

6. The control system shall include necessary pilot controls to provide automatic re-ignition of the burner. The control system shall provide a flame sensing and re-ignition sequence in case the pilot is lost. In case of a pilot flame failure, the solenoid valves shall fail close/powered open.

7. The ignition transformer shall be mounted on the waste gas burner. The flare manufacturer shall provide a high-temperature ignition cable for temperatures up to 550º C.

8. All elements shown as part of the vendor provided system in the contract drawings shall be prewired from the factory (in a facility approved by Underwriters Laboratories) and only require interconnection between the plant control system and Panelboard in the Gas Treatment area.. Components shall be functionally tested prior to shipment, simulating actual operation.

9. The Control Panel shall contain a controller to monitor and control the functions described under the Control System paragraph below

10. Furnish and install a secondary thermocouple to monitor the stack combustion temperature. Provide output of the thermocouple for remote monitoring of the temperature in the plant PLC/SCADA system.



11. Provide power for the middle and upper burner motorized ball valves.

K. Control System: The burner shall be equipped with an Underwriters Laboratories-recognized control system having the following functions: 1. The waste gas flare shall be equipped with a flame front type ignition system

capable of automatically igniting the pilot flame with digester gas. In case of pilot failure, the igniter shall automatically activate the gas pilot. The igniter shall operate on 120V single phase power.

2. The waste gas flare shall be capable of automatic repeated attempts to ignite the pilot until a device senses that the pilot is burning.

3. The control system shall open and close the motorized valves for the upper and lower burner rings based on the gas inlet pressure to the waste gas burner. The control panel shall provide power for these valves.

4. Contacts for remote indication of the following: a. Power On b. Ready (Control system is in “Auto” mode and that there are no faults.) c. System Fault d. Pilot on e. Upper Burner Ring – Open/Close f. Middle Burner Ring – Open/Close g. 4-20 ma output for the gas inlet pressure to the waste gas burner

5. A normally closed dry contact shall be provided for a remote common trouble alarm.

6. Local alarm panel and remote visible-only alarm to indicate flare shutdown. 7. The control system shall prevent the opening of the main gas valve until after the

presence of the pilot flame is confirmed.

2.04 SPARE PARTS

A. Provide the following spare parts for each low-emission waste gas burner model furnished for this Section: 1. Two - spare ignition spark plugs 2. One - spare thermocouple 3. Two - spare time delay relays 4. Three - panel lights 5. One - pilot gas solenoid valve

B. Itemize and deliver spare parts per the direction of the Owner.

PART 3 - EXECUTION

3.01 COATINGS

A. Per Specification Section 09960 unless approved otherwise

B. Primer Coating: Shall be factory-applied with field touchup.

C. Finish Coating: Shall be factory-applied with field touchup.

3.02 INSTALLATION

A. The low-emission waste gas burner shall be installed in accordance with the manufacturer’s recommendations. The installation shall be certified by the manufacturer in accordance with Section 01756.




3.03 COMPONENT TESTING

A. Procedures: Section 01756

B. Perform the following tests: 1. In addition to the testing requirements of this Section, the Contractor shall

perform all testing for this product or system to fulfill the requirements of Section 01756, the applicable codes, and the manufacturer’s current quality assurance program. The Contractor shall perform the following testing: a. Operate the system for a period of 120 continuous hours using waste gas

and/or digester gas to demonstrate satisfaction of the performance requirements specified herein.

b. To the extent the gas is available, operating over the full range of gas flow rates specified.

c. Satisfaction of the emissions requirements for air permit testing shall be documented by an independent testing laboratory. The Contractor shall pay for and arrange to have an independent and fully certified testing laboratory perform exhaust emissions testing to confirm performance with this Section. The testing laboratory shall be subject to approval by the Owner. All emissions testing shall be open to the Owner for observation. The emissions shall be tested using digester gas as the pilot fuel. Submit certified test result to the Owner for acceptance.

C. If required, the Contractor shall take corrective action and have the system retested to ensure full compliance with the specified requirements.

3.04 MANUFACTURER’S SERVICES

A. On-Site Inspections: Provide a factory-trained manufacturer’s representative at the Site for the following activities. Specified durations do not include travel time to or from the Site. 1. Installation Inspections: Assist, supervise, and inspect the Contractor’s activities

during installation. Provide a minimum of 8 hours of installation inspection. 2. Emission Test Phase Testing and System Tuning: Assist, supervise, and inspect

the Contractor’s activities during the system test phase specified in Section 01756 and this Section. Provide 8 hours for assistance for the emission phase testing. Furnish services as needed for tuning to ensure that the system passes the emissions test.

3. Operational Test Phase Testing Inspections: Assist, supervise, and inspect the Contractor’s activities during the operational test phase specified in Section 01756 and this Section. Provide 8 hours for inspection of operational test phase testing.



3.05 TRAINING

A. The equipment manufacturer(s) shall supply a factory certified field service engineer to provide classroom training sessions for equipment before operation of the system will be taken over by the Owner. Training shall include theory of operation, safety procedures, operating instructions, and preventive maintenance procedures. The Contractor shall schedule the date and time of the training(s) with the Owner two weeks in advance of the training.

1. Two classroom training sessions with a duration of up to 4 hours per session shall be provided for the Waste Gas Burner and associated controls.

END OF SECTION




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11750 - 1 Vehicle Fuel Equipment CNG Fueling Station

SECTION 11750

VEHICLE FUELING EQUIPMENT

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: 1. Inlet Dryer 2. Compressed Natural Gas (CNG) Compressors 3. Natural Gas Booster Compressor 4. Compressed Natural Gas (CNG) Booster Compressor 5. Time Fill Panel 6. Priority Valve Panel 7. Communications Panel 8. CNG Flow Monitoring System 9. 3-Pack CNG Storage System 10. Dual Hose Fuel Dispenser 11. Fueling Post with Two Fueling Nozzles 12. Fuel Master System

B. Related Sections: 1. Section 09960: Protective Coatings 2. Section 11001: General Equipment and Mechanical Requirements 3. Section 11002: Electric Motor Drives 4. Section 15050: Process Piping, Valves and Accessories

1.02 REFERENCES

A. American National Standards Institute (ANSI) 1. B31.2 – Industrial Gas and Air Piping Systems

B. Underwriters Laboratories (UL)

C. National Fire Protection Association (NFPA) 1. NFPA 52 Vehicular Natural Gas Fuel Systems Code

1.03 SUBMITTALS

A. Shop Drawings and Product Data: Submit the following as a single complete initial submittal in accordance with Section 01330: 1. Descriptive information including catalogue cuts and manufacturer’s

specifications for all components. 2. Shop drawings with performance data, descriptive literature, weights and

dimensions, and other physical characteristics verifying compliance with this section. When numerous options and sizes are shown, the shop drawings

Vehicle Fuel Equipment CNG Fueling Station



shall be marked to clearly indicate the size and types specific to this Section and project.

B. Manuals: The contractor shall furnish manufacturer’s installation, lubrication, operation and maintenance manuals, bulletins, and spare parts list. When numerous types and sizes are shown, the manuals shall be marked to clearly indicate the sizes and types specific to the project.


A. All equipment furnished under this Section shall be by a single manufacturer who has been regularly engaged in the design and manufacture of the equipment for at least five years. Demonstrate to the satisfaction of the City Representative that the quality is equal to equipment made by those manufacturers specifically named herein.

1.05 MANUFACTURER

A. ANGI Energy Systems or equal.

PART 2 - PRODUCTS

2.01 GENERAL DESIGN CRITERIA

A. Products shall be suitable for use within the classified areas in accordance with NFPA 52.

B. Piping, tubing, valves, storage vessels, and appurtenances on the outlet side of the CNG compressors shall be rated for use at 5000 psi.

2.02 GAS SAFETY EQUIPMENT

A. General: Furnish and install equipment suitable for use with treated gas from sewage sludge digestion tanks and natural gas that will be used to produce CNG. All devices shall be of corrosion-resistant material and shall have gas-tight and non-sparking features in conformance with requirements of UL. Assembly bolts and nuts on all aluminum equipment and anchors bolts and nuts shall be type 316 stainless steel. Screwed connections shall be National Pipe Thread and flanged connection shall be 125 lb. standard flanges matching the dimensions of ANSI B16.1, latest edition. Equipment shall be furnished in the quantities as shown on the Drawings.

B. Furnish and install an emergency stop device on all control panels listed below. The manufacturer shall design the system component wiring such that all equipment shall be stopped when any emergency stop button is depressed.

C. Furnish a Site emergency stop device and a Fuel Dispenser emergency stop device that will be located as shown on the Drawings. These emergency stop devices shall be integrated with the emergency stop devices installed on all control panels

2.03 INLET DRYER:

A. The Contractor shall provide an Inlet Dryer as shown on the Drawings to dry product gas (renewable natural gas, or RNG) from the Gas Treatment System.



B. The Dryer shall be standard design, single tower that uses a desiccant bed to dry the gas. The desiccant bed is regenerated manually using a heating process.

C. The Dryer shall include dew point monitor of the gas after the gas passes through the desiccant bed. The control system will alarm when the dryer outlet gas dewpoint increases above the temperature setpoint. The alarm indicates the need for regeneration.

D. Furnish a skid mounted control panel for the dryer with the following capabilities: 1. PLC programmed to monitor and control the dryer. 2. Touch screen HMI as an operator interface to monitor and control the dryer

and appurtenances. 3. All software and hardware to allow the PLC to send and receive commands

with other PLCs via Ethernet communications. 4. Program the PLC to allow all inputs and outputs to be accessible by the Plant

Modicon PLCs via Modbus-over-Ethernet protocol. 5. Control panel shall be designed to be installed within the NFPA 52, Class I,

Division 2 classified area.

2.04 CNG COMPRESSORS:

A. Furnish two (2) skid mounted compressor packages designed to compress a range of 30 to 60 SCFM RNG at approximately 13 psig inlet pressure to 4,500 psig discharge pressure for use as vehicle fuel (CNG).

B. Furnish a skid mounted control panel for each compressor with the following capabilities: 1. PLC programmed to control and monitor the compressor and appurtenances. 2. Touch screen HMI as an operator interface to monitor and control the

compressor and appurtenances. 3. All software and hardware to allow the PLC to send and receive commands


Modicon PLCs via Modbus-over-Ethernet protocol.. 5. Control panel shall be designed to be installed within the NFPA 52, Class I,


C. Motor shall be designed as follows: 1. Belt driven. 2. Rated for Class I Division 2 hazardous service. 3. Comply with Specification Section 11002.

D. Furnish and supervise installation of accessories, including: 1. Compressor inlet connections 2. Strainers 3. Check valves 4. Manual valves 5. Flexible hoses 6. Weather-proof enclosures including sound attenuation to limit noise to 79

dBA within 10 feet of the enclosure




2.05 CNG BOOSTER COMPRESSOR:

A. Furnish One (1) compressor designed to boost the vehicle fuel (CNG) pressure in the Mobile CNG Fueling Vehicle to approximately 4,500 psig for discharge to the CNG header at the PR&R site for use as vehicle fuel (CNG). The pressure in the Mobile Fueling Vehicle will be approximately 3000 psig when the storage vessel is full.

B. Furnish a pad mounted control panel for the compressor with the following capabilities: 1. PLC programmed to control and monitor the compressor and appurtenances.

PLC shall be programmed to maintain an operator adjustable outlet pressure when the Mobile Vehicle Fuel truck is connected to the compressor inlet piping.

2. Touch screen HMI as an operator interface to monitor and control the compressor and appurtenances.

3. All software and hardware to allow the PLC to send and receive commands with other PLCs via Ethernet communications.

4. Program the PLC to allow all inputs and outputs to be accessible by the Plant Modicon PLCs via Modbus-over-Ethernet protocol.

5. Control panel shall be designed to be installed within the NFPA 52, Class I, Division 2 classified area.


D. Furnish and supervise installation of accessories, including: 1. Compressor inlet connections 2. Strainers 3. Check valves 4. Manual valves 5. Flexible hoses 6. Weather-proof enclosures including sound attenuation to limit noise to 79

dBA within 10 feet of the enclosure

2.06 NATURAL GAS BOOSTER COMPRESSOR

A. Furnish a skid mounted compressor package designed to compress 30 to 60 SCFM natural gas at approximately 1 psig inlet pressure to 15 psig discharge pressure.

B. Furnish a skid mounted control panel for the compressor with the following capabilities: 1. PLC programmed to control and monitor the compressor and appurtenances. 2. Touch screen HMI as an operator interface to monitor and control the

compressor and appurtenances. 3. All software and hardware to allow the PLC to send and receive commands


Modicon PLCs via Modbus-over-Ethernet protocol.. 5. Control panel shall be designed to be installed within the NFPA 52, Class I,





D. Furnish and supervise installation of accessories, including: 1. Compressor inlet connections 2. Strainers 3. Check valves 4. Manual valves 5. Flexible hoses 6. Weather-proof enclosure including sound attenuation to limit noise to 79 dBA

within 10 feet of the enclosure

2.07 DUPLEX MOTOR FULL VOLTAGE STARTER PANEL

A. Furnish and supervise erection of an off-skid duplex motor Starter Panel with NEMA 3R Enclosure and 5 KVA control transformer. The panel shall be rated for 400F to 1040F.

B. The panel shall contain starters and all power needed for the inlet dryer, CNG compressors, Natural Gas Booster Compressor, Priority Panel, and other equipment furnished by the Vehicle Fuel System supplier.

2.08 PRIORITY VALVE PANEL

A. Furnish and supervise erection of a 3-bank electronic Priority Valve Panel with all appurtenances and controls as needed to monitor and control the pressure in the 3-Pack Storage System.

B. The Priority Valve Panel shall be provided with ½” isolation valves for emergency shut down (ESD) control and vehicle filling from cascade storage and Compressors.

C. The Priority Valve Panel shall include capability for remote monitoring of the pressure in the CNG storage banks. Remote monitoring can be achieved by using contacts for hard wired connections or via an Ethernet communication system.

D. Control panel shall be designed to comply with NFPA 52, Class I, Division 2

2.09 TIME FILL PANEL

A. Furnish and supervise erection of a Time Fill panel with all appurtenances and controls as needed to monitor and control the pressure in the CNG Header at the PR&R site when the Mobile Fueling Vehicle is connected to the CNG Booster Compressor inlet piping.

B. The Time Fill Panel shall be provided with ½” isolation valves for emergency shut down (ESD) control and vehicle filling from Mobile Storage Trailers and Compressor.

C. Control panel shall be designed to comply with NFPA 52, Class I, Division 2.




2.10 CNG FLOW MONITORING SYSTEM

A. Furnish and supervise erection of a gas flow monitoring system to indicate and totalize the volume of CNG delivered to the 3-Pack CNG Storage System.

B. Panel shall contain a Coriolis flow and density meter to measure flow and density of the gas. The meter shall be suitable for installation in a Class I Division 1 hazardous location per NFPA 54. The meter shall be an Emerson Micro Motion Model DH100S or equal.

C. Flow range of 0 to 100 scfm.

2.11 3-PACK STORAGE SYSTEM

A. Furnish and supervise erection of a 3-Pack CNG storage system as shown on the drawings. Each 3-Pack system shall have a total storage capacity of 34,713 cubic feet at 4,500 psig. Each 3-Pack storage assembly shall have three 20-inches diameter and 23-ft long storage vessels shipped loose. Each 3-pack assembly shall be provided with a single vent stack.

B. Storage assembly shall be designed in accordance with the seismic design criteria as specified in Section 01612.

2.12 DUAL HOSE FUELING DISPENSING NOZZLES

A. Furnish and supervise erection of a Dual Hose Fueling Dispenser with high pressure flexible hose rated for 5000 psi.

B. One nozzle shall be compatible with the connector for the mobile storage vehicle as specified in drawings.

C. One nozzle shall be an NGV1 Type 2 nozzle that is compatible with the CNG fuel connector for CNG vehicles.

D. Fuel Dispenser shall be designed in accordance with the seismic design criteria as specified in Section 01612.

2.13 FUELING POST WITH DISPENSING NOZZLES

A. Furnish and supervise erection of ten (10) fuel posts with two dispensing nozzles with high pressure flexible hose rated for 5000 psi.

B. Nozzles shall be an NGV1 Type 2 that are compatible with the CNG fuel connector for CNG vehicles.

C. Post shall be designed in accordance with the seismic design criteria as specified in Section 01612.

2.14 FUEL MASTER SYSTEM

A. Furnish and supervise erection a Fuel Master System consisting equipment developed to control access to, account for, and compile reports for transactions from the fuel dispenser. The Fuel Master System shall be automated and capable of self-service, fuel dispensing for Compressed Natural Gas (CNG) application for small service stations. The Fuel Management Units (FMUs) and Fuel Management Software shall be encoded to assure security and allow access only by the customer to which the system designator is assigned.



B. The Fuel Master equipment shall be rated for 120 V. 50/60 HZ and 2.4 amps.

PART 3 - EXECUTION

3.01 INSTALLATION

A. Installation of equipment shall be in strict conformance with the written instructions of the manufacturer.

B. Field service and affidavit certificate per Section 01756.

3.02 FIELD TESTING AND START-UP

A. After the installation of this equipment is complete the Contractor shall test all vehicle fuel equipment and gas piping for gas tightness to a pressure of 4500 psi for duration of 4 hours. All connections shall be checked for leaks by means of a soap suds solution. The system shall have no leaks. All leaks shall be corrected.

B. After the successful pressure test, demonstrate that the equipment functions properly and meets the performance requirements of this specification section.

C. Start-up shall be per Section 11001.

D. Provide a minimum of 16 hours of field service by the authorized factory trained representative for testing and start-up on two separate trips.

3.03 FIELD PAINTING

A. All equipment and appurtenances shall receive a final color coat in the field in accordance with Section 09960.

3.04 TRAINING

A. As specified in Section 01756.

3.05 PROGRAMMING COORDINATION SERVICES

A. Participate in up to 4 telephone conference calls at two hours each, with the City, City’s programmer, Design Engineer, and Contractor to coordinate programming of the vehicle fuel system communications with the Plant PLC and SCADA system.

B. Provide written information as requested by the City, City’s programmer, and the Design Engineer to coordinate programming for communications between the vehicle fuel system components and the Plant PLC and SCADA system. This information includes, but it not limited to, the following: 1. A list of signals to be read by the Plant PLC with P&ID tag, engineering units,

data type, etc. 2. A list of signals to be read by the Plant SCADA system with P&ID tag,

engineering units, data type, etc. 3. A list of PLC IP addresses 4. Memory addresses for reading signals 5. On/off state of alarms




3.06 WARRANTY


END OF SECTION


15050 - 1 Process Piping, Valves and Accessories CNG Fueling Station

SECTION 15050

PROCESS PIPING, VALVES AND ACCESSORIES

PART 1 - GENERAL

1.01 SUMMARY

A. Section includes: Provide all piping, including fittings, valves, supports, and accessories as shown on the Drawings, described in the Specifications and as required to completely interconnect all equipment with piping for complete and operable systems, including equipment drains.

B. Related Sections Including Work Provided in this Section:

1. Section 02301: Earthwork 2. Section 05090: Metal Fastenings 3. Section 05500: Metal Fabrications 4. Section 09960: Protective Coatings 5. Section 10400: Identifying Devices 6. Section 11001: General Equipment and Mechanical Requirements 7. Certain additional valves, piping, and accessories specified elsewhere:

a. Section 11209: Rotary Actuators b. Section 17120: Flow Measurement c. Section 17150: Pressure Measurement

1.02 REFERENCES

A. ASTM International (ASTM)

B. American Society of Mechanical Engineers (ASME)

C. American National Standards Institute (ANSI)

D. American Water Works Association (AWWA)

E. American Welding Society (AWS)

F. U.S. Department of Transportation (DOT)

G. Manufacturers Standardization Society of the Valve and Fittings Industry (MSS)

H. National Fire Protection Association (NFPA)

1.03 SUBMITTALS

A. Shop Drawings: 1. Verify by excavation, inspection and measurement all installation conditions,

including existing utilities and structures, for all pipe before preparation of Shop Drawings. Submit field measurements and photos with Shop Drawings where exposed conditions are significantly different than indicated on the Drawings. See also paragraph 3.02, Existing Utilities of Section 02301.

Process Piping, Valves and Accessories CNG Fueling Station



2. Layouts and Schematics: Submit detailed installation drawings of all piping. Schematics may be submitted for piping 4 inches and smaller. The Drawings and schematics shall include: pipe support locations and types, fittings, valves, other appurtenances. (Product Review)

3. Submit data to show that the following items conform to the Specification requirements: a. Pipe, fittings, and accessories (Product Review). b. Fabricated pipe supports and other pipe supports (Product Review). c. Pipe couplings and flexible pipe pieces (Product Review). d. Valves and Accessories (Product Review). e. Thermal insulation (Product Review).

4. Pipe, fittings and joint fabrication details for welded steel pipe (T.M-2P and T.W-1P) (Product Review).

5. Submit reinforcement calculations for T.M-2P to demonstrate compliance with AWWA M11.

6. Submit procedures for welding field joints of welded steel pipe (T.M-2P and T.W-1P) (Product Review).

7. Submit samples of gaskets and other materials where required by the detailed specifications.

8. Submit certified test reports as required herein and by the referenced standard specifications (Product Information).

9. Contractor or its subcontractor shall demonstrate experience in the installation of compressed natural gas (CNG) piping designed to operate in excess of 3600 psig. List at least two projects where the Contractor or subcontractor has successfully installed CNG piping which is currently operational.

10. Shop drawings shall also comply with the requirements of Specification Section 11001.

B. Samples: Not Used

C. Manuals: Furnish manufacturer's installation and operation manuals, bulletins, and spare parts lists for the following items: 1. Valves 4 inches and larger and all actuated valves. 2. Air Valves. 3. Pneumatic/motorized actuators, including positioners and I/P converters.

Include the actuator manuals for the valves requiring them. 4. Filters. 5. Pressure regulators.

D. Affidavits: Furnish affidavits from the manufacturers for the following equipment: 1. Valves, motorized operated. 2. All motorized or calibrated equipment.

E. Field test reports as required in Part 3.


A. Materials and equipment furnished under this Section shall be of manufacturers who have been regularly engaged in the design and manufacture of the materials and equipment for a period of at least 5 years. Demonstrate to the satisfaction of the City Representative that the quality is equal to the materials and equipment



made by the manufacturers specifically named herein, if an alternate manufacturer is proposed.

B. Factory Quality Control: The Contractor shall test all products as noted herein and by the reference specifications.

C. Field Quality Control: 1. The Contractor shall:

a. Provide independent testing of field welds if deemed necessary by the City Representative.

b. Perform leakage tests.

1.05 PIPING SYSTEMS

A. The various piping systems are identified by a multi-letter code on the Drawings. Unless otherwise shown on the Drawings, each system shall be constructed using the materials indicated for that system in the Piping Identification Schedule. Piping materials are identified by type designation in the schedule unless otherwise noted, and most valves and accessories are identified by a valve and accessory system unless otherwise noted.

1.06 APPURTENANCES

A. Furnish and install all necessary guides, inserts, anchors and assembly bolts, washers and nuts, hangers, supports, gaskets, couplings and flanges; all other appurtenant items shown on the Drawings, specified or required for the proper installation and operation of the piping; devices included in or on the piping equipment; and piping accessories.

1.07 PIPE SUPPORTS

A. General: 1. Piping 6 inches and larger: Pipe supports are shown on the Drawings for

piping 6 inches and larger in diameter, where the piping is shown on layout drawings. Each pipe support used is designed to resist seismic loading except where the support is of the sliding type for thermal expansion. Other supports are provided to resist axial seismic loading of pipes designed for thermal expansion. Pipe supports that are considered seismic resistant are so noted on the pipe support detail sheets on the Drawings. The location and types of supports and braces are indicative and may be modified by the Contractor to suit field conditions, provided the modified support system conforms to the design criteria stated herein, and receives the favorable review of the City Representative. Where piping is shown schematically only, it shall be the Contractor's responsibility to support all such piping in accordance with the design criteria stated herein and using support details shown on the Drawings. Pipe supports have been designed assuming flanged joints on ductile iron pipe and steel pipe, unless otherwise indicated on the Drawings. If groove type mechanical couplings are used as an alternative, provide additional supports where required, particularly to resist rotation. Shop drawings of these additional supports shall be favorably reviewed by the City Representative prior to installation.

2. Piping less than 6 inches: Pipe supports are generally not shown for piping less than 6 inches in diameter. Where supports are not shown, it shall be the




Contractor's responsibility to support all such piping in accordance with the design criteria stated hereinafter. Piping 2-½ inches and larger and all piping for hazardous chemicals shall be supported with pipe supports designed to resist seismic loads. Hazardous chemical piping includes fuel, natural gas, compressed air, and sludge gas. Piping smaller than 2-½ inches with non-hazardous contents may be supported with non-seismic resistant supports.

3. Where not detailed or otherwise indicated, pipe support types and spacing shall be in accordance with the Manufacturer's Standardization Society (MSS) Standard Practice No. SP-58 and No. SP-69, except as superseded by the requirements of these Specifications. Hangers and supports used as components of a fire protection system shall comply with NFPA Standard No. 13 and be listed and labeled by UL and FM.

B. Pipe Support System Design: 1. Design Loads: Pipe suspension shall be such as to prevent excessive stress

or excessive variation in supporting force while system is in operation. Pipe supports shall support the sum of the weight of the pipe, fittings, appurtenances, and contents. In addition, the pipe shall be anchored to resist internal pressure forces tending to separate any unrestrained joint at pressures 1-½ times the maximum working pressure for the applicable service.

2. Seismic Design Requirements: See Section 01611. 3. Location: All piping shall be supported in a manner that will prevent undue

strain on any valve, fitting, or piece of equipment. In addition, pipe supports shall be provided at changes in direction or elevation, adjacent to flexible couplings, at all nonrigid joints, at hose bibbs, and where otherwise shown or noted on Drawings. Where piping connects to equipment, it shall be supported by a pipe support and not by the equipment. a. Unless otherwise noted on Drawings, maximum support spacing shall

conform to the following table:

Pipe Size Inches Pipe Material Maximum Spacing Feet1-inch and smaller Iron or Steel

Copper Plastic Tubing

6 4-1/2

continuous continuous

1-¼-inch to 2-inch Iron or Steel Copper or Plastic

8 5

2-½-inch to 4-inch Iron or Steel Copper or Plastic

10 6

6-inch to 8-inch Iron or Steel Plastic

12 8

10-inch and larger Iron or Steel 15 b. Piping penetrations through concrete walls and slabs are considered to

resist seismic loading, provided penetrations for pipes 3 inches in diameter and larger are complete with a wall flange.

c. Branch piping is not considered to provide resistance to seismic forces. 4. Anchors: Anchors for connecting pipe supports to concrete shall be in

accordance with Section 05090.



5. Thermal Expansion Allowance: a. Provide one rigid pipe support for each straight run of pipe and between

each pair of flexible couplings, flexible connectors, or expansion loops for pipes listed below. Provide other supports at the required spacing that allow sliding or rolling, as noted, along the pipe axis: 1) PVC pipe larger than 1-inch in diameter (sliding inside PVC

sleeve). 2) Hot water (rolling). 3) Compressed Air.

b. Provide vertical support only, that is, no lateral support, within 4 feet of an angle or tee for pipes listed above.

PART 2 - PRODUCTS

2.01 GENERAL

A. Pipe and valve sizes are nominal inside diameter unless otherwise noted.

B. Construct vents of materials specified for the pipe system for which they serve.

C. All materials delivered to the job site shall be new, free from defects, and marked to identify the material, class, and other appropriate data such as thickness for piping.

D. Acceptance of materials shall be subject to strength and quality testing in addition to inspection of the completed product. Acceptance of installed piping systems shall be based on inspection and leakage tests as specified hereinafter.

E. Cutoff Flanges: Provide at all pipe or sleeve penetrations where cast into wall for pipes 4 inches and greater in nominal diameter, and at all penetrations of 3-inch and smaller nominal diameter pipe in wet or potentially wet locations as indicated on the Drawings. Cutoff flange outside diameter shall be at least a standard connection flange's outside diameter except that for pipe 30-inch-diameter and larger, nominal size, cutoff flange outside diameter may be 6 inches greater than outside pipe diameter. Cutoff flange shall be at least 1/4-inch thick and shall be continuously welded (or cast) onto the pipe. Conform to pipe penetration details in paragraph 3.01A.

2.02 GENERAL MATERIAL REQUIREMENTS

A. Gaskets: Except where specified otherwise, gaskets shall be Nitrile.

B. Bolts and Tie Rods: Unless specified otherwise herein, flange bolts and nuts, coupling bolts and nuts, tie rods and other hardware shall be as follows: 1. Exposed: Electroplated zinc or cadmium steel. 2. Submerged: Type 316 stainless steel, minimum tensile strength: 60,000 psi. 3. Concrete Encased: Steel. 4. Buried: Type 316 stainless steel, minimum tensile strength: 60,000 psi. 5. Apply an anti-gauling compound to the threads of stainless steel bolts.

C. Flexible Sealant: Flexible sealant for pipe joints, where shown on the Drawings, shall be a two-component polysulfide, non-sag; Sikaflex 2C, Dualthane, or equal.

D. Not Used.




2.03 PIPING MATERIALS

A. Pipe and Fitting Designation: Piping materials are identified by a "Type" designation in these Specifications. The "Type" designation identifies not only the pipe itself but the associated fittings and appurtenances and the installation and test procedures described for that "Type." The designation of a particular type shall indicate a complete installation including fittings, joints, cleaning and testing. The pipe and fitting materials for each type designation shall be as specified herein and summarized in the Pipe Type Schedule.

B. Piping Schedule: Piping systems and their corresponding piping and valve systems are listed on the Drawings.

C. Pipe Type Schedule: Pipe material, joints and fittings shall be as summarized below. A detailed specification of each pipe type follows. (The detailed specification supersedes the schedule in case of any conflicts.)

Pipe Type Pipe Description Field Joints Fittings PVC-1 PVC, Schedule,80 Solvent Weld PVC, Schedule, 80PVC-6 PVC, Schedule 40 DWV Solvent weld PVC-DWV HDPE High Density Polyethylene Heat Weld Polyethylene BS Black Steel Flanged or Weld Steel SS Stainless Steel Pipe Flanged or Weld Stainless SteelSST Stainless Steel Tube Compression or

WeldStainless Steel

D. PVC-1 Type V-1 Pipe: 1. Pipe: Schedule 80 polyvinyl chloride (PVC), gray, normal impact,

Type 12454 B, ASTM D1784 and ASTM D1785. Pipe shall bear the National Sanitation Foundation (NSF) label.

2. Joints: Solvent weld, except flanged or threaded permitted where required at equipment connections and where required on the Drawings. Use Military Specification T 27730A tape for threaded joints.

3. Fittings: Solvent weld, socket type, of same material as the pipe, Schedule 80, ASTM D2467.

4. Cement: Solvent weld: IPS Corp 'Weld-On' Plumbing Primer (ASTM F656) with 'Weld-On' 781 cement (ASTM D2564), or as recommended by the pipe manufacturer. Low VOC content.

5. Pipe Cleaner: As recommended by the pipe manufacturer for the schedule and size to be joined.

E. PVC-6: Type V-6 Pipe 1. Pipe: Schedule 40 PVC pipe. Design to ASTM D1785 or D2665 standard 2. Fittings: PVC Drain, Waste, Vent Fittings. Design to ASTM D2665 standard,

Fitting patterns to ASTM D3311. a. Prepare running trap assembly consisting of U-bend and sanitary street

elbow fittings and downstream reducing tee fitting. 3. Joints: Solvent weld 4. Cement: Solvent weld: IPS Corp 'Weld-On' Plumbing Primer (ASTM F656)

with 'Weld-On' 781 cement (ASTM D2564), or as recommended by the pipe manufacturer. Low VOC content.



F. BS (Black Steel Pipe: 1. Pipe: Schedule 40 black steel, ASTM A53, Grade B, butt weld or seamless. 2. Joints: Butt welded or socket welded, except where otherwise shown on the

Drawings and where screwed or flanged accessories or valves are required. 3. Fittings: Forged steel, butt weld type, same Schedule as pipe conforming to

ASTM A234, or 2,000 psi forged steel socket weld fittings conforming to ASTM A105.

4. Flanges: Where required to connect to flanged equipment or valves, shall be slip-on or weld-neck type conforming to ASTM A105 or ASTM A181. Flange drilling and facing shall match that of the flanged valves or equipment to which the pipe connects.

5. Branches two sizes or smaller than pipe main may be made with factory fabricated steel welding saddles manufactured by Bonney; Ladish; or equal.

G. SS (Stainless Steel Pipe): 1. Pipe: Stainless steel, ASTM A312 TP 316L and 304L. Type of stainless steel

per the Pipe Schedule on the Drawings. 2. Schedule 40S for pipes 6-inches and smaller. Schedule 20S for pipes 8-inch

and larger. 3. Joints: Socket welded, except where screwed or flanged joints are required

adjacent to valves or equipment. 4. Fittings: Wrought stainless steel, ASTM A774, TP316L or 304L to match the

pipe material, ANSI B16.9 for dimensions. 5. Flanges: Welding neck or slip-on, raised face, ASTM A182, TP316L or

TP304L to match the pipe material, ANSI B16.5 for dimensions. Class 150, drilled to match adjacent accessories or valves.

6. Bolts: ASTM A193 (bolts), ASTM A194 (nuts), 60 ksi minimum tensile strength, bolt/nut material to match the flange material,

7. Gaskets: Full face gasket per ANSI B16.21, non-asbestos Viton. 8. Flexible Metal Connector: Type 321 stainless steel, close pitch, annular

corrugated hose with a braided outer covering of type 316 stainless steel. End connections to be ANSI Class 150 type 316 stainless steel plate flanges with type 316 stainless steel flange bolts. a. Pressure rating: 150 PSI minimum b. Temperature rating: 250oF minimum c. Lateral offset: ¼” minimum d. Manufacturer: Proco Products, Inc; or equal.

H. SST (Stainless Steel Tubing): 1. Tube: Stainless Steel, Type 304L fully annealed, ANSI/AGA NGV 3.1,

ASTM A269, rated 5,000 psi. a. Dimensions: 1/2-inch (0.500 inch O.D. x 0.070-inch wall);

3/4-inch (0.750 inch O.D. x 0.109-inch wall); 1-inch (1.000 inch O.D. x 0.120-inch wall)

2. Joints: Compression or welded. 3. Fittings: Same material as tube

a. Compression: Imperial; Swagelok; or equal. b. Welded fittings and joints, where used, shall be stress relieved. c. Manufactured sweep elbows in accordance with ASTM A269 shall be

allowed.




d. Bending of tubing shall be prohibited. Bending of tubing may be considered if the Contractor furnishes information to demonstrate the following: 1) Compliance with bend flattening and wall thickness of the bend

after forming complies with ASME B31.3, paragraph 304.2.1, provided that: a) Demonstrate that the tubing strength is not decreased by the

bending b) Submit written approval from the tubing manufacturer that

bending of the tubing is acceptable

I. HDPE: 1. Pipe: High Density Polyethylene Gas Pipe, ASTM D2513, Performance Pipe,

'Yellowstripe 8300', or equal. a. Designation: PE4710 and DOT Title 49, Part 192.121. b. Dimension Ratio: DR11 maximum rated to 100 psi working pressure. c. Pipe shall be iron pipe size (IPS). d. Markings: Mark in accordance with ASTM D2513.

2. Fittings: Polyethylene, socket fusion or saddle fusion, ASTM D3261. Match material to pipe

3. Joints: Butt fusion, ASTM D2657, except mechanical where required to connect with other pipe, valve or equipment materials. a. Butt Fusion Joints: The tensile strength of the joint at yield shall not be

less than the pipe. Joints shall be made with equipment acceptable to the manufacturer. The equipment operators shall have been trained by certified fusion technicians. Submit description of the equipment and methods for favorable review.

b. Mechanical Joints: Joint shall consist of a flange adaptor fitting butt-fused to the pipe, a back-up ring of Type 316 stainless steel made to ANSI B16.1 dimensional standards (with modified pressure rating), bolts of Type 316 stainless steel, and chloroprene gaskets.

4. Fittings: Molded fittings to ASTM D3261, socket fusion or saddle fusion, required where available of the same material as the pipe, with DR no greater than the pipe, and with a pressure rating at least equal to the pipe. Manufacturer shall conduct X-ray inspection on samples from each molded fitting production lot. Fitting shall be produced by the same manufacturer as the pipe.

2.04 PIPE COUPLINGS AND FLEXIBLE PIPE PIECES

A. General: For typical pipe joints refer to pipe material specifications. Other joint devices shall be furnished where called for on the Drawings and as specified below.

B. Flexible Couplings and Flange Coupling Adaptors (water, sewer): 1. Sleeve: Cast iron or fabricated steel. 2. Followers: Cast iron, ductile iron, or steel. 3. Sleeve Bolts: ASTM A325, Type 3; malleable iron; or equivalent, except for

buried and submerged, which shall be Type 304 SS and Type 316 SS, respectively.



4. Coating: Fusion epoxy line and coat sleeve and followers. 5. Pressure Rating: The test pressure of the applicable service or 50 psi,

whichever is greater. 6. Performance: Longitudinal movement and angular deflection capabilities shall

meet AWWA C-219. 7. Flanged Coupling Adaptor Flanges: Match mating flanges. If required by

connecting valve or other device, provide flanges with inside diameter equal to nominal pipe diameter.

8. Manufacturers: a. Flexible Couplings:

1) Connecting Pipe with Identical Outside Diameters: Smith-Blair 411 or 441; Dresser Style 38 or 153; or equal.

2) Connecting Pipe with Slightly Different Outside Diameters: Smith-Blair 413 or R441; Dresser Style 162; or equal.

b. Flange Coupling Adaptors: Smith-Blair 912 or 913; Dresser Style 127 or 128; or equal.

9. Gaskets: Oil and grease resistant; Smith-Blair Grade 60; Dresser Grade 42; or equal.

10. Joint Restraint: Provide joint harnesses (tie rod lug or attachment plate assemblies) designed for the test pressure or 50 psi, whichever is greater, across flexible couplings and flange coupling adaptors. For steel pipe the joint harness shall conform to the requirements of Chapter 13 of AWWA M-11, paragraph 13.10, Table 13-6 - Tie Bolt Schedule for Harnessed Joints. Anchor studs may be used on flange coupling adapters for pipe up to 12 inches in diameter.

11. Protection for Buried Couplings and Adaptors: a. Double wrap with polyethylene encasement, AWWA C105 and tape the

edges of the encasement with PVC tape.

C. Flexible Couplings and Flange Coupling Adaptors (gas, low pressure): 1. Sleeve (Middle Ring): Steel, ASTM A-513. 2. Followers: Steel, ASTM A-569. 3. Sleeve Bolts: ASTM A242 'Trackhead' bolts, 70,000 psi minimum tensile

strength. 4. Coating: Fusion epoxy line and coat sleeve and followers. 5. Pressure Rating: 300 psi 6. Gaskets: ASTM D395, 70-75 Shore A Durometer hardness, 2100 psi tensile

strength. 7. Joint Restraint: stainless steel gripping band, stainless steel pressure

restraint ring, and wave spring shall provide restraint upon installation 8. Performance: longitudinal pipe restrain and angular deflection to 2%

maximum, 9. Manufacturers:

a. Flexible Couplings: 1) Connecting Pipe with Identical Outside Diameters: Smith-

Blair 'Maxi-Grip' EZ-series Class I; or equal 2) Connection Pipe with IPS to CI O.D. transitions: Smith-Blair

'Maxi-Grip' EZ-series Class III; or equal b. Flange Coupling Adaptors: Smith-Blair 'Maxi-Grip' EZ-UFA series;

Dresser Style 127 or 128; or equal. Flange design to ANSI B16.5, Class 150




10. Protection for Buried Couplings and Adaptors: a. Double wrap with polyethylene encasement, AWWA C105 and tape the

edges of the encasement with PVC tape.

D. Dismantling Joint: 1. General: The Dismantling Joint shall be a self-contained flanged restrained

joint fitting, including both flanged components and sufficient harness bars to withstand the imposed thrust complying with AWWA C219 where applicable. The Dismantling Joint shall be furnished as a complete assembly consisting of spigot piece, flange adapter, tie bars and gasket. The gasket seal and compression stud and nut arrangement shall be separate and independent of the tie bar restraint system.

2. Performance: No less than 5 inches of longitudinal adjustment and installed with 4 inches of inward adjustment and 1 inch of expansion.

3. Pressure Rating: 150 psi. 4. Spigot Piece and Flange Adapter: Steel. 5. Exterior Fasteners: All exterior fasteners including the bars shall be 316

stainless steel. The bar diameter shall be equal to the corresponding bolt diameter of the mating flange.

6. Flanges: AWWA C207 Class D. 7. Coating: Coated inside and out with a fusion bonded epoxy coating applied to

a DFT thickness of 5 to 10 mils. The epoxy shall comply with the requirements of AWWA C550 and AWWA C213. Stainless steel fasteners and tie bars shall not be painted.

8. Gaskets: a. Flanged gaskets shall be full faced gaskets SBR, 1/8-inch thick. b. Wedge gaskets shall be EPDM Grade 199, Buna-S or Buna-N.

9. Manufacturer: The dismantling joint shall be Style 131 as manufactured by Dresser Industries/SVE or equivalent by Romac; or equal.

E. Mechanical Groove Couplings: 1. Application: Mechanical couplings (segmental clamp joints) shall be used

wherever shown on the Drawings. They may be substituted for flanged joints on steel pipe if 6 inches or smaller in diameter and if favorably reviewed by the City Representative and may be substituted for flanges on ductile iron pipe to the extent permitted under the ductile iron pipe specification.

2. Type: AWWA C606, pressure rated at least 300 psi. 3. Joints: Cut groove, except shoulder joints may be used for steel pipe where

the wall thickness of the pipe is less than that allowed by Table 4 (AWWA C606). Only Type B, Type C, and Type D special ends are acceptable for shoulder joints.

4. Grooves: a. Ductile Iron Pipe where Mechanical Groove Couplings are shown on the

Drawings: Flexible joint, Table 2 (AWWA C606). b. Ductile Iron Pipe where Flanges are Shown on the Drawings: Rigid

joint, Table 3 (AWWA C606). c. Steel Pipe: Table 4 (AWWA C606).

5. Gaskets: Nitrile.



F. Flexible Rubber Connectors: 1. Up to 12-inch-Diameter:

a. Type: Built-up, single arch (unless otherwise shown on Drawings) filled-arch rubber expansion joints with full rubber flanges and retainer rings.

b. Materials: Neoprene cover over nitrile tube, reinforced with nylon or polyester body and galvanized steel retainer rings. Protect cover with Hypalon paint where exposed outdoors.

c. Pressure Rating: 190 psi. d. Manufacturers: Proco Series 230; Holz Type 200; Garlock Style 204

HP; or equal. 2. Restraint: Provide galvanized steel control rod-compression sleeve

assemblies for all flexible spools, except where pipelines cross structural expansion joints or where specifically omitted by note in the Drawings. Number and size of control rods shall be as required for the test pressure of the pipe system or 50 psi, whichever is greater.

3. Provide full size intermediate metal pipe flanges where rubber spool connects with wafer style valves, lug style valves or other pipeline items that do not have full-face metal flanges.

2.05 VALVES AND ACCESSORIES

A. Valve and Accessory System Designation: Most valves and accessories to be furnished and installed are identified by a valve and accessory system designated by a letter symbol in the Piping Schedule.

B. General Requirements for Valves: 1. All valves of each type shall be the product of one manufacturer. 2. All exposed valves shall be furnished with operators, handwheels, levers, or

other suitable type wrench including handles as specified herein or as shown on the Drawings. Valves 4-inch and larger located more than 7 feet above the floor level shall be furnished with chain operators. Chains shall be galvanized and shall extend to within 3 feet of the floor. Provide hook so that chain may be stored clear of walkways. All buried valves shall be provided with 2-inch-square operating nut and valve boxes.

3. All threaded stem valves shall open by turning the valve stem counter-clockwise.

4. All exposed valves and valve operators shall have a non-bleeding shop coat, unless otherwise specified.

5. Rotary Actuators: Refer to Section 11209. 6. Pressure Gauge Assembly:

a. Complete assembly shall include isolation valve, pulsation dampeners or snubbers. Provide a support plate to the nearest flange.

b. Pressure gauges shall have a dial size not less than 4-½ inches, phenolic or polypropylene flangeless case, bronze brushed movement, phosphor bronze or stainless steel bourdon tube, 1% accuracy, friction mounted adjustable pointer, black figures on white dial, glass or acrylic window. Label face of dial to identify unit of measurement. Complete gauge shall be Ashcroft 1279; Trerice Series 450; or equal.

c. Isolation valves shall be Type 316 stainless steel needle valves (unless ball valves are shown on the Drawings); Trerice 735 or 740; Ashcroft 7004L; or equal.




d. Pulsation dampeners and snubbers shall be stainless steel for the specific service involved, and shall be Chemquip 25B; Trerice No. 870; or equal.

C. General Requirements for Accessories: Pressure Gauges: Provide shutoff valves for all pressure gauges. Conform to additional requirements in this Section below.

D. Valve and Accessory Systems: See Piping Schedule in Contract Drawings. 1. Valve and Accessory System B:

Applicable Service Conditions: Sludge, drainage, sewage and wastewater at working pressures to 100 psig. a. Plug valves 2-inch and larger:

1) Rating: 175 psi through 12-inch. 2) Type: Resilient faced eccentric plug, lever operated 4-inch and

smaller, worm geared handwheel operated 6-inch and larger, or pneumatically actuated as shown on the Drawings. Valves shall provide driptight shutoff in both directions.

3) Connections: Flanged, 125-pound ANSI, except screwed connections may be used for 2-inch valves.

4) Materials: Cast iron body, welded nickel seat, NBR or Buna-N coated plug, NBR or Buna-N packing or U-cup stem seal. Valves shall have interior and exterior metal surfaces other than the plug and valve seat coated with two coats of high-solids epoxy with total dry film thickness 12 mils minimum.

5) Manufacturers: Dezurik PEF, or equal. 6) Installation: Unless otherwise necessary for proper installation or

permitted by City Representative, all eccentric plug valves shall be installed with shaft horizontal and with plug in upper half of body. Valves in sewage lines shall be installed with seat on upstream end.

b. Check Valves: 1) Unless specifically called out otherwise by the Drawings, provide

swing- type check valves. Swing check valves shall be as specified above for System A. All sludge check valves shall have an external lever weighted arm.

2) Duckbill Check Valves: Provide only where specifically called out on the Drawings. a) Rating: 100 psi service with 1 inch water column cracking

pressure. b) Type: One-piece elastomer duckbill with integral flange. c) Connections: Flanged, 125-pound ANSI with backup ring. d) Materials: Buna-N duckbill and integral flange reinforced with

nylon or similar material. 316 stainless steel flange backup ring.

e) Manufacturers: Tideflex Technologies Series 35, equivalent by Cla-Val, or equal.

c. Pressure Gauges: 1) Complete installation, unless otherwise shown, shall include

¾-inch plug valve isolation at the main, a gauge protector made specifically for solids handling service, a snubber and gauge.



Provide a support plate to the nearest flange. All protectors and gauge bourdon tubes shall be evacuated of air, glycerine filled at the factory and factory calibrated.

2) Plug Valve: Shall be DeZurik PEC; or equal. Connections shall be threaded.

3) Protector: Shall be for slurry service with flushing connection. Body shall be steel or cast iron. Diaphragm shall be of removable Type 316 stainless steel. Complete unit shall be Trerice, M & G (U.S. Gauge), or equal.

4) Pressure gauges shall have a dial size not less than 4 ½ inches, phenolic or polypropylene flangeless case, bronze brushed movement, phosphor bronze or stainless steel bourdon tube, 1% accuracy, friction mounted adjustable pointer, black figures on white dial, glass or acrylic window. Label face of dial to identify unit of measurement. Complete gauge shall be Ashcroft 1279; Trerice Series 450; or equal.

5) Isolation valves shall be Type 316 stainless steel needle valves (unless ball valves are shown on the Drawings); Trerice 735 or 740; Ashcroft 7004L; or equal.

6) Pulsation dampeners and snubbers shall be stainless steel for the specific service involved, and shall be Chemquip 25B; Trerice No. 870; or equal.

2. Valve and Accessory System C: Applicable Service Condition: Utility water, reclaimed water, sump drain. a. Ball Valves Through 4-inch Size:

1) Rating: 150 psi at 75°F. 2) Type: Double union. 3) Connections: Socket. 4) Materials: PVC body, teflon seats and EPDM O-ring seals, except

Viton O-ring seals with chlorine solution. 5) Manufacturers: Asahi/America, Hayward, or equal.

b. Ball Check Valves - Double Union Type: 1) Rating: 150 psi at 75°F. 2) Type: Ball for horizontal or vertical service. 3) Connections: Union ends for socket weld. 4) Materials: PVC body, Viton O-ring seals and seats. 5) Manufacturers: Asahi/America, Hayward, equal.

3. Valve and Accessory System D: Applicable Service Condition: Low Pressure Air piping for Fume and Odor Control Systems in PVC Piping. a. Ball Valves: Refer to Valve System 'C' b. Butterfly Valves:

1) Rating: 150 psi at 75°F. 2) Type: Wafer type. 3) Connections: Uniflange. 4) Actuator: Manual, Lever type 5) Materials: PVC body, PVC disc, Viton O-ring seals and seats,

Polypropylene handle, stainless steel stem. 6) Manufacturers: Asahi/America Type 56, Hayward BYV Series,

equal.




c. Gate Valves: 1) Rating: 150 psi at 75°F. 2) Connections: Flanged. 3) Actuator: Handwheel-operator, non-rising stem. 4) Materials: PVC body and bonnet, PVC stem, polypropylene gate,

Viton O-ring seals and gaskets, Polypropylene handwheel. 5) Manufacturers: Asahi/America, Hayward, equal.

d. Globe Valves: 1) Rating: 150 psi at 75°F. 2) Connections: Flanged. 3) Actuator: Handwheel-operator, outside stem and yoke (OS&Y)

design. 4) Materials: PVC body and bonnet, PVC (internal) stem and disc,

copper alloy (brass) external stem, Viton gland/gasket, polypropylene handwheel.

5) Manufacturers: Asahi/America, Spears, equal. e. Swing Check Valves:

1) Rating: 150 psi at 75°F. 2) Type: Standard, (no external lever/weight or lever/spring

assembly). 3) Connections: Flanged. 4) Materials: PVC body and bonnet (cover), PVC disc and shaft

assembly, Viton O-ring seals and seats, stainless steel bolts for bonnet.

5) Manufacturers: Asahi/America, Spears, or equal. 4. Valve and Accessory System F: Applicable Service Conditions: Sludge gas, natural gas below 200 psi,

Refrigerated Liquid (RL). a. Plug Valves:

1) As specified in System B, except as follows 2) Connections: Flanged. 3) Seats and Bearings: Suitable for wet digester gas.

b. Ball Valves: 1) Rating: 500 psi WOG. 2) Type: Lever operated, double-seal, UL listed. 3) Connections: Threaded. 4) Materials: Type 316 stainless steel body and ball, teflon seats. 5) Manufacturers: Jamesbury A36TT; Crane 950-TRE; or equal.

c. Pressure gauges shall be as specified for System B (except for diaphragm seal) and have all 316 stainless steel components. Provide oversized diaphragm seal capable of low pressure measurements less than 5-inch of water.

d. Pressure Regulating Valves 1) Off-Gas Pressure Regulator

a) Suitable for use with gas containing varying proportions of carbon dioxide and methane

b) Inlet Pressure: 5 psig c) Outlet Pressure: Adjustable between 8 to 18 inches water

column d) Capacity: 3000-4200 scfh at 5 psig inlet pressure



e) Valve pressure rating: 150 psig f) Valve size: 2 inches g) Body Material: 316 SST h) Disk/Seat Material: 316 SST/NBR (nitrile) i) Diaphragm Material: NBR (nitrile) j) Manufacturer: Fisher NPS 2 Y692 or equal

2) Natural Gas Pressure Regulator a) Suitable for use with natural gas b) Inlet Pressure: 1-5 psig c) Outlet Pressure: Adjustable between 8-20 inches water

column e. Air Release Valves (ARVs):

1) Function: Releases accumulated air under pressure at pipe line high points.

2) Materials: 304 SS body, 304 SS float and linkage, chrome-plated steel seats.

3) Pressure Rating: 200 psi. 4) Manufacturers: Armstrong model 11 AV; Watson McDaniel

AE1800 series; or equal.

5. Valve and Accessory System G: Applicable Service Conditions: High pressure gas above 3000 psi. a. Ball Valves (ANSI/IAS NGV 4.6 standard):

1) Rating: 6000 psi MAWP, minimum, 2) Type: Manual (Lever) operated 3) Connections: Compression 4) Materials: 316 SS body, ball, stem and packing gland, PEEK seat,

PTFE bearing and packing 5) Manufacturers: DK-LOK VC86 series, Parker-Hannifin B Series, or

equal

6. Valve and Accessory System H: Not Used.

E. Miscellaneous Valves and Accessories: 1. Hose Bibbs:

a. Indoor: Nibco Model 55; Arrowhead Brass Model 353; or equal. b. Outdoor (Non-freezing type): J.R. Smith 5913; Zurn Z-1385; or equal. c. Hose Racks: Suitable for 50 feet of ¾-inch hose. Note to Specifier

2. Link-Type Seals: Link-type seals shall be interlocking synthetic rubber links connected by stainless steel bolts and nuts to form a continuous belt. Tightening of the bolts shall expand the rubber to form a watertight seal of the annular space between a pipe and the hole or sleeve in the wall.

3. Backflow Preventer: a. Reduced pressure type with shutoff valves and test cocks, size as

shown on the Drawings. Headloss shall not exceed 10 psi at maximum flow.

b. Backflow preventer shall be ClaVal Model RP-2 for 1-½-inch and smaller and RP-1EX for 2-inch and larger, equivalent Febco, or equal.

c. Double-check type: ClaVal Model D, equivalent Febco, or equal. 4. Flexible Rubber Hose:




a. General: At each hose rack, provide 50 feet of flexible rubber hose of the same diameter as the hose bibb. Also provide hose at other locations where shown on the Drawings. Provide each hose with nozzle, and male and female threaded connectors. Specifically design all hose to resist deterioration due to weather, sunlight, and outdoor exposure, and to hot water or chlorine solution where applicable.

b. Nozzles: Provide compatible nozzles on each hose associated with a hose bibb and hose rack. Nozzles shall be brass or bronze.

c. Cold Water Service: Provide rubber hose with fiber-reinforced carcass designed for 150 psi working pressure. Provide Newtype Spec. No. N-135 or Corsican Spec. No. S-3 by Goodall Rubber; Standard Water Hose Style B-11 by American Rubber Manufacturing; or equal.

d. Hot Water Service: Provide specialty hose designed for steam service at 100 psi working pressure for all locations having hot water. Provide butyl rubber inner tube and wire or synthetic braid carcass. Provide Super Inferno N-84 steam hose by Goodall Rubber; Crackerjack Steam Hose by American Rubber Manufacturing; or equal.

5. Valve Boxes for Buried Valves: Adjustable, cast iron, screw-type, installed with top set at finished grade. All valve boxes and covers shall be suitable for H20 AASHTO wheel load. Clow Figure F-2454 with Figure F-2476 extension; equivalent products by Mueller; or equal.

6. Concrete Vaults and Valve Boxes: Precast reinforced concrete, of the size and orientation shown on the Drawings. Unless otherwise shown or noted, all vaults, boxes and their covers shall be designed for H20 AASHTO wheel loads. Steel lids shall be galvanized. Provide Christy, Brooks, or equal.

7. Angle Valves: Brass with 1-1/2-inch male outlet and 1-½-inch female inlet. Inlet threads shall be IPT, and outlet threads shall be standard hose threads. Angle valves shall be W.D. Allen Figure 170U; Potter-Roemer Figure 4060; or equal. Provide cap with corrosion-resistant chain.

8. Valve Tags: Plastic, fiberglass, or plastic material, 2-inch square with grommeted hole. The tags shall be attached to valves with a brass jack chain. For buried installations use a nylon strap. Lettering shall be stamped or cut into the tag at least 3/16-inch high.

9. Pipe Escutcheons: a. Manufactured wall, ceiling, and floor plates; cast brass, polished chrome

plated, with set-screw, deep pattern type where required to conceal protruding fittings and sleeves.

b. Inside Diameter: Closely fit around pipe, tube, and insulation of insulated piping.

c. Outside Diameter: Completely cover opening. d. One-piece design for piping to plumbing fixtures and to equipment in

finished spaces. e. Split, concealed hinge type for piping not serving plumbing fixtures or

equipment in finished spaces.

2.06 THERMAL INSULATION AND HEAT TAPE FOR PLUMBING AND PIPING

A. General: 1. Delivery: Deliver insulation materials to the job in original packages with

manufacturer's "R" values clearly shown. Provide certification of compliance.



2. Warning: The Contractor is warned that working with fiberglass or rock wool materials may constitute a serious health hazard. The Contractor shall take all necessary precautions to ensure the safety of the workers.

3. Shields: Insulation protection shields are required per paragraph 2.07C. 4. The following table summarizes the insulation system by use and service:

System Location ServiceInsulation System

Insulation Thickness (Inches)

Refrigerant Liquid (RL) (supply) Outdoors E C 1-inchRefrigerant Liquid (RL) (return) Outdoors E C 1½-inch

For Service: E = Exposed including concealed space B = Buried

B. Insulation System C: 1. Material: Insulation shall be nominal 3/8-inch wall thickness flexible closed

celled elastomeric foam, pre-slit, self-sealing with lap seal tape. Insulation shall have a "K" factor of not more than 0.30 at 75°F. Insulation shall have a usage range from -30°F to 220°F. Insulation shall be Armacell 'AP Armaflex Black Lap Seal'; Aeroflex 'Aerocel SSPT'; or equal.

2. Application: Seal all butt joints with adhesive supplied by manufacturer. Fittings shall be covered with mitered insulation according to manufacturer's recommended procedures and sealed with adhesive. Insulation shall have first class appearance.

3. Finish: Finish all exposed insulation with two coats of manufacturer supplied finish for outdoor environment.

2.07 PIPE SUPPORTS

A. Manufacture and Design: Pipe supports shall to the maximum extent possible be standard factory fabricated units conforming to the typical supports and braces shown in the Drawings and as specified below. Where required support cannot be provided by standard factory fabricated units, and is not detailed on the Drawings, the Contractor shall provide special pipe supports. Supports shall be manufactured or special fabrications or combination as shown on the Drawings or specified. Special fabrications shall be in conformance with Section 05 50 00. Provide ¾-inch chamfer on corners of all support elements and file or grind smooth. Supports designated to allow axial pipe movement shall have smooth and even contact surfaces.

B. Materials: All support systems shall be galvanized steel except that those that are submerged or that are located within a tank, channel, or other structure designed to hold water, below the top of surrounding walkway elevation or tank wall top, or otherwise called out on the Drawings, shall be Type 316 stainless steel. Trays for continuous support of plastic pipe or tubing shall be made of 20-gauge galvanized steel.

C. Insulation Protection Shields: Provide insulation protection shields at all pipe supports for insulated piping.

D. Provide plastic caps with rounded corners on all exposed ends of channels.




PART 3 - EXECUTION

3.01 PIPING INSTALLATION

A. General Handling and Placing: 1. Exercise great care to prevent injury to or scoring of the pipe lining and

coating, as applicable, during handling, transportation or storage. Handle fusion epoxy coated pipe and ceramic epoxy lined pipe in accordance with AWWA C213. Do not store pipe on rough ground and do not roll the pipe on the coating. Any damaged pipe sections, specials, or fittings shall be repaired or replaced at the expense of the Contractor as satisfactory to the City Representative.

2. Carefully inspect each pipe, fitting, valve and accessory before installation to insure there is no defective workmanship or obstructions. Inspect the interior and exterior protective coatings and patch all damaged areas in the field or replace to the satisfaction of the City Representative.

3. Place or erect all piping to accurate line and grade and backfill, support, hang, or brace against movement as specified or shown on the Drawings, or as required for proper installation. Remove all dirt and foreign matter from the pipe interior prior to installation and thoroughly clean all joints before joining.

4. Use reducing fittings where any change in pipe size occurs. Do not use bushings unless specifically noted on the Drawings. Use eccentric reducing fittings wherever necessary to provide free drainage of lines.

5. Cast all metallic pipes and sleeves 6-inch and larger into new concrete walls without blockout. Pipes 5 inches and smaller may be cast in place or installed in a smooth core drilled hole using a link type seal at the Contractor's option. Maintain at least ½-inch clearance between reinforcing steel and metal pipe in penetrations.

6. Cover PVC pipe stored outside for more than two months with canvas or other opaque material. Provide for air circulation under the covering.

B. General Buried Piping Installation: 1. Trenching, bedding, and backfill for buried piping shall be as shown on the

Drawings and as specified in Section 02301. 2. Where pipe grade elevations are shown on the Drawings, install the pipe with

straight grades between the indicated elevations. 3. Where no pipe grade elevations are shown on the Drawings, install buried

piping with at least 3 feet of cover to finished grade. Where piping crosses under buried electrical ducts, provide at least 4 feet 6 inches of cover. Provide 12 inches minimum separation between the buried pipes and ducts.

4. Provide each pipe with a firm, uniform bearing for its full length in the trench except at field joints. Do not lay pipe in water or when trench conditions or weather are unsuitable for such work.

5. Protect buried piping against thrust by use of restrained pipe joints and/or thrust blocks. All exposed free pipe ends shall be securely braced. Cap or plug pipe ends that are left for future connections as shown on the Drawings and in a manner favorably reviewed by the City Representative.

6. Where piping leaves a structure or concrete encasement, provide a joint capable of angular deflection within 12 inches of the structure for pipes 12-inch and smaller or as shown on the Drawings for larger pipe sizes. Conform to details on the Drawings where such details are shown.



7. Snake buried PVC pressure pipe from side to side in the trench in long sweeps.

8. Concrete Encasements: All piping and conduits installed under slabs or footings on earth or crushed rock shall be encased in concrete not less than 6-inch thickness on all sides and extending up to the bottom of the slab or footing, unless otherwise specifically noted on the Drawings. Encasement shall extend to within 6 inches of the first pipe joint beyond the slab or footing. Provide concrete encasement whether or not the encasement is shown on the Drawings. Provide encasement under slabs on earth or crushed rock even if the structure is supported on piles, caissons, or footings. Provide continuous concrete cradles where shown.

9. Do not pull bell and spigot, gasketed joints more than 50% of the maximum deflection permitted by the pipe manufacturer.

10. Coat bolts on buried flanges or other buried appurtenances in accordance with Section 09960. Wrap the appurtenance with polyethylene encasement and tape the encasement tightly closed to the pipe.

C. General Exposed Piping Installation: 1. Unless shown otherwise, install piping parallel to building lines, plumb and

level. 2. Install piping without springing or forcing the pipe in a manner that would set

up stresses in the pipe, valves, or connected equipment. 3. Set all pipe flanges level, plumb, and aligned. All flanged fittings shall be true

and perpendicular to the axis of the pipe. All bolt holes in flanges shall straddle vertical centerline of pipes.

4. Flexibility and Expansion: Provide flexible couplings, flexible hose, or flexible spools for all piping connections to motor driven equipment and where otherwise shown. The Contractor may install additional flexible couplings at favorably reviewed locations to facilitate piping installation, provided that he submits complete details describing location, pipe supports, and hydraulic thrust protection. Anchor piping subject to expansion or contraction in a manner permitting strains to be evenly distributed. Sleeves for branches through walls from adjacent mains shall be of sufficient size to allow for free side motion of covered pipe in sleeves.

5. Install unions or flexible connections where shown on the Drawings, and at all non-motor-driven equipment to facilitate removal of the equipment.

6. Provide valves wherever equipment drain connections are furnished and carry the discharge pipe to the nearest floor drain, drain trench or sump. Where no receptacle for drain exists, install drain piping to 1-inch above the floor. Drain piping and valve materials shall conform to the requirements of the system served.

7. Where piping conveying liquids passes over motor control centers, electrical panels and other electrical devices, install a protective drainage tray below the piping.

D. Pipe Welding: 1. General: Unless specified otherwise, shop and field welding of pipe shall

conform to ANSI B31.1 as amended by this paragraph. 2. All field and shop welding shall be done by the electric arc process unless

otherwise specified. All field welding shall be done in passes not thicker than ¼-inch. Size and type of electrodes, and current and voltages used, shall be




subject to the favorable review of the City Representative. Give particular attention to the alignment of edges to be joined, so that complete fusion and penetration will be effected throughout the bottom of the weld. Welds shall contain no valleys or undercuts in the center or edges of the weld. Thoroughly clean each pass, except the final one, of dirt, slag, and flux before the succeeding bead is applied.

3. Clean completed field welds of pipe joints of dirt, slag and flux, and then visually inspect. Completely chip out all defects in welds discovered during field inspection in a manner that will permit proper and complete repair by welding subject to the favorable review of the City Representative. Under no circumstances will caulking of defective welds be permitted.

4. All welding shall be done by experienced, skilled operators familiar with the methods and materials to be used. Hand welding will be done only by welders qualified under the standard qualification procedure of Section IX of the ASME Boiler and Pressure Vessel Code. The Contractor shall conduct tests of his welders, when required by the City Representative, in accordance with that code and in the presence of the City Representative. An independent testing laboratory, favorably reviewed by the City Representative, shall supervise the testing and determine the quality of the test work. Weld specimens in the same positions as those in which the welder is to qualify his work. The City Representative may require test specimens at any time. Any welder whose work is found unsatisfactory shall not remain employed on this Contract, regardless of the quality of his earlier work. Each hand weld specimen shall be plainly marked with the welder's identifying symbol. The Contractor shall furnish all materials required and pay all costs for qualifying welders.

5. Field welds shall follow as closely as possible to the laying operation. All field welds shall be complete before lining or coating of the joints in steel pipe is begun. Where pipe is fusion epoxy lined and/or coated, follow AWWA C-213 procedures for field welded joints.

6. A single, continuous, watertight, full fillet weld shall be the minimum required at all field joints. Double welded joints are required on all piping specifically noted to be double welded.

7. See also installation specifics for welding of pipe.

E. Installation Specifics: 1. PVC (Polyvinyl Chloride):

a. Place PVC pipe within the installation areas at least 24 hours prior to installation to permit temperature equalization.

b. Cut pipe ends squarely, ream and deburr inside and out, and bevel the ends.

c. Solvent Weld Joints: Clean pipe ends and sockets and join in strict conformance with the pipe manufacturer's instructions. Make joints in accordance with ASTM D2855. Handle solvent cements and primers in accordance with ASTM F402.

d. No work shall be performed until the pipe manufacturer provides onsite installation training and certifies the installers are trained per ASTM D-2855. The City Representative shall be present for the training session.

2. BS (Black Steel Pipe) a. Install and weld in accordance with ANSI B31.1.



3. SS (Stainless Steel Pipe): a. Install and weld in accordance with CGA G-4.4 and ANSI B31.1. Back

purge all welds with cover gas. Seal weld all slip-on flanges. b. Provide anti-seize compound on threaded connections. c. Temporarily plug or cap all points of connection to exclude moisture,

dust or other contaminants or impurities prior to being connected. 4. SST (Stainless Steel Tubing):

a. Install and weld in accordance with manufacturer’s instructions and stainless steel piping requirements.

5. HDPE a. Handling and laying of pipe and fittings shall be in accordance with the

manufacturer's instructions, PPI guidelines, AWWA M55, and as specified herein to line and grades as shown on the Drawings.

b. Pipe and fittings shall not be dropped. All pipe and fittings shall be examined before laying and no piece shall be installed which is found to be defective. Any damage to the pipe shall be repaired as directed by the manufacturer and approved by the Owner. If any defective pipe is discovered after it has been laid, it shall be removed and replaced with a sound pipe in a satisfactory manner at the Contractor's expense. Any pipe with gouges exceeding 5% of the nominal wall thickness will be rejected.

c. All pipe and fittings shall be thoroughly cleaned before laying, shall be kept clean until they are used in the work.

d. The Contractor shall not drag the pipe. Rollers or other such devices shall be used to reduce dragging of the pipe. Damage to pipe caused by dragging is the responsibility of the Contractor and cause for replacement of damaged portion as determined by the Owner. If, in the opinion of the Owner, the pipe may have been dragged to an extent where damage may have occurred to the pipe wall, the Contractor will rotate the pipe in a manner which will facilitate inspection.

e. As much as practicable, the print line on the pipe shall be installed facing upward to facilitate identification of the pipe when initially installed

f. Pipe fused above ground shall be carefully handled to avoid damage to the pipe. Chains or cable type chokers will not be allowed when lifting sections of pipe. Nylon or other wide fabric slings or other similar lifting apparatus with spreader bars shall be used where necessary.

g. Prior to installing a pipe section, the bedding material shall be brought to grade along the entire length of the section to be installed.

h. The joining method shall be the thermal butt fusion method and shall be performed in strict accordance with these Specifications, PPI guidelines, and the pipe manufacturer's recommendations. Should there be a conflict between these Specifications and the pipe manufacturer's recommendations, the more stringent requirement shall govern. The butt fusion equipment used in the joining procedures shall be capable of meeting all conditions and procedures recommended by the pipe manufacturer, including but not limited to, temperature requirements, alignment, and interfacial fusion pressure and automatic recording of parameters for joining.




i. Heat fusion joining shall be complete, efficient, and match the outer diameter of the two pipe being heat fused. Any offset or mismatch shall not exceed 10% of the minimum wall thickness. In all cases, heat fusion pipe joints shall have a joint weld strength equal to or greater than the tensile strength of the pipe.

j. Submit detailed fusion joint reports as recorded by the heat fusion machine for all joints. Submit a report to the Owner's Inspector the same day the fusion is made. Submit a formal report of all fusions to the Owner's Project Manager on a weekly basis, no later than 4:00 p.m. each Friday. If any joint as indicated by these reports is found to be unsatisfactory, the Contractor shall remove portions of the pipe containing such joint and install a new pipe piece as required and approved by the Owner.

k. The first fusion shall be a trial fusion to be performed in the field in the presence of the Owner. The trial fusion shall be allowed to cool completely, then fusion test straps shall be cut out. The test strap shall be the longer of 12 inches or 30 times the wall thickness in length with the fusion in the center, and 1 inch minimum or 1.5 times the wall thickness in width. Then, the test strap shall be bent until the ends of the strap touch. If the fusion fails at the joint, or if the joint exhibits cracking or crazing, a new trial fusion shall be made, cooled completely and tested. Butt fusion of the pipe to be installed shall not commence until the trial fusion has passed the bend back test.

l. Following the successful initial trial fusion, the bend back test shall be performed once every fiftieth joint.

m. Bending of the pipe to achieve horizontal or vertical changes in direction is allowed. The minimum bending radius, measured along the centerline axis of the pipe is 50 times the nominal pipe size.

n. Flange connections shall be in accordance with the manufacturer’s requirements. Flange bolts shall not be used to draw the connection into alignment. Bolt threads shall be lubricated and flat washers shall be used under nuts. Tighten bolts evenly according to the pipe manufacturer’s tightening pattern and torque step recommendations. Retighten flange connections at least one hour after the initial tightening using the pipe manufacturer’s tightening pattern and torque step recommendations.

o. Install tracer wire and warning tape. p. All HDPE pipe must be at the temperature of the surrounding soil at the

time of backfilling and compaction.

3.02 COUPLING INSTALLATION

A. Flexible Couplings and Flange Coupling Adaptors: Prior to installation, thoroughly clean oil, scale, rust, and dirt from the pipe to provide a clean seat for the gasket. Wipe gaskets clean before they are installed. If necessary, flexible couplings and flanged coupling adapter gaskets may be lubricated with soapy water or manufacturer's standard lubricant before installation on the pipe ends. Install in accordance with the manufacturer's recommendations. Tighten bolts progressively, drawing up bolt on opposite sides a little at a time until all bolts have a uniform tightness. Workers tightening bolts shall be equipped with torque-limiting wrenches or other favorably reviewed type.



B. Tie Rods: Except where double nutting is required, install the nuts snug. Tighten the nuts gradually and equally at opposite sides of the pipe until snug to prevent misalignment and to ensure that all rods carry equal loads. If double nutting is required, double nut each end of each tie rod. The space between the pairs of nuts shall be ½-inch greater than the distance between the lugs. Provide double nutting at buried locations and where otherwise required on the Drawings.

C. Flexible Rubber Spools: 1. Install in accordance with manufacturer's instructions. Unless otherwise

shown on the Drawings, install flat with half the maximum expansion. 2. Connect rubber spools only to full-face metal flanges. 3. Install control rod-compression sleeve assemblies with control rod nuts snug,

to relieve stress on adjacent pipe, except at buried locations. Comply with manufacturer’s instructions.

4. Paint buried galvanized steel retainer rings, bolts and other appurtenances in accordance with Section 09960.

3.03 INSTALLATION OF VALVES AND ACCESSORIES

A. Install valves and accessories such that all parts are easily accessible for maintenance and operation. Provide valve boxes for buried valves.

B. Where valve handwheels are shown on the Drawings, valve orientation shall be as shown. Where valve handwheels are not shown, orient valves to permit easy access to the handwheels or handles and to avoid interferences.

C. Install pressure gauges and thermometers in a position to permit reading them from a point approximately 5 feet above floor level, except that pump pressure gauges shall be installed close to the pump elevation.

D. Rigidly support pressure switches and connect them to piping and equipment using a suitable flexible linkage that will not permit transmission of vibrations from the piping or equipment to the pressure switches.

E. Provide a union adjacent to each screwed end valve and accessory with additional unions as necessary to facilitate removal.

F. Provide a shutoff valve below each pressure gauge, protective device or air valve unless otherwise specified.

G. Connections between ferrous and non-ferrous piping, valves, accessories or pipe supports shall be made using a dielectric coupling, union, or flange.

H. Where valves or other pipeline items require metal full-face connecting flanges, provide intermediate flanges if the connecting flange is not adequate.

I. Install link-type seals in cast-in-place metal sleeves or in smooth core drilled holes. Grout both sides flush with non-shrink grout unless otherwise shown on the plans.

3.04 INSTALLATION OF INSULATION

A. General: Apply insulation material, accessories, and finishes according to the manufacturer’s printed instructions. Seal joints and seams to maintain vapor barrier. Seal penetrations for hangers, supports, and anchors. Keep insulation material dry during application. Apply vapor barrier on seams, joints, over staples, and at end butt to fittings.




B. Whenever possible, slip insulation on pipe before making connections. Seal joints with adhesive. Where the slip-on technique is not possible, cut one side longitudinally and apply to the pipe. Seal seams and joints with adhesive.

3.05 INSTALLATION OF PIPE SUPPORTS

A. General: 1. Install and adjust supports for each pipeline such that the pipeline is true to

the indicated line and grade. 2. Locate anchors and braces for any single support on a continuous structure;

that is, not on two sides of a structural expansion joint. 3. Tighten clamps to develop full friction along the pipeline except where loose

fitting clamps are called for.

B. Electrolytic Protection: Pipe supports serving copper pipe or tubing shall be dielectrically insulated from the pipe by dielectric sleeves or plastic pipe wrap at the point of contact.

3.06 PIPE AND VALVE IDENTIFICATION

A. General: Identify all exposed piping in this project by painting, banding, system name labels, and direction arrows. The color and banding shall be as selected by the City Representative. Identify all buried and exposed valves with tags as specified below.

B. Exposed Pipe Identification: Before painting, banding and labeling, pipes shall be identified by the Contractor with temporary wired-on cardboard tags showing the proposed marking for review by the City Representative.

C. Piping: Paint all exposed pipes with the appropriate paint system as specified in Section 09960 and provide pipe markers per the schedule specified in Section 10400.

D. Valves: Provide each buried valve with a valve tag identifying the pipeline contents, and either its valve number, or the area or item served by the valve for valves without a valve number. Contents shall be as designated in the Piping Schedule on the Drawings.

3.07 CLEANING

A. Prior to testing, thoroughly clean the inside of each completed piping system of all dirt, loose scale, sand and other foreign material. Cleaning shall be by sweeping, flushing with water or blowing with compressed air or oil-free nitrogen gas, as appropriate for the size and type of pipe. Flushing shall achieve a velocity of at least 3 feet per second. The Contractor shall install temporary strainers, temporarily disconnect equipment or take other appropriate measures to protect equipment while cleaning piping.

3.08 FIELD TESTING

A. General: Perform leakage tests on all pipe installed in this project. Furnish all equipment, material, personnel and supplies to perform the tests and make all taps and other necessary temporary connections. The test pressure, allowable leakage and test medium shall be as specified and as shown in the following Schedule. Test pressure shall be measured at the highest point on the line, except that



pressure at lowest point shall not exceed pipe manufacturer’s rated test pressure, unless specifically noted otherwise. Leakage tests shall be performed on all piping at a time agreed upon and in the presence of the City Representative.

B. Buried Piping: The leakage test for buried piping shall be made after all pipe is installed and backfilled. However, the Contractor may conduct preliminary tests prior to backfill. If the Contractor elects to conduct preliminary tests, provide any necessary temporary thrust restraint.

C. Exposed Piping: All supports, anchors and blocks shall be installed prior to the leakage test. No temporary supports or blocking shall be installed for final test.

D. Encased Piping: The leakage test for encased piping shall be made after all pipe is installed and encased, and before any structures are constructed above it. However, the Contractor may conduct preliminary tests prior to encasement. If the Contractor elects to conduct preliminary tests, provide any necessary temporary thrust restraint.

E. Accessories: It shall be the responsibility of the Contractor to block off or remove equipment, valves, gauges, etc., which are not designed to withstand the full test pressure.

F. Testing Apparatus: Provide pipe taps, nozzles and connections as necessary in piping to permit testing including valves to isolate the new system, addition of test media, and draining lines and disposal of water, as is necessary. These openings shall be plugged in a manner favorably reviewed by the City Representative after use. Provide all required temporary bulkheads.

G. Pneumatic Testing: Piping tested by air or another gas shall show no reduction of pressure during the test period after corrections have been made for changes in temperature in conformance with the following relationship:

1

1

2

2

P

T= P

T

Where T1 and T2 are the absolute temperatures of the gas in the pipe and P1 and P2 are the absolute pressures. The subscript "1" denotes the starting conditions and the subscript "2" denotes the final conditions.

H. Precautions for Pneumatic Testing: Where air or another gas is called for as the test medium, the Contractor shall take special precautions to protect personnel. During the initial pressurization of a pipeline to the specified test pressure, personnel shall be protected by suitable barricades or shall remove themselves to locations where portions of the concrete structure itself are between them and the pipeline under test.

I. Correction of Defects: If leakage exceeds the allowable, the installation shall be repaired or replaced and leakage tests shall be repeated as necessary until conformance to the leakage test requirements specified herein have been fulfilled. All visible leaks shall be repaired even if the pipeline passes the allowable leakage test.

J. Drying: Gas lines tested with water shall be drained and blown dry with air or oil-free nitrogen gas.




K. Reports: The Contractor shall keep records of each piping test, including: 1. Description and identification of piping tested. 2. Test pressure. 3. Date of test. 4. Witnessing by Contractor and City Representative. 5. Test evaluation. 6. Remarks, to include such items as:

a. Leaks (type, location). b. Repairs made on leaks.

7. Test reports shall be submitted to the City Representative.

L. Venting: Where not shown on the Drawings, the Contractor may install valved "tees" at high points on piping to permit venting of air. Valves shall be capped after testing is completed.

M. Testing Specifics: Piping shall be tested as indicated in the following Schedule. All other piping systems shall be tested as required for the pipe type used.

Piping Test Schedule

System

Pipe Type

Test Pressure (psi)

Test Medium Duration (hours)

Allowable Leakage

3W PVC-1 100 Water 4 None

AIR PVC-1 10 Air 4 None

CNG SST 4800 Nitrogen gas 4 None

D PVC-6 5 Water 4 None

DG SS/HDPE 10 Nitrogen gas 4 None

NG BS/HDPE 50 Nitrogen gas 4 None

OG SS 200 Nitrogen gas 4 None

PD DI 50 Water 4 None

PG SS 100 Nitrogen gas 4 None

RL SS 50 Water 4 None

TWS HDPE 25 Water 4 None

WG SS 10 Nitrogen gas 4 None

3.09 WARRANTY


END OF SECTION


15400 - 1 Plumbing CNG Fueling Station

SECTION 15400

PLUMBING

PART 1 - GENERAL

1.01 SUMMARY

A. Section Includes: 1. Plumbing fixtures and accessories. 2. Piping, valves, and accessories.


A. American National Standards Institute (ANSI) Publication: 1. A117.1 Specifications for Making Buildings and Facilities Accessible to

and Usable by the Physically Handicapped

B. Underwriters Laboratories Inc. Standards: 1. U.L. 174 Standards for Safety

C. Sheet Metal and Air Conditioning Contractors National Association (SMACNA): 1. Seismic Restraint Manual, Guidelines for Mechanical Systems.

D. All state and local building codes including plumbing, mechanical, fire, building, and electrical.

1.03 SUBMITTALS


B. Submit manufacturer’s information with materials, dimensions, and data to show that the products conform to the specification requirements. All products in this Section shall be included in a single initial submittal.

C. Submit operation and maintenance manuals where available from manufacturers.


A. Codes: Comply with the rules and regulations of authorities having jurisdiction over the work specified herein, including the applicable Plumbing Code with amendments.

B. Permits and inspections shall be in accordance with General Conditions.

C. The Drawings shall be taken in a sense as diagrammatic. Size of pipes and general method of running them are shown, but it is not intended to show every offset and fitting nor every structural difficulty that may be encountered.

D. ADA compliance means that the plumbing item is accessible and usable by persons with disabilities.

1.05 SEISMIC PROTECTION

A. Provide equipment and piping with seismic protection as specified and as recommended by “Seismic Restraint Manual - Guidelines for Mechanical Systems”,

Plumbing CNG Fueling Station



latest edition by SMACNA. Provide more rigid restraint if required by Specification Section 15050.

PART 2 - PRODUCTS

2.01 GENERAL

A. Provide equipment and materials conforming to the standards and manufacturers' serial numbers shown, or equal.

2.02 PLUMBING FIXTURES AND ACCESSORIES

A. Hose Bibbs: Brass, 'no-kink' design, 3/4" MIP inlet x 3/4 " hose outlet. Arrowhead 351, Matco-Norca, or equal

B. Floor Drains: Cast iron drains having inside caulk or push-on compression type neoprene gasket joints. 1. FD-2 (For Deck Areas): 12" wide floor drain with troweling flange, heavy duty

grate with sediment bucket, and membrane flashing clamp. Zurn Z-532; Jay R. Smith DX2565R; or equal.

2. FD-4 (CISP Bell Outlet): Funnel drain formed by stubbing bell of bell and spigot soil pipe up ½-inch above floor level. Include a backwater valve where shown on the Drawings.

C. Area Cleanouts: Nickel-Bronze body with scoriated deck plug with O-ring seal. Zurn Z-1456; Jay R. Smith 4890; or equal.

2.03 PIPING, VALVES, AND ACCESSORIES

A. Refer to Piping Schedule, Sheet G003 of the Project Drawing Set and Section 15050, paragraphs 2.03 and 2.05 for materials.

PART 3 - EXECUTION

3.01 INSTALLATION

A. Provide all fixtures with traps and vents unless otherwise indicated on the Drawings.

B. Provide unions or flanges where equipment is installed in piping. Also provide dielectric unions or couplings at points of connection of ferrous to non-ferrous metal piping.

C. Do not install threaded PVC fittings. Provide steel reinforced adapter fittings where for joining PVC pipe to equipment with threaded connections.

D. Provide a shut-off stop valve in the branch of every pipe service upstream of every fixture or outlet.

E. Provide identification nameplates for each item of mechanical equipment. Refer to Section 11001.

F. Furnish and install all supports, bracing and blocking required for the proper installation of the plumbing work specified herein.


15400 - 3 Plumbing CNG Fueling Station

G. Provide valves where equipment drain connections are furnished and carry the discharge pipe to the nearest floor drain, drain trench, or sump. Where no receptacle for drain exists, install drain piping to 1-inch above the floor. Drain piping and valve materials shall conform to the requirements of the system served.

3.02 TEST AND INSPECTION

A. Test the systems and arrange for inspection by the proper authorities.

B. Water piping shall be hydraulically tested at not less than working pressure psig and demonstrated to be leak-free for a 1-hour test period or greater if required by Section 15050.

C. Waste, drain and vent piping shall be tested in conformance with the Uniform Plumbing Code with local amendments.

END OF SECTION

Plumbing CNG Fueling Station



PAGE INTENTIONALLY

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16010 - 1 General Requirements for Electrical Work CNG Fueling Station

SECTION 16010

GENERAL REQUIREMENTS FOR ELECTRICAL WORK PART 1—GENERAL 1.01 SUMMARY

A. SCOPE: This section specifies general requirements for electrical work. Detailed requirements for specific electrical items are specified in other sections but are subject to the general requirements of this section. The electrical drawings and schedules included in this project manual are functional in nature and do not specify exact locations of equipment or equipment terminations.

B. DEFINITIONS:

1. WIRING, ELEMENTARY OR SCHEMATIC DIAGRAM: A schematic (elementary) diagram shows, by means of graphic symbols, the electrical connections and functions of a specific circuit arrangement. The schematic diagram facilitates tracing the circuit and its functions without regard to the actual physical size, shape, or location of the component devices or parts.

2. ONE-LINE DIAGRAM: A one-line diagram shows by means of single lines and graphical symbols the course of an electrical circuit or system of circuits and the components, devices or parts used therein. Physical relationships are usually disregarded.

3. BLOCK DIAGRAM: A block diagram is a diagram of a system, instrument, computer, or program in which selected portions are represented by annotated boxes and interconnecting lines.

4. CONNECTION DIAGRAM: A connection diagram includes all of the devices in a system and shows their physical relationship to each other including terminals and interconnecting wiring in an assembly. This diagram shall be (a) in a form showing interconnecting wiring only by terminal designation (wireless diagram), or (b) a panel layout diagram showing the physical location of devices plus the elementary diagram.

5. INTERCONNECTION DIAGRAM: a. Interconnection diagrams shall show all external connections between

terminals of equipment and outside points, such as motors and auxiliary devices. References shall be shown to all connection diagrams which interface to the interconnection diagrams. Interconnection diagrams shall be of the continuous line type. Bundled wires shall be shown as a single line with the direction of entry/exit of the individual wires clearly shown. Wireless diagrams and wire lists are not acceptable.

b. Each wire identification as actually installed shall be shown. The wire identification for each end of the same wire shall be identical. All devices and equipment shall be identified. Terminal blocks shall be shown as actually installed and identified in the equipment complete with individual terminal identification.

c. All jumpers, shielding and grounding termination details not shown on the equipment connection diagrams shall be shown on the interconnection diagrams. Wires or jumpers shown on the equipment connection diagrams shall not be shown again on the interconnection diagram. Signal and DC

General Requirements for Electrical Work CNG Fueling Station



circuit polarities and wire pairs shall be shown. Spare wires and cables shall be shown.

6. ARRANGEMENT, LAYOUT, OR OUTLINE DRAWINGS: An arrangement, layout, or outline drawing is one which shows the physical space and mounting requirements of a piece of equipment. It may also indicate ventilation requirements and space provided for connections or the location to which connections are to be made.


A. REFERENCE STANDARDS: 1. This Section incorporates by reference the latest revisions of the following


2. Unless otherwise specified, references to documents shall mean the documents in effect on the effective date of the Agreement. If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued.

Reference Title

NECA-1 National Electrical Contractors Association – Standard Practices for Good Workmanship in Electrical Contracting

NFPA-70 National Electrical Code (NEC)

NFPA-70E Electrical Safety in the Workplace

IBC International Building Code

B. IDENTIFICATION OF LISTED PRODUCTS:

1. Electrical equipment and materials shall be listed by an independent testing laboratory for the purpose for which they are to be used. Three such organizations are Underwriters Laboratories (UL), Canadian Standards Association (CSA), and Electrical Testing Laboratories (ETL). Independent testing laboratory shall be acceptable to the inspection authority having jurisdiction.

2. When a product is not available with a testing laboratory listing for the purpose for which it is to serve, the product may be required by the inspection authority to undergo inspection at the manufacturer's place of assembly. All costs and expenses incurred for such inspections shall be included in the original contract price. Contractor shall comply with Washington Administrative Code regulations concerning Listing requirements for electrical equipment.

C. FACTORY TESTS: Where specified in the individual product specification section,

factory tests shall be performed at the place of fabrication and performed on completion of manufacture or assembly. The costs of factory tests shall be included in the contract price.



1.03 SUBMITTALS

A. PROCEDURES: Section 01330 B. ACTION SUBMITTAL ITEMS FOR THIS SECTION:

1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. a. The Owner shall be the final authority for determining acceptability of

requested deviations. The remaining portions of the paragraph not underlined will signify compliance with the specifications.

b. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration.

2. Catalog cuts of equipment, devices, and materials requested by the individual specification sections. Catalog information shall include technical specifications and application information, including ratings, range, weight, accuracy, etc. Catalog cuts shall be edited to show only the items, model numbers, and information which apply. a. Catalog cuts shall be assembled in a tabbed three ring binder. Each binder

shall contain a cover sheet and index listing the submitted items and cross-referenced to the appropriate specification paragraph. Where submittal information for equipment or materials covered by more than one specification Section is included within one binder, each tab shall be submitted as a separate submittal number. The tab shall be labeled with the submittal number.

3. Interconnection diagram: The Contractor shall prepare interconnection diagrams depicting all cable requirements together with their actual terminations as specified in Section 16010.

4. Conduit layout drawings indicating size, location, and support, for all conduits other than single runs of 1-inch diameter or less cast in concrete construction. a. Conduit layout drawings shall illustrate a system which conforms to the

requirements of Section 16010. b. For layouts that do not conform to 16010, provide engineering design and

calculations signed and sealed by a Professional Engineer registered in the state of the project. Engineering design and calculations shall demonstrate that the proposed layout does not impair or significantly reduce the design structural strength.

5. Safety disconnect switch list including legend with equipment tag, equipment description, and power feeder circuit source and location information.




1.04 DRAWINGS

A. Where the Contractor is required to provide information on drawings as part of the specified work, such drawings shall be prepared on 11-inch by 17-inch paper, and on CD Rom in AutoCAD 2000. Drawings shall be complete with borders and title blocks clearly identifying project name, equipment and the scope of the drawing. Drawing quality and size of presentation shall be such as to permit 50 percent reduction of such drawings for insertion in operation and maintenance manuals. Drawings deemed illegible shall be rejected.

B. Where the Contractor is required to provide equipment or system submittal

information on drawings as part of the specified work, such drawings shall be prepared on 11-inch by 17-inch paper and shall be included within a three ring binder. Drawings shall be complete with borders and title blocks clearly identifying project name, equipment and the scope of the drawing. Drawing quality and size of presentation shall be such as to permit 50 percent reduction of such drawings for insertion in operation and maintenance manuals. Drawings deemed illegible shall be rejected.

1.05 PROJECT/SITE CONDITIONS

A. GENERAL: Unless otherwise specified, equipment and materials shall be sized and derated for the ambient conditions not less than an ambient temperature of 40 degrees C at an elevation ranging from sea level to 3000 feet without exceeding the manufacturer's stated tolerances.

B. CORROSIVE AREAS: Areas where chlorine or sulfur dioxide gas under pressure,

sulfuric acid, or liquid polymer are stored or processed. C. HAZARDOUS (CLASSIFIED) AREAS: The following areas are designated as

hazardous (classified) in accordance with the NEC:

Reference Drawing

Room Name /Description

HazardousClassification

22-E-01 H2S Removal Vessel

Areas within 10 feet envelope of all tanks, valves and appurtenances

Class 1, Division 1

22-E-01 Gas Treatment Skid

Areas within 10 feet envelope of all tanks, valves and appurtenances

Class 1, Division 2

22-E-01 Waste Gas Burner

Areas within 10 feet envelope of waste gas burner and appurtenances

Class 1, Division 1

22-E-01

Waste Gas Burner

Areas within 15 feet envelope of waste gas burner and appurtenances

Class 1, Division 2



23-E-01

CNG Compressor

Areas within 15 feet envelope of compression and ancillary equipment

Class 1, Division 2

23-E-01

Inlet Dryer


Class 1, Division 2

23-E-01

NG Compressor


Class 1, Division 2

23-E-01

CG Storage Unit

Areas within 10 feet within of storage containers

Class 1, Division 2

PR-03

NG Compressor


Class 1, Division 2

PR-03

Fueling Post

Areas within 5 feet within of fueling post

Class 1, Division 2

D. SEISMIC: Electrical equipment supports, and anchorage shall be designed and

installed in accordance to Division 01.

1.06 ELECTRICAL NUMBERING SYSTEMS

A. TAGGING: All circuit raceways and armored cables shall be tagged at all terminations, panels, MCCs, pull boxes, junction boxes, etc. in accordance with the assigned numbers on the circuit/raceway schedule and schematic/plan drawings. The tags shall be installed in a clean and high workmanship manner. In addition to tags at the terminations, exposed raceways and armored cables shall be tagged at each side of concealment.

B. PREFIX MODIFIERS: The following prefix modifiers shall be used when

scheduling/tagging cables and raceway:




Raceway Prefix Type of Function

P Power

C Control (120V)

S Low level signal (less than 90 volt communication or less than 30 volt instrumentation)

C. RACEWAY NUMBERS:

1. The circuit schedule identifies individual and discrete circuits necessary for the operation of their associated piece of equipment or element. Where multiple and similar control type circuits “C” and signal type “S” circuits only are listed going from one enclosure, MCC, panel, cabinet, etc. to another enclosure, MCC, panel, cabinet, etc. the contractor may combine like “S” circuit types and combine like “C” circuit types into a single “S” or “C” raceway or cable type. The Contractor is responsible for maintaining the NEC fill requirements and raceway/cable numbering on the combined circuits as identified in the circuit schedule for as-builting purposes.

2. Where circuit/raceway numbers have not been assigned, Contractor shall

assign raceway numbers in accordance with the following system. a. Prefixes shall be followed by a process area code, multi-alpha numeric

number defined by the equipment number or source panel, cabinet, MCC, etc. Where there is more than one raceway to a particular piece of equipment, a letter suffix is added to distinguish the raceways and cables.

Example:

Raceway number = Pxxxx

where:

P

=

Raceway contains power wiring

xxxx = The first two digits shall be the same as the process area of the equipment being fed.

D. CABLE NUMBERS: Where cable numbers have not been assigned, Contractor

shall assign cable numbers in accordance with the above system:

E. CONDUCTOR NUMBERS: 1. WIRE MARKERS: All control and signal conductors in panels, pull boxes,

power, instrument, and relay compartments of motor control centers, control cabinets, instrument cabinets, field cabinets and control stations, as well as connections to mechanical equipment, shall be tagged at each end with legible, coded tight fitting wire-marking sleeve showing the complete wire designation. The letters and numbers that identify each wire shall be machine printed on sleeves with permanent black ink. The figures shall be 1/8 inch high. Sleeves shall be yellow or white tubing, sized to fit the conductor insulation. The sleeves shall be shrunk to fit the conductor with hot air after installation. They shall be T&B, SHRINK-KON HVM or equal. Adhesive strips are not acceptable.



Conductors size No. 10 AWG or smaller shall have identification sleeves. Conductors No. 8 AWG and larger shall use cable markers of the locking tab type. Tabs shall be white plastic with conductor identification number permanently embossed.

2. INTERNAL WIRING: a. Wiring within a single enclosure shall be marked with the basic wire and

terminal number at each end. The wire number shall designate the terminal or equipment number at each end of the wire separated by a slash.

b. Wiring within MCC buckets shall have a simple numbering scheme, and shall use the same number at each end. (1,2,3,4,5, etc.) Wiring which lands on field terminals shall utilize the terminal number for the internal wire number.

3. FIELD WIRING: All field wiring shall have wire labels at each end. The labels shall be marked with the output terminal number at the original equipment (control cabinet, or MCC) and the remote device terminal # (if applicable) and tag name separated by a slash. Conductors shall be identified with numbers at both ends. Conductor tag numbers shall be the conductor number specified on the control diagram or if not shown, shall follow the convention below. a. Wires from MCC buckets shall be labeled with [MCC number - bucket

number(A4) - terminal number (6)] (S04EDSMCC001-A4-6) b. Wires from Local Control Panels shall be labeled with [panel number-

terminal number (12)] (S02HVAALV001-12) c. Wires from PLC Processor panels shall have Rack or Bus (1) – Card or

Block (7) -Terminal number(A3) only (1-7-A3) d. Wires from devices, instruments etc. shall have the instrument or device

name and terminal number if applicable. Equipment name is typically SYSTEM - DEVICE TYPE – NUMBER, e.g S04PW3PIT100; S02INFLIT101.

1.07 INDICATING LAMP COLORS

A. All indicating lamps shall have an integrated lamp-test function or a common lamp test switch for all lamps on a single line-up of equipment (i.e. Motor Control Center, Switchgear).

B. Unless otherwise specified, indicating lights shall be equipped with colored lenses in

accordance with the following schedule:

Color Function Example

Green Run, open valve Equipment operating, motor running

Red Stopped, Closed valve Alarm, end of cycle, motor stopped

White or clear Normal condition, Ready

Control power on, status OK

Amber (yellow) Abnormal condition Failure of equipment or status abnormal, fault condition




1.08 EQUIPMENT COORDINATION

A. The Contractor is responsible to coordinate the equipment supplied from various manufacturers and vendors. This includes but is not limited to: 1. Obtaining specific information on equipment ratings and sizes and verifying the

electrical components supplied meet, or match the requirements such as voltage, phase, frequency, starter types, etc.

2. Providing equipment that will fit within the space allocated and meet OSHA and NEC clearances.

3. Coordination of the supplied equipment’s electrical power and control requirements.

4. Providing power and control equipment, wiring, and raceways to meet the requirements of the mechanical equipment supplied.

5. Providing all necessary control wiring and components for any special requirements from an equipment manufacturer.

B. The Contractor shall verify as a minimum:

1. Correct voltage, phase and frequency 2. Size and space requirements 3. Mounting requirements 4. Correct motor starter type and NEMA size. 5. Proper coordination with the controls and control system Integrator.

C. Any discrepancies between the electrical equipment and other equipment shall be

brought to the immediate attention of the Owner. D. The Contractor shall assure that no instrumentation or control interferences are

created by the variable frequency drives (VFDs) or load wiring. The Contractor shall coordinate with the VFD manufacturer to provide necessary separation of conductors or shielding and/or filtering equipment as required by the VFD manufacturer. If interferences do occur, the Contractor shall be responsible to take corrective action at no additional cost to the Owner.

E. WIRING FOR VENDOR PACKAGES:

1. Equipment specifications indicate when the Vendor is responsible for providing interconnection wiring between components of a Vendor package that are installed on separate skids or assemblies. In this circumstance, interconnection wiring between skids or assemblies in a Vendor package is scheduled as “Vendor Wiring” in the conduit/cable schedules.

2. Where equipment specifications do not specify Vendor furnished wiring between skids or assemblies in a Vendor package, the Contractor shall provide and install interconnection wiring between skids or assemblies per the Vendor’s interconnection wiring requirements. Interconnection wiring between skids or assemblies in a Vendor package that is furnished and installed by the Contractor is not scheduled in the conduit/cable schedules.

3. Equipment specifications that specify interconnection wiring between separate skids or assemblies of a Vendor package are listed below. a. Section 11381 – Digester Gas Processing Equipment b. Section 11700 – Waste Gas Burner

4. Determination of cable requirements.



a. Coordinate cable/conductor requirements with the selected Vendors to determine the correct wiring required to interconnect the package system components/skids.

b. Wiring between Vendor furnished components shipped on separate skids or assemblies shall conform to requirements specified in Division 16 and Division 17.

c. Wiring between the plant control system and Packages system components/skids are specified in the conduit/cable schedules.

d. Wiring between external power supplies and the packaged system components/skids are specified in the conduit/cable schedules.

5. Assign numbers and tagging for unscheduled raceway, and cable between Vendor furnished components on separate skids or assemblies as specified in Section 16010. Coordinate this information in submittals, record drawings, and O&M manuals provided under this contract.

6. Contract documents shall be updated in the record drawing set to include the work provided for wiring the vendor packages.

1.09 BASIS OF DESIGN

A. The basis of the mechanical and electrical design is the installation of equipment and motors as shown in the electrical one-line drawing(s) and load/panel schedules. In the event that different equipment motors are provided in order for the vendor’s equipment to meet mechanical performance requirements, the contractor shall coordinate various suppliers, vendors, and subcontractors to change the required electrical conduit, cables, breakers, motor control center sections, starters units and accessories, etc. as necessary to meet the vendor’s equipment installation requirements of the National Electrical Code. The traits and characteristics of all provided materials, equipment, and devices shall meet the specifications. These changes to materials, equipment, and devices shall be at no cost to the Owner. Electrical submittal information shall be coordinated with the equipment and motors provided.

1.10 ARC FLASH MITIGATION METHODS

A. The following mitigation method requirements shall apply to all power distribution and utilization equipment supplied for any products supplied on the project and applies to all equipment divisions in the Contract Documents. Refer to the NFPA-70 (NEC), and NFPA- 70E (Electrical Safety in the Workplace) for equipment labeling requirements. 1. EQUIPMENT LABELS: Equipment labels shall be installed on the outside of the

electrical equipment enclosure, cabinet, and panels to avoid opening the equipment to access the manufacture’s data or the equipment ratings.

2. HINGED DOORS: Power distribution equipment shall have hinged rear doors where back access is shown.

3. POWER AND CONTROL EQUIPMENT SEPARATION: a. Provide separation between power equipment within an enclosure, cabinet,

or panel by the use of barriers, separate access doors, or by other means. b. Provide separation barriers between main breaker feeders coming into

equipment and other termination points or bussing on the load side of the main breaker.




4. AUTOMATIC SHUTTERS: Provide automatic shutters, where possible, to close the access to the power bus when a power device is not engaged.

5. IR Viewing windows on the Switchgear. 6. Arc Flash Mitigation Switches (ARMS) on the Switchgear. 7. Remote racking devices on the Switchgear.

PART 2--PRODUCTS 2.01 EQUIPMENT AND MATERIALS

A. GENERAL: Equipment and materials shall be new and free from defects. All material and equipment of the same or a similar type shall be of the same manufacturer throughout the work. Standard production materials shall be used wherever possible.

B. EQUIPMENT FINISH: Unless otherwise specified, electrical equipment shall be

painted by the manufacturer as specified in Section 09960. C. GALVANIZING: Where specified, galvanizing shall be in accordance with Section

05500. 2.02 WIRE MARKERS

A. Each power and control conductor shall be identified at each terminal to which it is connected. Conductors size No. 1 AWG or smaller shall have identification sleeves. Conductors No. 2 AWG and larger shall use cable markers of the locking tab type. Tabs shall be white plastic with conductor identification number permanently embossed.

B. Conductors shall be identified in accordance with Section 16010. Adhesive strips

are not acceptable. C. The letters and numbers that identify each wire shall be machine printed on sleeves

with permanent black ink with figures 1/8 inch high. Sleeves shall be yellow or white tubing and sized to fit the conductor insulation. Shrink the sleeves with hot air after installation to fit the conductor.

D. Conductor and Wire Marker Manufacture:

1. TMS Thermofit Marker System by Raychem Co 2. Sleeve style wire marking system by W. H. Brady Co. 3. Approved equal.

2.03 MULTICONDUCTOR CABLE AND RACEWAY TAGS

A. Tags shall be: 1. Manufactured of permanent metal or heavy mill plastic. 2. Fastened to the raceways at both ends of the tag with permanent fasteners. 3. Tag numbers shall be 1” tall and machine printed. Hand labeled tags are

unacceptable. 2.04 NAMEPLATES



A. Nameplates shall be provided on all electrical devices, including but not limited to

motor control equipment, MCC cubicles/cells/buckets, control stations, junction boxes, panels, Accusine filters, instruments, disconnect switches, indicating lights, meters, and all electrical equipment enclosures.

B. Nameplates shall also be provided on all electrical panel interior equipment,

including but not limited to relays, circuit breakers, power supplies, terminals, contractors, and other devices.

C. Equipment nameplates shall have both the equipment name and number. D. Nameplates shall be made of 1/16" thick machine engraved laminated phenolic

having black letters not less than 3/16" high on white background or as shown on the drawings or other sections of the specifications. Nameplates on the interior of panels shall be White Polyester with printed thermal transfer lettering and permanent pressure sensitive acrylic; TYTON 822 or equal. All nameplates shall include the equipment name and number (and function, if applicable).

E. Provide warning nameplates on all panels and equipment which contain multiple

power sources. Lettering shall be white on red background. F. Nameplates shall be secured to equipment with stainless steel screws/fasteners. G. Nameplates for disconnect switches shall contain name and number as well as

voltage, phases and colors of conductors. 2.05 TERMINAL BLOCKS

A. GENERAL: 1. Unless otherwise specified, terminal blocks shall be panhead strap screw type.

Terminals shall be provided with integral marking strips which shall be permanently identified with the connecting wire numbers as shown on the drawings. Terminal blocks for P-circuits (power 120-600 volts) shall be rated not less than the conductor current rating and shall be rated not less than 600 volts AC. Terminal blocks for C-circuits (control and/or control power 120

volts or less) and S-circuits (signal) shall be rated not less than 20 amperes and shall be rated not less than 600 volts AC. Terminals shall be tin-plated.

Insulating material shall be nylon. Terminal blocks shall be in accordance with section 16010 for all electrical equipment.

2. Provide Allen Bradley, Phoenix Contact or equal. 3. Provide terminals for all wire connections to field wiring and internal power

distribution. Analog loops that are 24 VDC powered and all digital inputs shall have a fused knife switch to disable the loop if necessary.

4. Connections shall have compression terminals capable of terminating 2 #14 AWG stranded wires. Terminals shall be DIN rail strip mounted. Provide number strips for terminal blocks that are referenced by the wire marker, as manufactured by Phoenix Contact. Provide contact bridge bars for jumpering between terminal blocks. Provide end clamps to separate and terminate




terminal block groups. Provide end covers for groups of terminal blocks in sets to match the number of points associated with individual I/O cards in the PLC block.

5. Provide separation plates on each side of terminals that are at a different potential or polarity than surrounding terminals.

6. Provide clear plastic DIN rail mounted name tag stanchions for each block of terminations. Each name tag shall hold a preprinted label designating the PLC bus and PLC block that terminates to that set of terminals.

7. Terminals shall be mounted such that there is a minimum of 1.5 inches of clear space on both sides of the terminal; for ease of wiring.

8. Mount all terminals strips on 2” standoffs. 9. Provide 10, or 5% whichever is the greater amount, spare (non-installed)

replacement terminals for each type used. 10. Provide wired terminals to match the number of points supplied on each I/O

card in a cabinet.

B. PLC I/O TO TERMINAL WIRING: 1. Wire all I/O points on all modules provided to terminal blocks. Wiring from filed

equipment directly to PLC I/O modules is not permitted. PART 3--EXECUTION 3.01 GENERAL

A. CONSTRUCTION: 1. The work under Division 16 shall be performed in accordance with these

specifications.

2. Unless otherwise detailed or dimensioned, electrical layout drawings are diagrammatic. The Contractor shall coordinate the field location of electrical material or equipment with the work of other disciplines and subcontractors. Minor changes in location of electrical material or equipment made prior to installation shall be made at no cost to the Owner.

B. HOUSEKEEPING:

1. Electrical equipment shall be protected from dust, water and damage. Motor control centers, switchgear, and buses shall be wiped free of dust and dirt, kept dry, and shall be vacuumed on the inside within 30 days of acceptance of the work.

2. Before final acceptance, the Contractor shall touch up any scratches on equipment as specified in Section 09960.

3. Electrical equipment temporarily exposed to weather, debris, liquids, or damage during construction shall be protected as specified in Section 01500.

C. ELECTRICAL EQUIPMENT LABELING:

1. Electrical equipment shall have field marked signs and labeling to warn qualified persons of the potential electric arc flash hazards per NEC Article

110.16 Flash Protection. 2. Electrical equipment shall have NFPA 70E labels installed stating the results of

the Arc Flash analysis specified in Section 16015.



3. Electrical distribution equipment and utilization equipment shall be provided with field labels to identify the power source and the load as specified. Refer to NEC Article 110.22 for Identification of Disconnecting Means installation criteria. Specific information is required such as the equipment tag number and equipment description of both the power source and the load equipment.

D. SAFETY DISCONNECT SWITCHES: Section 16140. E. MOTOR CONNECTIONS: Verify that the motors are purchased with the correct size

of motor termination boxes for the circuit content specified in the conduit and cable schedules or submit custom fabrication drawing indicating proposed motor termination box material, size, gasket, termination kit, grounding terminal, boot type insulated motor lead connection (T&B type MSC, or equal), and motor terminal box connection/support system. Verify the motor termination box location prior to raceway rough-in. For makeup boxes of smaller motors with limited space, T&B color keyed KUBE connector motor lead disconnects w/MDBOOT will be allowed.

F. CONDUCTOR INSTALLATION: An enclosure containing disconnecting means,

overcurrent devices, or electrical equipment shall not be used as a wireway or raceway for conductors not terminating within the enclosure. Provide wireways, raceways, termination boxes, or junction boxes external to the enclosure for the other conductors.

3.02 TESTING

A. GENERAL: Prior to energizing the electrical circuits, insulation resistance measurements tests shall be performed using a 1000-volt megohmmeter to verify the conductor is acceptable for use on the project. The test measurements shall be recorded on the specified forms and provided in accordance with Section 16015.

B. INSULATION RESISTANCE MEASUREMENTS:

1. GENERAL: a. Insulation resistance measurements shall be made on conductors and

energized parts of electrical equipment (600V or less). Minimum acceptable values of insulation resistance shall be in accordance with the applicable ICEA, NEMA or ANSI standards for the equipment or material being tested, unless otherwise specified. The ambient temperature at which insulation resistance is measured shall be recorded on the test form.

b. Insulation resistance measurements shall be recorded. Insulation with resistance of less than 10 megohms is not acceptable.

2. CONDUCTOR AND CABLE TESTS: The phase-to-ground insulation resistance shall be measured for all circuits’ rated 120 volts and above except lighting circuits. Measurements may be made with motors and other equipment connected. Solid state equipment shall be disconnected, unless the equipment is normally tested by the manufacturer at voltages in excess of 1000 volts DC.

3. MOTOR TESTS: The Installed Motor Test Forms shall be completed for each motor after installation. Motors shall have their insulation resistance measured before they are connected. Motors 50 HP and larger shall have their insulation resistance measured at the time of delivery as well as when they are connected. Insulation resistance values less than 10 megohms are not acceptable.




C. PRE-FUNCTIONAL TEST CHECKOUT: Functional testing shall be performed in

accordance with the requirements of Section 16. Prior to functional testing, all protective devices shall be adjusted and made operative. 1. Submit a description of the proposed functional test procedures prior to the

performance of functional checkout. 2. Prior to energization of equipment, perform a functional checkout of the control

circuit. Checkout: a. Energizing each control circuit. b. Operating each control device, alarm device, or monitoring device. c. Operate each interlock to verify that the specified action occurs.

D. Verify motors are connected to rotate in the correct direction. Verification may be

accomplished by momentarily energizing the motor, provided the Contractor confirms that neither the motor nor the driven equipment will be damaged by reverse operation or momentary energization.

END OF SECTION


16015 - 1 Testing of Electrical Systems CNG Fueling Station

SECTION 16015

TESTING OF ELECTRICAL SYSTEMS

PART 1 - GENERAL

1.01 SUMMARY

A. SCOPE: This section specifies the acceptance testing of electrical materials, equipment, and systems; and maintenance testing of the two existing 12kV distribution switchgear. Provide all labor, tools, material, power, and other services necessary to provide the specified tests. All testing described in this section shall be coordinated with the requirements of Division 1. Tests specified herein shall be included in the Test Plan submitted under Division 1.

B. TESTING FIRM: Peterson Power Systems or equal.





Reference Title

ANSI/NETA ATS-2013 Standard for Acceptance Testing Specifications for Electrical Power Distribution Equipment Systems

ANSI/NETA MTS-2015 Standard for Maintenance Testing Specifications for Electrical Power Equipment and Systems

B. APPLICATION: Where testing in accordance with this section and other Division 16 Sections is required, the required tests, including the retesting after the correction of found defects must be complete, and the submittal of final test reports to the Owner for review shall be completed prior to the energizing of material, equipment, or systems.

1.03 SUBMITTALS

A. PROCEDURES: Division 1

B. ACTION SUBMITTAL ITEMS FOR THIS SECTION: 1. A copy of this Section, addendum updates included, with each paragraph

check-marked to indicate compliance or marked to indicate requested deviations from Section requirements.

2. Proposed testing procedures including proposed test report forms.

Testing of Electrical Systems CNG Fueling Station



3. Test reports including documentation for all tests performed. Test reports shall be submitted for review prior to the equipment being energized.

4. Execution plan including schedule. 5. All testing required herein and the test results shall also be submitted and

documented as required under Divisions 1 and 16, and where identified within the specific sections.

6. Test results for a specific piece of equipment shall also be included in the operation and maintenance manual(s).

PART 2 - PRODUCTS

2.01 TESTING EQUIPMENT AND INSTRUMENTS

A. The test equipment, instruments and devices used for testing shall be calibrated to test equipment standards with references traceable to the National Institute of Standards and Technology. The test equipment, instruments and devices shall have current calibration stickers indicating date of calibration, deviation from standard, name of calibration laboratory and technician, and date of next recalibration.

2.02 PRODUCT DATA

A. The following information shall be provided in accordance with Division 1: 1. Defects: Notify the Owner of any material or workmanship found defective

within 24 hours of discovery. 2. Short circuit analysis and protective device curves. 3. Test reports: Provide the report required in NETA ATS-2013. Results shall be

placed on the forms specified in this Section. Test reports shall also be part of the operation and maintenance manuals.

PART 3 - EXECUTION

3.01 TESTING

A. GENERAL 1. Ensure that all testing performed is in strict conformance with the electrical

acceptance tests specified in this specification. Contact the Owner 10 days prior to the testing to allow witnessing of all tests.

2. The test measurements shall be recorded on specific forms for the subject test.

3. Acceptance Testing shall be per ANSI/NETA ATS 2013. Provide testing data sheet for the following: a. Switchboard assemblies. b. Transformers – Small Dry-type, air cooled (600 VAC and below, 30 kVA

and larger) c. Transformers – Liquid-Filled d. Cables – Low voltage (600 VAC maximum)


16015 - 3 Testing of Electrical Systems CNG Fueling Station

e. Cables – Medium-Voltage f. Switches, Medium-Voltage g. Active Harmonic Filters h. Circuit breakers –

1) Low voltage (Insulated Case/Molded Case) 2) Power Circuit Breakers

i. Instrument Transformers j. Metering and Monitoring Equipment k. Grounding Systems l. Ground Fault Protection Systems m. Rotating Machinery n. Motor Control Centers o. Adjustable Frequency Drive Systems p. Surge Protective Devices q. Uninterruptable Power Supply r. Fiber-Optic Cables

4. Maintenance Testing shall be per ANSI/NETA MTS 2015. Provide testing

data sheet for the following: a. Main Electrical Building:

1) 1- 12kV Power Lynx Switchgear 2) 10- Eaton CH 150 VCP-750 circuit breakers 3) 9- GE 760/737 Relays 4) 1- GE G30 Generator Management Relay 5) 3- 15kV Drawout Voltage Transformers

b. 12kV Ponds Switchgear: 1) 1- 12kV IEM Switchgear 2) 1- 1200 15kV GE Power Vac Breaker 3) 2- SEL 501 Dual Universal Overcurrent Relay 4) 1- VT’s CPT 15kV Drawout Control Power Transformer 5) 2- 15kV rated Load Interrupter Switch

B. FUNCTIONAL CHECKOUT: 1. Functional testing shall be performed in accordance with the requirements of

this specification. Prior to functional testing, all protective devices shall be adjusted and made operative. Prior to energizing the equipment, perform a functional checkout of the control circuits. Checkout shall consist of energizing each control circuit and operating each control, alarm or malfunction device and each interlock in turn to verify that the specified action occurs. Submit a description of proposed functional test procedures prior to the performance of functional checkout.

2. Verify that motors are connected to rotate in the correct direction. Verification may be accomplished by momentarily energizing the motor after confirming that neither the motor nor the driven equipment will be damaged by reverse operation

END OF SECTION

Testing of Electrical Systems CNG Fueling Station



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16020 - 1 ArcFlash Analysis, Short Circuit Study and Protective Device Coordination Report

CNG Fueling Station

SECTION 16020

ARC FLASH ANALYSIS, SHORT CIRCUIT STUDY AND PROTECTIVE DEVICE COORDINATION REPORT

PART 1 - GENERAL

1.01 SUMMARY

A. SCOPE: This section specifies the preparation of a Power System Study Report using PowerTools SKM software. The report shall include arc flash analysis, short circuit and coordination studies for all voltage levels of the electrical power system. The “electrical power system” starts at and includes the 12.5kV utility feed from the PG&E. Refer to the single-line diagrams of this Contract for details of the electrical power system. Provide in the report an evaluation of the electrical power system and the model numbers and settings of the protective devices for the entire system. Arc flash analysis shall include the method and recommendation in determining proper Personal Protective Equipment (PPE) and proper labeling of equipment as specified in this section. Provide equipment arc flash warning labels.

B. SPECIFICATIONS REFERENCED 1. 01300 2. 16010





Reference Title IEEE 141 Recommended Practice for Electric Power

Distribution for Industrial Plants

IEEE 242 Recommended Practice for Protection and Coordination of Industrial and Commercial Power Systems

NFPA 70E Electrical Safety in the Workplace

NFPA 70 National Electrical Code

IEEE 1584 IEEE Guide for Performing Arc-Flash Hazard Calculations

ArcFlash Analysis, Short Circuit Study and Protective Device Coordination Report CNG Fueling Station



B. QUALIFICATIONS: 1. Prepared by the manufacturer of the electrical equipment or by an electrical

testing service or an engineering company which is regularly engaged in power system studies.

2. All calculations shall be prepared by or prepared under direct supervision of a Washington State registered professional electrical engineer.

C. CERTIFICATION: Power System Study Report shall be stamped and signed by a California registered professional electrical engineer.

1.03 SUBMITTALS

A. PROCEDURES: Section 01300.



2. Qualifications of the entity conducting the Power System Study. 3. Short Circuit Analysis and recommended breaker and relay setting selections

in coordination with Section 16010. 4. Electronic copies of power study software models with associated electronic

library files. 5. Submit a draft report to the Owner 21 days after receiving all electrical

distribution system submittal data and feeder lengths. Approval of submittals shall be contingent on the results of the Power System Study Report.

6. SCOPE OF EQUIPMENT: Contractor shall provide a short circuit and protective device coordination study and arc flash analysis for phase and ground faults for the entire electrical distribution system. The study shall provide labeling that conforms to the latest version of NFPA 70E and the National Electric Code.

PART 2 - PRODUCTS

2.01 POWER SYSTEM STUDY REPORT

A. Prepare a Power System Study Report summarizing the short circuit and coordination study, arc flash analysis and conclusions or recommendations which may affect the integrity of the electric power distribution system. The model and report shall reflect the project naming convention.

B. As a minimum, include the following in the report: 1. Equipment manufacturer’s information used to prepare the study. 2. Assumptions made during the study. 3. Short circuit calculations listing short circuit levels at each bus. 4. Evaluation of the electrical power system and the model numbers and

settings of the protective devices associated with the system. 5. Time-current curves including the instrument transformer ratios, model

numbers of the protective relays, and the relay settings associated with each breaker.

6. Comparison of short circuit duties of each bus to the interrupting capacity of the equipment connected to that bus.



CNG Fueling Station

7. Analyze the short circuit, protective device coordination, and arc flash calculations and highlight any equipment that is determined to be underrated or causes an abnormally high incident energy calculation. Propose approaches to reduce the energy levels.

8. Summarize the arc flash study and conclusions or recommendations which may affect the integrity of the electric power distribution system.

9. ONE-LINE DIAGRAMS: a. Location and function of each protective device in the system, such as

relays, direct-acting trips, fuses, etc. b. Type designation, current rating, range or adjustment manufacturer’s

style and catalog transformers. c. Power, voltage ratings, impedance, primary and secondary connections

of all transformers. d. Nameplate ratings of all motors and generator with their subtransient

reactances. e. Transient reactances of generator and synchronous reactances of

generator. f. Sources of short circuit elements such as utility ties, generators, and

induction motors. g. All significant circuit elements such as transformers, cables, breakers,

fuses, reactors, etc. h. Standby as well as normal switching conditions. i. Calculated 3-phase and single-line-ground fault currents at each bus j. Calculated X/R ratio at each bus k. Calculated incident energy level at each bus l. Hazard Risk Category at each bus

2.02 SHORT CIRCUIT STUDY

A. As a minimum, include the following: 1. CALCULATIONS:

a. Determine the paths and situations where short circuit currents are the greatest. Assume bolted faults and calculate the 3-phase and line-to-ground short circuits of each case.

b. Calculate the maximum and minimum ground-fault currents. c. Model variable frequency drives and Solid-State-Soft Starters and

include by-pass switches. d. Where the calculated available fault current is higher than the device

ratings determine if a Series-rated system exists. Where series-rated systems have been identified provide labeling per NEC Article 110.22

e. Provide labeling at each separately derived system indicating calculated available fault current per NEC Article 110.24

f. A copy of the SKM “Device Evaluation Comprehensive Branch Report”. Generate report after an “Equipment Evaluation” analysis has performed using the following settings: 1) Study Result: Balanced 2) Device Type: Protective Devices 3) Fault Type: Bus 4) Fault Study: Comprehensive




2.03 COORDINATION STUDY

A. As a minimum, include a 17”x11” drawing which includes protective device coordination analysis (TCC) and associated single line. The TCC shall be shown on a 5-cycle, log-log graph background and include: 1. Time-current curve for each circuit breaker, protective relay, or fuse showing

graphically that the settings will allow protection and selectively within Industry standards. Identify each curve and specify the tap and time dial setting. Any circuit protective device that has programmable characteristics shall be included in the coordination study.

2. Time-current curves for each device to be positioned for maximum selectivity to minimize system disturbances during fault clearing. Where selectivity cannot be achieved, notify the Owner as to the cause.

3. Time-current curves and points for cable and equipment damage. 4. Circuit interrupting device operating and interrupting times. 5. Indicate maximum fault values on the graph.

2.04 ARC FLASH ANALYSIS

A. As a minimum, include the following: 1. CALCULATIONS:

a. For each major part of the electrical power system, determine the following: 1) Flash hazard protection boundary. 2) Limited approach boundary. 3) Restricted approach boundary. 4) Prohibited approach boundary. 5) Incident energy level. 6) PPE hazard/risk category. 7) Type of PPE required.

b. Produce arc flash warning labels. c. A copy of the SKM “Arc Flash_IEEE 1584 Report”. Generate report

after an “Arc Flash Evaluation” analysis has performed using the following settings: 1) Standard: IEEE 1584 2) Flash Boundary Calculation Adjustments: Use 1.2 cal/cm^2 3) ≤ 240 V: Report Calculated Values From Equations 4) Units: English 5) Distance and Boundary: inches

PART 3 - EXECUTION

3.01 GENERAL

A. Perform the studies using actual equipment data from the equipment and devices that are provided by the Contractor and Puget Sound Energy. The Contractor is responsible to gather all field information for the short circuit and coordination studies. Where the report or study is conducted on equipment that is not installed, the short circuit report and the coordination study shall be completely redone at the Contractor’s expense.



CNG Fueling Station

3.02 IMPLEMENTING SETTINGS AND ARC FLASH SIGN INSTALLATION

A. The Contractor shall implement the protective device coordination study settings on equipment as required in Section 16010, based on the Owner’s accepted Protective Device Coordination Report specified herein and submit a final amended report of the Record As-Built electrical equipment protective device settings subsequent to start-up and testing.

B. The Contractor shall work with the entity preparing the Power System Study Report for implementing the Arc Flash Hazard sign installation requirements for electrical equipment as specified in NEC Article 110.16 and NFPA 70E.

END OF SECTION




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16110 - 1 Raceway, Fittings, and Supports CNG Fueling Station

SECTION 16110

RACEWAYS, FITTINGS, AND SUPPORTS

PART 1 - GENERAL

1.01 Summary

A. Scope: This section provides specifications for all raceways, wire ways, raceway supports, cable trays and concrete encased ducts.

B. Type: All raceways shall be polyvinyl chloride (PVC) coated rigid galvanized steel, Robroy Plasti-Bond II or equal, conduit unless otherwise noted in Conduit Tables

1.02 References

A. All work specified herein shall conform to or exceed the applicable requirements of the referenced portions of the following publications to the extent that the provisions thereof are not in conflict with other provisions of these specifications.

Reference Title

ANSI C80.1 Electrical Rigid Steel Conduit

UL 1 Flexible Metal Conduit

UL 5 Surface Metal Raceway and Fittings

UL 6 Electrical Rigid Metal Conduit – Steel

UL 514B Conduit, Tubing and Cable Fittings

UL 651 Schedule 40 and 80 Rigid PVC Conduit and Fittings

NEMA RNI-2005 PVC Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit

NEMA TC-2-2003 Electrical PVC Tubing and Conduit

NEMA TC-3-2004 PVC Fittings for Use With Rigid PVC Conduit and Tubing

ANSI/UL 467 Grounding and Bonding Equipment

NEC National Electric Code, latest edition

1.03 Submittals

A. Submittals shall comply with the provisions set forth in Sections 01330 and 16010. Submittals shall include the following data, drawings, and description of materials. 1. Manufacturer and manufacturer's type and designations for each equipment item 2. List of construction material for all conduits, fittings, supports and accessories 3. The Contractor shall furnish copies of the manufacturer’s certified test reports for

the material being supplied to establish compliance with NEMA RN-1

1.04 Quality Assurance

A. Performance and Design Requirements: The conduits and fittings shall be premium quality and suitable for installation in wastewater facilities. The PVC used for Schedule 40/80

Raceway, Fittings, and Supports CNG Fueling Station



conduits and the PVC coating on rigid galvanized steel conduit shall be made from virgin material.

B. Inspection: All ducts shall be inspected by the Engineer prior to backfill. The Engineer shall inspect for drainage slope, spacers, conduit condition, and joints.

C. All equipment furnished by the Contactor shall be listed by and bear the label of Underwriters’ Laboratories, (UL) or of an independent testing laboratory acceptable to the Owner.

PART 2 - PRODUCTS

2.01 Manufacturers

A. The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired only.

2.02 Equipment and Materials

A. All raceways shall be PVC coated rigid galvanized steel conduit unless otherwise indicated on the drawings or in these specifications. With the exception of raceways with non-linear loads, underground raceways shall be polyvinyl chloride (PVC) Schedule 40, within duct banks without concrete caps. Underground raceways with non-linear loads shall be PVC coat rigid steel conduits. Raceways installed in stud walls or above suspended ceilings shall be electrical metallic tubing (EMT). All raceways installed in exposed locations shall be rigid galvanized steel conduit with a PVC bonded coating and lining. Flexible metal conduit shall be employed for connections to lighting fixtures. Final raceway runs to electrical equipment on machinery requiring flexibility or that is subject to vibration shall be liquid-tight flexible metal conduit. All fittings and supports installed in exposed locations shall be PVC coated. Minimum size of all conduits shall be 3/4-inch.

B. Rigid Steel Conduit 1. Comply to Underwriter's Laboratories UL-6 specification, ANSI C80.1-77 and

Federal specification WW-C-581E (77 APR 04) or latest revisions. Rigid steel conduit shall be zinc coated both inside and outside after fabrication by hot-dip galvanizing. The threads shall also be hot-dip galvanized.

2. Use rigid steel conduit, including bushings, couplings, elbows, nipples, and other fittings, galvanized by hot-dipping, and meeting the requirements of ANSI C80.1 and ANSI C80.4, UL.

3. Do not use setscrew type couplings, bushings, bends, nipples, and other fittings, unless approved by the ENGINEER or the INSPECTOR. Factory bends are not permitted unless approved by the ENGINEER or the INSPECTOR. Conduit bending radius shall not be less than the minimum cable bending radius of the cable to be installed.

C. PVC Schedule 40 and Schedule 80 Conduit: 1. Nonmetallic conduit shall be high impact polyvinyl chloride (PVC), unless otherwise

noted in this Specification Section or where shown otherwise on the contact drawings. The nonmetallic conduit shall be corrosion resistant. Minimum tensile strength shall be 6000 psi, and minimum compressive strength shall be 9000 psi. The material shall have a smoke emission rate of not more than 5.1 grams/100 grams by the Arapahoe smoke chamber test.



2. Use rigid PVC conduit, UL listed for concrete-encased, underground direct burial, concealed and direct sunlight exposed use, and UL listed and marked for use with conductors having 90 degrees C insulation. Use conduits, couplings, bushings, elbows, nipples, and other fittings meeting the requirements of NEMA TC 2 and TC 3, Federal Specification W-C-1094, UL, NEC, and ASTM specified tests for the intended use.

D. PVC Coated Rigid Steel 1. PVC coated conduit shall be hot-dip galvanized including the threads. The interior

and exterior surfaces shall be coated with 2 mils thick urethane. The exterior of the conduit shall be PVC coated to a minimum 40-mil thickness. The PVC coating shall be permanently bonded to the conduit. The coating shall have a minimum tensile strength of 3500 psi. The interior shall be coated with a urethane coating no more than 7 mils thick.

2. A PVC coated coupling shall be furnished with each length of conduit. The PVC sleeve of the coupling shall equal the outside diameter of the coated conduit and shall extend 1-1/2 inches from each end of the coupling.

3. Prior to coating, the galvanized conduits and fittings shall be UL listed. Use PVC coated fittings with the same interior and exterior coating requirements. PVC coated fittings and sleeves shall be completely watertight to prevent moisture from penetrating the interior of the conduits and fittings.

4. The PVC coating shall be resistant to ultra-violet rays when installed outdoors. The conduit and fittings shall meet all the requirements of NEMA RN-1 1989.

E. Flexible Metal Conduit 1. Flexible metal conduit shall be formed from spirally wound galvanized steel strip

with successive convolutions that are securely interlocked. Minimum size of the flexible metal conduit shall be 3/4 inch. Fittings shall be of the compression type. Lengths shall not exceed 60 inches. Flexible metal tubing shall include a code size insulated green ground conductor.

F. Flexible Metal Conduit, Liquid-Tight 1. Use UL listed liquid-tight flexible metal conduit consisting of galvanized steel

flexible conduit covered with an extruded PVC jacket and terminated with nylon bushings or bushings with steel or malleable iron body and insulated throat and sealing O-ring.

2. Provide external grounding connector and appropriately sized grounding conductor to assure ground continuity.

3. Minimum size shall be 2 inch.

G. Wireways 1. All wireways and auxiliary gutters shall be JIC sectional flange oil-tight type with

hinged covers. Minimum size shall be 8 inches by 8 inches unless otherwise noted. All wireways shall be painted.

2. Provide outdoor, rain-tight steel-enclosed wireway and auxiliary gutter where indicated. Utilize wireways and fittings that are UL listed, and have a cover that can easily be removed. Manufacturers and types: Square D Square-Duct; General Electric Type HS; or equal.

H. Pulling Tape – pulling conductors into Conduits 1. Flat, woven, polyester tape used for installing fiber optic, copper, and coaxial

cables in underground conduit. Tape shall have the following characteristics: a. Lubricated for easy installation and reduced friction.




b. Printed with sequential footage markings. c. 2,500 pound tensile strengths.

I. Ducts: 1. Ducts shall be PVC, Type EB, UL listed for concrete encased burial, conforming to

NEMA Standard TC6 and UL 651A, and rated at 90°C. Base and intermediate spacers shall be interlocking plastic type made for the specific sizes of ducts used. Duct spacing shall be 7-1/2-inch center-to-center.

2.03 Components and Accessories

A. Fittings in Hazardous Areas: In hazardous areas, use only fittings approved for the atmosphere involved.

B. Fittings for seismic area: When conduits penetrate from the earth to a solid manmade structure, expansion/deflection couplings shall be installed for a 4” deflection. 1. Use Cooper Type XJGD series expansion/deflection couplings and expansion

joints or equal for rigid metal conduits.

C. Use cable sealing fittings forming a watertight nonslip connection to pass cords and cables into conduit. Size cable sealing fitting for the conductor OD. For conductors with OD's of ½-inch or less, provide a neoprene bushing where the conductor enters the connector. Use Crouse-Hinds CGBS, Appleton CG Series, or equal, cable sealing fittings.

D. Fittings for Rigid Steel 1. Fittings used with rigid galvanized steel conduit shall be hot-dip galvanized.

Locknuts shall be extra heavy galvanized steel for sizes through 2 inches. Locknuts larger than 2 inches shall be galvanized malleable iron. Bushings shall be galvanized malleable iron with insulating collar. Grounding bushings shall be of the locking type and shall be provided with feed-through compression lugs for securing the ground cable. Unions shall be galvanized ferrous alloy types UNF or UNY. Thread-less fittings shall not be utilized with rigid galvanized steel conduits.

2. Expansion fittings in embedded runs shall be of the watertight type and shall be provided with an internal bonding jumper. The expansion material shall be neoprene and shall allow for 3/4-inch movement in any direction.

3. Use insulated throat bushings of metal with integral plastic bushings rated for 105 degrees C.

4. For insulated throat bushings for rigid steel conduit, use Thomas & Betts Nylon Insulated Metallic Bushings, or O.Z. Gedney Type B, or equal.

5. Use Myers Scru-Tite, or equal hubs for rigid steel conduit. 6. Use conduit bodies for rigid steel conduit of metal and sized as required by the

NEC (NFPA 70-2008). Use Appleton Form 35 threaded Unilets; Crouse-Hinds Mark 9 or Form 7 threaded condulets; Killark Series O Electrolets; or equal, for normal conduit bodies for rigid steel conduit. Where conduit bodies for rigid steel conduit are required to be approved for hazardous (classified) locations, use conduit bodies manufactured by Appleton, Crouse-Hinds, or Killark, or equal.

7. Use only couplings for rigid steel conduit supplied by the conduit manufacturer. 8. Use Appleton Type EYF, EYM, or ESU; Crouse-Hinds Type EYS or EZS; Killark

Type EY or EYS; or equal, sealing fittings for rigid steel conduit. Where condensate may collect on top of a seal, provide a drain by using Appleton Type SF Crouse-Hinds Type EYD or EZD, or equal Drain Seal.

9. Use Appleton Type ECDB, Crouse-Hinds ECD, or equal drain fittings for rigid steel conduit.



E. Fittings for PVC Conduit 1. Fittings used with PVC conduits shall be of the PVC solvent-weld type and shall be

of the same material as the conduit. 2. Expansion fittings shall be provided as recommended by the manufacturer.

F. Fittings for PVC Coated Rigid Steel Conduit 1. Fittings with PVC coated rigid steel conduit shall be PVC coated in a manner

similar to the conduit. The exterior of the fittings shall be coated with 2-mil thick urethane prior to the application of the 40-mil exterior PVC coat. Interior of the fittings shall have a 2-mil urethane finish. The fittings shall have ribbed finish to assist in the installation of fittings.

2. Thread-less fittings shall not be used with PVC coated rigid steel conduit. 3. Bushings and ground bushings shall be as specified for rigid galvanized steel

conduits.

G. Fittings for Flexible Metal Conduit 1. Fittings used with flexible metal conduit shall be compression type, cadmium-plated

malleable iron body with locknut and bushing 2. Where applicable, 45- and 90-degree fittings shall be used

H. Fittings for Liquid-Tight Flexible Conduit 1. Fittings used with liquid-tight conduit shall have cadmium-plated malleable iron

body and gland-nut, brass grounding ferrule threaded to engage conduit. These fittings shall also use spiral and "O" ring seals around the conduit, the box connection and insulated throat. The insulated throat connectors for liquid-tight flexible metal conduit of metal will have an integral plastic bushing rated for 105 degrees C, and of the long design type extending outside of the box or other device at least 2-inches.

2. Use Thomas & Betts Super-Tite Nylon Insulated Connectors or equal 3. Where applicable, 45- and 90-degree fittings shall be used

I. Raceway Supports 1. General: Raceway support systems shall be designed to provide a factor of safety

of no less than five. 2. Conduit Supports: Conduit supports shall be one-hole galvanized malleable iron

pipe straps used with galvanized clamp backs and nesting backs where required. When used with PVC coated rigid steel conduit, the conduit supports shall be 40 mils thick PVC coated.

3. Ceiling Hangers: Ceiling hangers shall be adjustable galvanized carbon steel, PVC coated 40 mils thick, pipe hangers. Straps or hangers of plumber's perforated type will not be acceptable. Hanger rods shall be 2-inch minimum galvanized all-thread rod and shall meet or exceed ASTM A193-B7 and ASME Boiler and Pressure Vessel Code specifications. Trapeze, rod type hangers shall not be loaded in excess of 700 pounds per rod. Where loading exceeds this value, rigid frames shall be provided.

4. Racks: Racks shall be constructed from framing channel. Channels and all associated hardware shall be steel, hot-dip galvanized after fabrication of the channel. Field cuts shall be painted with zinc-rich paint. Channels attached directly to building surfaces shall be 14-gage minimum material 1-5/8 inches wide by 13/16 inch deep. All other channels shall be 12-gage minimum material 1-5/8 inch wide by 1-5/8 inch minimum depth. Racks shall be designed to limit defection to 1/360 of span. All exposed ends of framing channel shall be covered with




manufacturer's standard plastic inserts. The racks shall be PVC coated to 40 mil thickness.

J. Raceway Tags 1. Provide permanent, nonferrous metal markers with raceway designations pressure

stamped, embossed, or engraved onto the tag. 2. Tags relying on adhesives or taped-on markers are not acceptable. 3. Attach tags to raceways with noncorrosive wire.

K. Warning Tape: 1. Provide electrical warning tape in duct bank and trenches as shown on the

Drawings. The tape shall be 6 inches wide, red with black lettering stating "CAUTION BURIED ELECTRIC LINE." The tape shall be made of 6-mil polymer with 36,000 psi tensile strength.

2.04 Conduit Sealants

A. Moisture Barrier Types: Sealant shall be a non-toxic, non-shrink, non-hardening, putty type hand applied material providing an effective barrier under submerged conditions.

B. Fire Retardant Types: Fire stop material shall be a reusable, non-toxic, asbestos-free, expanding, putty type material with a 3-hour rating in accordance with UL 1479. Provide products indicated by the manufacturer to be suitable for the type and size of penetration.

PART 3 - EXECUTION

3.01 Preparation

A. In addition to the provisions of the Division 01 – General Requirements, and Division 16 "Electrical," prior to installation, store all products specified in this section in a dry location.

B. Minimum Raceway Size: Use no circular raceway less than 3/4-inch.

C. Preparation for pulling in conductors: 1. Do not install crushed or deformed raceways. Avoid traps in raceways where

possible. Take care to prevent the lodging of plaster, concrete, dirt, or trash in raceways, boxes, fittings, and equipment during the course of construction. Make raceways entirely free of obstructions or replace them. Ream all raceways, remove burrs, and clean raceway interior before introducing conductors or pull wires.

2. Immediately after installation, plug or cap all raceway ends with watertight and dust-tight seals until the time for pulling in conductors.

3.02 Installation

A. All conduits containing conductors connected to the input or output of a non-linear load, such as a variable frequency drive, shall be rigid steel, PVC coated.

B. Unless otherwise indicated, all underground conduits shall PVC coated rigid steel.

C. Each conduit shall be identified at each end with a permanent non-corrosive metal marker. Designation shall be pressure stamped into the tag. The conduit identification shall be the designated conduit number as shown.



CONDUIT USE TABLE 1

Outside Buildings Transition

Circuit Type

Exposed

Buried In Soil

Duct Bank Encased In Concrete

Within 5 Feet of Building

Power & 120 Vac Control

GRS PVC-80* PVC –Type EB* PVC Coated GRS

Signal (subject to RF) PVC Coated GRS PVC Coated GRS GRS* PVC Coated GRS

* Provide ground wire sized per NEC requirements for all circuits. ** PVC coated GRS in wet wells, etc., that are both hazardous and/or corrosive, otherwise, GRS.

D. Location, Routing, and Grouping: 1. Conceal or expose raceways as indicated. Group raceways in same area together.

Locate raceways at least 12-inches away from parallel runs of heated piping for other utility systems.

2. Run exposed raceways parallel or perpendicular to walls, structural members, or intersections of vertical planes to provide a neat appearance. Follow surface contours as much as possible. Conduit supports spaced not more than 8 feet apart.

3. No conduit shall approach closer than 6 inches to any object operating above the rated temperature of its cable temperature.

4. Conduit supported directly from the concrete structure shall be spaced out at least 1/4 inch using one-hole hot-dip galvanized malleable iron straps with nesting backs or, if three or more conduits are located in a parallel run, they shall be spaced out from the wall approximately 5/8 inch to 1 inch by means of framing channel. Runs of individual conduit suspended from the ceiling shall be supported with galvanized wrought steel pipe hangers. Where three or more conduits are suspended from the ceiling, suitable steel racks shall be constructed subject to submittal to the Engineer for review.

5. Conduit rack and tray supports shall be secured to concrete walls and ceilings by means of cast-in-place anchors in accordance with the structural section of these specifications. Individual conduit supports may be similar to cast-in-place anchors, die-cast, rustproof alloy expansion shields or cast flush anchors. Wooden plugs, plastic inserts or gunpowder-driven inserts shall not be used as a base to secure conduit supports.

6. All conduit entering sheet steel boxes or cabinets shall be secured by locknuts on both the interior and exterior of the device and shall have an insulating bushing constructed over the conduit end. All conduit entering NEMA 12 boxes shall be terminated with a rain-tight hub having an insulated liner. All surface mounted cast boxes and plastic enclosures shall have threaded hubs. All joints shall be made with standard threaded couplings or specified unions. Metal parts of plastic control stations and coated boxes shall be bonded to the conduit system. Running threads shall not be used in lieu of conduit nipples, nor shall excessive thread be used on any conduit. The ends of all conduit shall be cut square, reamed and threaded with straight threads. Rigid steel conduit shall be made up tight and without thread compound. Male threads on rigid steel conduit shall be coated with electrically conductive zinc rich paint. Threading shall be done with dies, with the guide sleeve




bored out to allow for increased diameter or the PVC coated conduit. Conduit shall be made with the next larger bend or next larger shoe bushed for proper fit.

7. Avoid obstruction of passageways. Run concealed raceways with a minimum of bends in the shortest practical distance considering the building construction and other systems.

8. In block walls, do not run raceways in the same horizontal course with reinforcing steel.

9. In outdoor, underground, or wet locations, use watertight couplings and connections in raceways. Install and equip boxes and fittings so as to prevent water from entering the raceway.

10. Paint all threads of galvanized conduits with UL approved zinc-rich paint or liquid galvanizing compound before assembling. Touch up after assembly to cover nicks or scars.

11. Do not notch or penetrate structural members for passage of raceways except with prior approval of the Engineer or the Inspector.

12. Do not run raceways in equipment base foundations. 13. Locate above ground raceways concealed in poured concrete so that the minimum

concrete covering is not less than 1-1/2-inches. 14. Except at raceway crossings, separate raceways in slabs not less than six times

the raceway outside diameter 15. Raceways installed under slab floors shall lie completely under the slab with no

part of the horizontal run of the raceway embedded within the slab. 16. Install concealed, embedded, and buried raceways so that they emerge at right

angles to the surface. Provide support during pouring of concrete to ensure that raceways remain in position.

17. Allow a minimum of 7 feet headroom for conduit passing over walkways. 18. Communication and instrumentation conduits crossing power circuits shall be

separated from such circuits by the minimum distance stipulated by the IEEE standards.

19. Welding, brazing or otherwise heating of the conduit is not allowed. Plumber's perforated tape shall not be used for any purpose.

20. Where required for ease of pulling and as necessary to meet code, the Contractor shall provide cast junction or pullboxes even though not shown on the drawings. The Contractor shall limit the number of equivalent 90-degree bends to three in any run between pull boxes. Runs shall be limited to 400 feet, less 100 feet for each equivalent 90-degree bend in the run. Bends and offsets shall be avoided where possible, but where necessary, shall be made with an approved hickey or conduit bending machine, or shall be factory preformed bends.

21. All conduit entering sheet steel boxes or cabinets shall be secured by locknuts on both the interior and exterior of the device and shall have an insulating bushing constructed over the conduit end. All conduit entering NEMA 12 boxes shall be terminated with a rain-tight hub having an insulated liner. All surface mounted cast boxes and plastic enclosures shall have threaded hubs. All joints shall be made with standard threaded couplings or specified unions. Metal parts of plastic control stations and coated boxes shall be bonded to the conduit system. Running threads shall not be used in lieu of conduit nipples, nor shall excessive thread be used on any conduit. The ends of all conduit shall be cut square, reamed and threaded with straight threads. Rigid steel conduit shall be made up tight and without thread compound. Male threads on rigid steel conduit shall be coated with electrically conductive zinc rich paint. Threading shall be done with dies, with the guide sleeve



bored out to allow for increased diameter or the PVC coated conduit. Conduit shall be made with the next larger bend or next larger shoe bushed for proper fit.

22. Conduit constructed in concrete slabs or walls shall be placed in the middle third of the slab or wall. Conduit rising through a slab shall be protected by a formed concrete pad approximately 6 inches in diameter and 4 inches above the finished floor, or the conduit shall come up through the equipment pad. Clearances equal to the conduit trade diameter, but not less than 1-1/2 inches, shall be maintained between conduits encased in slabs. Clearances of less than 1-1/2 inches at conduit crossing and terminating locations may be allowed at the discretion of the Engineer.

23. Flexible conduit shall not be used as a general purpose raceway but shall be provided in locations requiring flexibility with the approval of the Engineer.

24. Liquid-tight conduit shall be used for all motor connections as detailed. Where flexibility is required for electrical raceways on equipment, liquid-tight conduit shall be used in accordance with JIC standards, these specifications, and the local codes. The maximum length of flexible, liquid tight conduit shall be 36-inches. The terminating fitting and sealing shall be as shown in the motor details.

25. The Contractor shall exercise the necessary precautions to prevent the lodging of dirt, concrete or trash in the conduit, fittings and boxes during the course of construction.

E. Support: 1. Support raceways at intervals not exceeding NEC requirements unless otherwise

indicated. Support multiple raceways adjacent to each other by ceiling trapeze. Support individual raceways by wall brackets, strap hangers, or ceiling trapeze, fastened by toggle bolts on hollow masonry units, expansion shields on concrete or brick, and machine screws or welded thread studs on steelwork.

2. Threaded studs driven in by a powder charge shall not be accepted. 3. Support all raceways from building structural members only. 4. Do not use nails anywhere or wooden plugs inserted in concrete or masonry as a

base for raceway or box fastenings. Do not weld raceways or pipe straps to steel structures. Do not use wire in lieu of straps or hangers.

F. Bends: 1. Make changes in direction of runs with symmetrical bends. Make bends and

offsets of the longest practical radius. Do not heat metal raceways to facilitate bending.

2. Make bends in parallel or banked runs of raceways from the same center or centerline so that bends are parallel and of neat appearance. Make field bends in parallel runs.

3. For PVC conduits, use factory made elbows for all bends 30 degrees or larger. Use acceptable heating methods for forming smaller bends.

4. Make no bends in flexible conduit that exceed 90 degrees or allowable bending radius of the cable to be installed or that significantly restricts the conduits flexibility.

G. Bushing and Insulating Sleeves: 1. Where metallic conduit enters metal equipment enclosures through conduit

openings, install a bonding bushing on the end of each conduit. Install a bonding jumper from the bushing to any equipment ground bus or ground pad.

2. If neither exists, connect the jumper to a threaded bolt connection to the metallic enclosure.




3. Use manufacturer's standard insulating sleeves in all metallic conduits or insulated bushings terminating at an enclosure.

H. Expansion Joints: 1. Provide minimum of 2” expansion/deflection fittings for raceways crossing

expansion joints in structures or concrete slabs, or provide other suitable means to compensate for expansion, deflection, and contraction.

2. Provide for the high rate of thermal expansion and contraction of PVC conduit by providing PVC expansion joints as recommended by the manufacturer and as required for 2” deflection.

I. PVC Conduit: 1. Solvent weld PVC conduit joints with solvent recommended by the conduit

manufacturer. Follow manufacturer's solvent welding instructions and provide watertight joints.

2. Use acceptable PVC terminal adapters when joining PVC conduit to metallic fittings.

3. Use acceptable PVC female adapters when joining PVC conduit to rigid metal conduit.

J. PVC Coated Rigid Steel Conduit: 1. Install in strict accordance with the manufacturer's Instructions. 2. Touch up any damage to the coating with conduit manufacturer acceptable

patching compound. 3. PVC boot shall cover all threads. 4. Where belled conduits are used, bevel the un-belled end of the joint before joining.

Leave no metallic threads uncovered. 5. PVC coated conduit shall be tightened, with strap wrenches, and the plastic overlap

shall be coated and sealed in accordance with the manufacturer's recommendations. Pipe wrenches and channel locks shall not be used for tightening plastic coated conduits. All damaged areas shall be patched, using manufacturer's recommended material. The area to be patched shall be built up to the full thickness of the coating. Joints in multiple conduit runs shall be staggered.

6. Threading: a. Plasti-Bond can be threaded with any standard threading tool. Larger model

power threaders with open die heads require no modification beyond optional grip inserts for PVC coated conduit.

b. If a threader with a tight-fitting die head is to be used, like many hand-held models, it is necessary to machine out the interior diameter of the stationary guide approximately 12/100ths of an inch to allow for clearance of the PVC coating. Prior to machining the pipe guide take note of the sequence in which the dies are removed; then replace dies in the proper sequence.

c. If conduit is to be threaded manually it must be pencil cut before threading to enable the die teeth on the threader to engage the conduit. In the same manner as sharpening a pencil with a knife, cut away 1/4" of the exterior coating from the end to be threaded. This allows the pipe guide to ride up and over the PVC coating enabling the removal of the coating and threading in one operation.

d. Before threading, by any method, a series of cuts should be made in the PVC coating along the longitudinal axis of the conduit. The thread protector attached to one end of the conduit can be used to gauge the length of the cuts. Make a slit up one side of the thread protector with a knife and remove it



from the conduit. Push the thread protector over the cut end of the conduit to be threaded and place a mark on the PVC coating at the end of the protector. With a knife, cut around the circumference of the conduit at the mark, through the PVC coating, to the metal. This cut will indicate the starting point for the longitudinal cuts and it will give an even ending to the PVC coating removed during threading. The longitudinal cuts will allow the PVC coating to be removed in small pieces instead of long strips that can foul the die head causing the conduit to collapse.

e. Use a good quality thread cutting oil to flush away the metal and PVC chips. After threading use a degreasing spray to thoroughly clean the threads and the interior of the pipe. Use care not to contaminate the cutting oil with the degreasing spray. Degreasing is important in order to insure that the touch up compound will adhere to the unprotected steel. Bare steel is the most vulnerable area to corrosion in any conduit system, therefore, touch up compound must be used on all field cut threads and internal reams. These specially formulated interior and thread touch-up compounds are available in 4 ounce and quart cans. When an access fitting or coupling is attached to the newly threaded conduit a colored band red for Plasti-Bond), will form at the end of the sleeve. This indicates proper installation procedures have been followed

K. Penetrations: 1. Seal the interior of all raceways entering structures at the first box or outlet with

oakum or suitable plastic expandable compound to prevent the entrance into the structure of gases, liquids, or rodents.

2. Dry pack with non-shrink grout around raceways that penetrate concrete walls, floors, or ceilings aboveground, or use one of the methods specified for underground penetrations.

3. Where an underground conduit enters a structure through a concrete roof or a membrane waterproofed wall or floor, provide an acceptable, malleable iron, watertight, entrance sealing device. When there is no raceway concrete encasement specified or indicated, provide such a device having a gland type sealing assembly at each end with pressure bushings which may be tightened at any time. When there is raceway concrete encasement specified or indicated, provide such a device with a gland type sealing assembly on the accessible side. Securely anchor all such devices into the masonry construction with one or more integral flanges. Secure membrane waterproofing to such devices in a permanently watertight manner.

4. Wherever conduits penetrate concrete wall panels to outdoors or as shown, the Contractor shall detail the required mountings. He shall locate and use a galvanized pipe sleeve for passage of the conduit. A compression type seal shall be used to form a complete watertight installation. The installation design shall be submitted to the Engineer.

5. Where an underground raceway without concrete encasement enters a structure through a non-waterproofed wall or floor, install a sleeve made of Schedule 40 galvanized pipe. Fill the space between the conduit and sleeve with a suitable plastic expandable compound, or an oakum and lead joint, on each side of the wall or floor in such a manner as to prevent entrance of moisture. A watertight entrance sealing device as specified may be used in lieu of the sleeve.

6. Where raceways penetrate fire-rated walls, floors, or ceilings, fire stop openings around electrical penetrations to maintain the fire-resistance rating




7. Raceways passing through roofs shall be flashed. 8. Provide conduit seals where required by Article 500 of the NEC.

L. Underground Conduits, Direct Burial raceways: 1. Remove entirely and properly reinstall all raceway installations not in compliance

with these requirements. 2. Do not use union type fittings underground. 3. Provide a minimum cover of 2-feet over all underground raceways unless otherwise

indicated. Warning tape as specified in Article 2.11A shall be placed no less than 12 inches above conduit and duct bank.

4. Do not backfill underground direct burial raceways until they have been inspected by the Engineer.

5. Warning Tapes: Bury warning tapes approximately 8-inches below grade and above all underground conduit runs or duct banks. Align parallel to and within 12-inches of the centerline of runs.

6. When the contract drawings indicate underground PVC conduits then a transition shall be provided. The transition shall be made from PVC Schedule 80 conduit to PVC coated rigid galvanized steel conduit at all stub-ups and when entering equipment. The transition shall consist of a PVC coated rigid galvanized conduit. Conduits shall be laid with a minimum grade of 2 inches per 100 feet from structure to manhole or from high point to manholes.

7. Ducts shall be of the dimensions and materials and with reinforcing as shown. They shall have a uniform continuous slope with no low points to entrap water. All duct runs shall be placed on an undisturbed excavated soil base wherever possible. Where duct runs pass through backfilled areas, the soil base shall be a backfill of loam, placed in layers. Each layer shall be solidly tamped or rolled, as required, to obtain complete compaction to the elevation and pitch of the bottom of the duct run shown. The compaction shall be as specified in the structural section of these specifications.

8. Plastic spacers shall be manufactured by the conduit supplier. Wire ties shall be made at each spacer location and shall be securely anchored. Duct runs shall be watertight. When the termination of duct is not detailed on the duct run drawing, a coupling shall be installed.

9. The ends of all conduits shall be suitably plugged, capped and protected from damage during construction. Ends of conduits which are not to be used for long periods shall be protected from dirt, rodents, etc., by plugging at the ends with wooden or manufactured plugs. A non-setting compound may be used on the plug to make it adhere to the conduit end. A 1/4-inch hole shall be drilled in the lower portion of the plug to provide drainage of the plugged conduit.

10. A No. 9 galvanized wire shall be pulled through each medium voltage and 480-volt power feeder conduit and a No. 12 wire shall be pulled through branch feeder conduits as the conduit sections are laid and the wire shall be securely fastened at each end of the finished duct run. When ducts are reserved for future use, the galvanized wire shall be replaced with a 5/8-inch nylon cord.

11. A galvanized wire shall always be attached to the rear end of the swab or mandrel to replace the wire being pulled out. When not in use, this wire shall be securely fastened at both ends of the duct.

12. Each conduit in a manhole, handhole, or pull box shall be identified with a stamped aluminum or brass tag bearing the conduit number. The tags shall be permanently attached to conduits by means of 316 stainless steel or nylon tie wrap. Install



conduit couplings and cap ends of all spare underground conduits at each handhole/manhole.

13. Each conduit shall be identified at each end with a permanent non-corrosive metal marker. Designation shall be pressure stamped into the tag. The conduit identification shall be the designated conduit number as shown.

14. Separation and Support: a. Separate parallel runs of two or more raceways in a single trench with

preformed, nonmetallic spacers designed for the purpose. Install spacers at intervals not greater than that specified in the NEC for support of the type raceways used, and in no case greater than 10-feet.

b. Support raceways installed in fill areas to prevent accidental bending until backfilling is complete. Tie raceways to supports, and raceways and supports to the ground, so that raceways will not be displaced when concrete encasement or earth backfill is placed.

15. Arrangement and Routing: a. Arrange multiple conduit runs substantially in accordance with any details

shown on the Drawings. Locate underground conduits where indicated on the Drawings.

b. Make minor changes in location or cross-section as necessary to avoid obstructions or conflicts. Where raceway runs cannot be installed substantially as shown because of conditions not discoverable prior to digging of trenches, refer the condition to the Engineer for instructions before further work is done.

c. Where other utility piping systems are encountered or being installed along a raceway route, maintain a 12-inch minimum vertical separation between raceways and other systems at crossings. Maintain a 12-inch minimum separation between raceways and other systems in parallel runs. Do not place raceways over valves or couplings in other piping systems. Refer conflicts with these requirements to the Engineer for instructions before further work is done.

d. Provide insulated grounding bushings on all metallic raceways entering manholes. Provide bell-ends flush with manhole walls on all nonmetallic raceways entering manholes.

e. In multiple conduit runs, stagger raceway coupling locations so that couplings in adjacent raceways are not in the same transverse line.

f. Provide markers at grade to indicate the direction of underground conduits provided under this Contract. Provide markers consisting of double-ended arrows, straight for straight runs and bent at locations where runs change direction. Provide markers at all bends and at intervals not exceeding 100-feet in straight runs. Use markers made of sheet bronze not less than 1/4-inch thick embedded in and secured to the top of concrete posts. Use markers not less than 10-inches long and 3/4-inch wide and marked ELECTRIC CABLES in letters 1/4-inch high incised into the bronze to a depth of 3/32-inch.

g. All conduits shall enter maintenance holes and structures at right angles. 16. Raceway Coating:

a. At couplings and joints, coat metallic underground direct-burial conduits with Koppers Bitumastic No. 505 or equal, or wrap with Scotchwrap No. 51, or equal plastic tape with 1/2-inch overlap.




17. Direct Earth Burial Conduit Zone Backfill Installation: a. Backfill material for the conduit zone of direct burial conduit trenches may be

selected from the excavated material if it is free from roots, foreign material, and oversized particles.

b. Use material with 3/4-inch maximum particle size and suitable gradation for satisfactory compaction. Remove material if necessary to meet these requirements.

c. Imported 3/4-inch minus gravel or sand may be used in lieu of material from the excavation.

d. After conduits have been properly installed, backfill the trench with specified material placed around the conduits and carefully tamped around and over them with hand tampers. Final, tamped conduit cover shall be 4-inches minimum.

18. Backfill Installation Above Conduit Zone of Direct Burial Conduit: a. Unless otherwise required in Section 02301“Earthwork”, Backfill material

above the conduit zone of direct burial conduit may be selected from the excavated material, if it contains no particles larger than 3-inches in diameter and is free from roots or debris. Imported material meeting these same requirements may be used in lieu of material from the excavation. Compact backfill in maximum 12-inch layers to at least 95 percent of the maximum density at optimum moisture content as determined by ASTM D 1557.

M. Wireways: 1. Mount wireways securely in accordance with the LAEC and manufacturer's

instructions. Locate removable cover or hinged cover on accessible vertical face of wireway unless otherwise indicated.

N. Empty Raceways 1. Certain raceways will have no conductors pulled in as part of this Contract. Identify

with tags at each end and at any intermediate pull point the origin and destination of each such empty raceway. Where a raceway has been identified with a name (number) in the Raceway Schedule, use that name on the tag in lieu of origin and destination. Provide a removable permanent cap over each end of each empty raceway. Mandrel and provide a nylon pull cord in each empty raceway.

O. Firestops: 1. The Contractor shall furnish adequate firestops and seals for cables, conduits,

trays, and wireways, etc., passing through building floors or wall openings. 2. Products which utilize intumescent compounds capable of being leached out by

water shall not be used. 3. Flamenastic 71A, Vimasco No. 1-A, or equal, shall be used for this purpose and

shall be applied in accordance with manufacturer's recommendations.

P. Painting 1. Paint raceway systems in accordance with and as specified in Section 09 96 00 -

Protective Coating Systems.

3.03 Field Quality Control

A. Provide raceway systems meeting or exceeding the requirements of the NEC.



3.04 Adjusting / Cleaning / Protection

A. Following installation, protect products from the effects of moisture, corrosion, and physical damage during construction. Keep openings in conduit and tubing capped with manufactured seals during construction.

END OF SECTION




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16120 - 1 Low Voltage Conductors, Wires and Cables CNG Fueling Station

SECTION 16120

LOW-VOLTAGE CONDUCTORS, WIRES AND CABLES

GENERAL

SUMMARY

SCOPE: This section specifies cables, conductors and fibers including: Stranded copper cables, conductors, and wire rated 600 volts insulation used for

power; lighting, analog, digital, or pulse signals and control circuits. Copper cables and coax cable rated 300 volt insulation used for data,

communication, and signaling. Fiber optic data cable used for data communication.

QUALITY ASSURANCE

REFERENCE STANDARDS: This Section incorporates by reference the latest revisions of the following


Unless otherwise specified, references to documents shall mean the documents in effect on the effective date of the Agreement. If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued.

Reference Title ASTM B3 Soft or Annealed Copper Wire

ASTM B8 Concentric-Lay-Stranded Copper Conductors, Hard, Medium- Hard, or Soft

ASTM B33 Tinned Soft or Annealed Copper Wire for Electrical Purposes

ICEA S-95-658 / NEMA WC70

Nonshielded 0-2kV Cables

NFPA 70 National Electric Code (NEC)

UL 44 Rubber-Insulated Wires and Cables

UL 83 Thermoplastic-Insulated Wires and Cables

ANSI X3.166 Information Systems--Fiber Data Distributed Interface (FDDI)-- Token Ring Physical Layer Medium Dependent (PMD)

EIA RS232D Interface Between Data Terminal Equipment and Data Circuit Terminating Equipment Employing Serial Binary Data Interchange

Low Voltage Conductors, Wires and Cables CNG Fueling Station



Reference Title EIA RS422

Electrical Characteristics of Balanced Voltage Digital Interface Circuits

EIA RS485 Electrical Characteristics of Generators and Receivers for Use in Balanced Digital Multipoint Systems

IEEE 802 IEEE Standards for Local and Metropolitan Area Networks: Overview and Architecture

IEEE 802.3 Information Processing Systems--Local and Metropolitan Area Networks--Part 3: Carrier Sense Multiple Access with Collision Detection (CSMA/CD Access Method and Physical Layer Specifications

IEEE 802.3k Supplement to ISO/IEC 8802-3, Carrier Sense Multiple Access with Collision Detection (CSMA/CD) Access Method and Physical Layer Specifications: Layer Management for 10 Mb/s Baseband Repeaters

IEEE 802.4 Information Processing Systems--Local Area Networks--Part 4: Token-Passing Bus Access Method and Physical Layer Specifications

ANSI/NFPA 72 Installation, Maintenance, and Use of Protective Signaling Systems

ANSI/NFPA 72H Testing Procedures for Signaling Systems

DEFINITIONS: The following types of signals may be used in systems included in this project: LOW LEVEL ANALOG: A signal that has a full output level of 100 millivolts or less.

This group includes thermocouples and resistance temperature detectors. DATA OR DIGITAL CODE: Coded information such as that derived from the output

of an analog to digital converter or the coded output from a digital computer or other digital transmission terminal. This type includes those cases where direct line driving is utilized, such as EIA RS422.

PULSE FREQUENCY: Counting pulses such as those emitted from speed transmitters.

HIGH LEVEL ANALOG: Signals with full output level greater than 100 millivolts but less than 30 volts, including 4-20 mA transmission.

MODULATED SIGNALS: Signals emanating from modems or low level audio signals. Normal signal level is plus 4 dBm to minus 22 dBm. Frequency range is 300 to 10,000 hertz.

DISCRETE EVENTS: Dry contact closures monitored by solid state equipment. If the conductors connecting to dry contacts enter enclosures containing power or control circuits and cannot be isolated from such circuits in accordance with NEC Article 725, this signal shall be treated as low voltage control.

LOW VOLTAGE CONTROL: Contact closures monitored by relays, or control circuits operating at less than 30 volts and 250 milliamperes.

HIGH LEVEL AUDIO SIGNALS: Audio signals exceeding plus 4 dBm, including loudspeaker circuits.



RADIO FREQUENCY SIGNALS: Continuous wave alternating current signals with fundamental frequency greater than 10 kilohertz.

SUBMITTALS

PROCEDURES: Section 013300

ACTION SUBMITTAL ITEMS FOR THIS SECTION: A copy of this Section, addendum updates included, with each paragraph check-

marked to indicate compliance or marked to indicate requested deviations from Section requirements.

Catalog cuts showing information of the conductors and cables to be supplied under this section.

Field test reports showing conductor and cable insulation resistance test results. Provide engineering pull calculations for all 600V main feeders run underground

outside building footprints.

PRODUCTS

GENERAL

UNSCHEDULED CONDUCTORS AND CABLES: With the exception of lighting, voice communication, paging, security and

receptacle circuits, the type, size and number of conductors shall be as specified on the drawings or schedules. 120/208V panel circuit conductors mentioned above that are unscheduled shall be sized by the Contractor in accordance with the breakers specified and the NEC to limit voltage drop to 3 percent. Minimum size of power, lighting, and receptacle circuits shall be 12 AWG. Number and types of communication, paging, and security cables shall be as required for the particular equipment provided. Power, lighting, and receptacle circuit conductors shall be provided in accordance with CABLESPEC "THWN," unless otherwise specified.

Where not specified on the Drawings, conductors and cables shall be sized in accordance with the National Electrical Code for the particular equipment served with the minimum size as specified herein. Unscheduled conductors shall be sized by the Contractor in accordance with NEC tables and to limit voltage drop to 3 percent.

Unscheduled conductors with insulation shall be provided in accordance with the CABLE SPECIFICATIONS in TABLE 2 according to the purpose.

CABLE SPECIFICATION SHEETS (CABLESPEC): General requirements for conductors and cables specified in this Section are listed on CABLESPEC sheets.

COLOR CODING

POWER AND CONTROL CABLES: Wire coloring shall conform to the color code shown in the table below. Insulation on phase conductors run in conduits sizes #10 AWG and smaller shall

be colored, #8 AWG and larger may have black insulation with plastic tape of the appropriate color from the table below.




Insulation on the grounded conductor (neutral) sizes #8 AWG and smaller shall be colored, #6 AWG and larger may have black insulation with plastic tape of white or gray in accordance with the table below.

Description 120/208V 277/480V Control

Phase A (Left) Black Brown --

Phase B (Center) Red Orange --

Phase C (Right) Blue Yellow --

Neutral White Gray White

Ground Green Green Green

Description 120/208V 277/480V Control

120 VAC Control -- -- Red

120 VAC Control Neutral -- -- White

DC Control (+) -- -- Blue

DC Control (-) -- -- Gray

Signal (+) -- -- Red

External Source -- -- Yellow

Computer/Signal Ground Green/yellow stripe

All control wiring in control panels or other enclosures that is powered from an

external source and is not disconnected by the control panel disconnect shall be terminated at a disconnecting terminal block upon entering the enclosure. The color of the wire shall then be changed to yellow to identify it as being powered from an external source. Provide identification nameplate on exterior of enclosure to indicate sources of external power.

All wiring in industrial machines and equipment shall be in accordance with NFPA 79. Notify owner of any deficiencies noted during installation.

Multi-conductor power cable colors shall be manufacturer’s standard. Cables sized No. 6 AWG and larger may be black with colored ¾-inch vinyl plastic

tape applied in 3-inch lengths around the cable at each end. The cables shall be tagged at terminations and in pull boxes, handholes and manholes.

SIGNAL AND DATA CABLES: Unless otherwise specified, cables shall be color coded black for common and red for positive for pairs, or black, red, and white for triads.

POWER AND CONTROL CONDUCTORS AND CABLE, 600 VOLT

SINGLE CONDUCTOR: Single conductor cable shall be stranded copper and shall be used in conduits for power and control circuits. Single conductor cable shall be provided in accordance with CABLESPEC “THWN” type of conductors unless otherwise specified.



MULTICONDUCTOR CABLE: Provide multi-conductor power cable and multi-conductor control cable where identified on the drawings. Multi-conductor cables shall be in accordance with CABLESPEC “MC” type cables.

PORTABLE CABLE: Cord shall be NEMA Type SOW-A flexible cord rated at -50 deg C to 105 deg C.

All cords shall contain an equipment grounding conductor. Cord shall be rated for use as a fully submersible cable.

Conductors: Bunch or rope stranded, uncoated annealed copper conforming to UL and CSA requirements. A suitable separator is applied over the conductor.

Insulation: Ethylene Propylene (EPDM) conforming to UL Standard 1581 and CSA requirements. Minimum average wall thickness is 45 mils for 14 AWG, 12AWG, and 10 AWG; and 50 mils for sizes 8 AWG through 2 AWG.

Color code: Insulation colored as follows: 2 Conductors - Black, White 3 Conductors - Black, White, Green 4 Conductors - Black, White, Red, Green 5 Conductors - Black, White, Red, Green and Orange

Cable assembly: The applicable number of insulated conductors are cable together with elastomeric fillers, as necessary, and with a suitable lay.

Jacket: Black or Yellow special thermosetting compound conforming to UL and CSA requirements.

Marking: Jacket surface is printed in accordance with requirements of UL, CSA and MSHA.

Portable cord for supply to permanent installations, such as pumps, cranes, hoists and portable equipment shall have a wire mesh cord grip of flexible stainless steel wire to take the tension from the cable termination. Weatherproof strain relief fittings shall be used for all connections. To prevent unnecessary strain on cords, 45-degree and 90-degree connectors shall be used where applicable. Flexible cords feeding submersible non-wicking neoprene construction.

Manufacturer shall be American Mustang, York Wire & Cable or equal.

GROUNDING WIRE: Ground wires, no. 1/0 AWG or larger tinned stranded bare copper cable. All

smaller ground wires shall be insulated with green color insulation

SIGNAL, DATA AND INSTRUMENTATION CABLES

A. GENERAL: Signal cable shall be provided for instrument signal transmission, alarm,

communication, and other circuits as specified. Circuit shielding shall be provided in addition to cable shielding.

Single circuit signal cable shall be provided in accordance with CABLESPEC "INS,". Multi-circuit signal cable shall be provided in accordance with CABLESPEC "INS/M".

Terminal blocks shall be provided at cable junction for running signal leads and shield drain wires. Each conductor shall be identified at such junctions. Shields shall not be used as a ground path. Shields shall be grounded at one end only. Refer to I drawings for grounding

location.




Signal, data, and communication cables shall be terminated and spliced on terminal strips properly mounted and labeled in accordance with this Section and Section 16010. No exceptions..

CABLE SPECIFICATION SHEETS (CABLESPEC): General requirements for conductors and cables specified in this Section are listed on CABLESPEC sheets in Paragraph 3.07.

FIBER OPTIC CABLE: Fiber optic cable shall be Single Mode or Multi Mode as shown on the drawings and as specified in the CABLESPEC descriptions.

COMMUNICATION, PAGING, AND SECURITY SYSTEM CABLES: Voice communication, paging, and security system cables shall be specified in their respective specification sections.

WIRE MARKERS

600 VOLT AND 300 VOLT RATED CONDUCTORS: Per Section 16010.

FIBER OPTIC: Provide Markers for labeling each end of a fiber optic cable. Fiber optic markers

must have space for typed or machine printed text. Provide Markers for Individual fiber optic strands, jumpers, and patch cables. Fiber

optic markers must have space for typed or machine printed text. Fiber optic markers shall be attached to the fiber using tie wrap or other approved method of securing the marker listed.

COMMUNICATION, PAGING, AND SECURITY SYSTEM CABLES: Provide Markers for labeling each end of a cable.

SPLICING AND TERMINATING MATERIALS

600 VOLT AND 300 VOLT RATED CONDUCTORS: Connectors shall be tool applied compression type of correct size and UL listed for

the specific application. Connectors shall be tin-plated high conductivity copper. Connectors for wire sizes No. 10 AWG and smaller shall be nylon self- insulated, ring tongue or locking-spade terminals. Connectors for wire sizes No. 8 AWG and larger shall be one-hole lugs up to size No. 3/0 AWG, and two-hole or four-hole lugs for size No. 4/0 and larger. Mechanical clamp, dimple, screw- type connectors are not acceptable.

In-line splices and taps shall not be used. All circuits shall be continuous though all junction boxes, wireways, pull boxes, etc. until the circuit conductors are terminated at suitable terminal strips within motor control centers, PLC cabinets and panels, distribution panels, local control stations, etc.

Motor terminations at 460-volt motors shall be made by bolt-connecting the lugged connectors. Connections shall be insulated with Thomas and Betts (T&B), MSC series Motor Stub Splice Insulators and sealed with the appropriate tape for the motor voltage. (Example 480V = Scotch 33). For makeup boxes of smaller motors with limited space, T&B color keyed KUBE connector motor lead disconnects w/MDBOOT will be allowed. Refer to the electric motor specification Section 11002.

FIBER OPTIC TERMINATIONS:



Fiber optic terminations shall be: IT Fiber: LC type. SCADA Fiber: ST type.

CORD GRIPS

Cord grips shall be provided where specified on the Drawings to attach flexible cord to equipment enclosures. Cord grips shall consist of a threaded aluminum body and compression nut with a neoprene bushing and stainless steel wire mesh for strain relief. Cord grip shall provide a watertight seal at enclosure interface and sized to accommodate the flexible cord.

EXECUTION

GENERAL

Conductors shall be identified at each connection terminal and at splice points. The identification marking system shall comply with Section 16010.

Pulling wire and cable into conduit or trays shall be completed without damaging or putting undue stress on the insulation or jacket. Manufacture recommended and UL Listed pulling compounds are acceptable lubricants for pulling wire and cable. Grease is not acceptable.

Raceway construction shall be complete, cleaned, and protected from the weather before cable is installed. Where wire or cable exits a raceway, a wire or cable support shall be provided.

Provide tin-plated bus bar. Scratch-brush the contact areas and tin plate the connection where flat bus bar connections are made with un-plated bar. Bolts shall be torqued to the bus manufacturer's recommendations.

600 VOLT CONDUCTOR AND CABLE

Conductors in panels and electrical equipment shall be bundled and laced at intervals not greater than 6 inches, spread into trees and connected to their respective terminals. Lacing is not necessary in plastic panel wiring duct or wall mounted steel raceway used above countertops. Lacing shall be made up with plastic cable ties. Cable ties shall be tensioned and cut off by using a tool specifically designed for the purpose such as a Panduit GS2B. Other methods of cutting cable ties are unacceptable.

Conductors crossing hinges shall be bundled into groups not exceeding 10 to 15 conductors and protected using nylon spiral flexible covers to protect conductors. Provide oversized plastic panel wiring duct within panels and panelboards.

Slack shall be provided in junction and pull boxes, handholes and manholes. Slack shall be sufficient to allow cables or conductors to be routed along the walls. Amount of slack shall be equal to largest dimension of the enclosure. Provide dedicated electrical wireways and insulated cable holders mounted on unistrut in manholes and handholes.

Raceway fill limitations shall be as defined by NEC and the following:




Lighting and receptacle circuits may be in the same conduit in accordance with de-rating requirements of the NEC. Lighting and receptacle circuits shall not be in conduits with power or control conductors. Signal conductors shall be in separate conduits from power conductors. Motor feeder circuits shall be in separate conduits including small fan circuit unless combination fan-light fixture.

Power conductors derived from uninterruptible power supply systems shall not be installed in raceways with conductors of other systems. Install in separate raceways.

Splices and terminations are subject to inspection by the Owner prior to and after insulating.

Motor terminations at 460-volt motors shall be made by bolt-connecting the lugged connectors.

In-line splices and tees, where approved by the Owner, shall be made with tubular compression connectors and insulated as specified for motor terminations. Splices and tees in underground handholes or pull boxes shall be insulated using Scotch-cast epoxy resin or Raychem splicing kits.

Terminations at solenoid valves, 120 volt motors, and other devices furnished with pigtail leads shall be made using self-insulating forked compression connectors and terminal strips within a termination/junction box.

Terminations at valve and gate motor actuators shall be made directly into the actuator where possible. Power termination shall be made in the actuator power disconnect. Control and signal cable may be routed to a termination box near the actuator on 20-ampere rated terminal strips with label identification for the control and signal conductors. Control conductors and analog cable can then be installed in flexible conduit to the actuator control and signal termination compartments.

Solid wire shall not be used. Sharing neutrals for power circuits is not permitted. Conductor and cable markers shall be provided at splice points.

SIGNAL CABLE

Circuits shall be run as individually shielded twisted pairs or triads. In no case shall a circuit be made up using conductors from different pairs or triads. Triads shall be used wherever 3-wire circuits are required. Terminal blocks shall be provided at instrument cable junctions, and circuits shall be identified at such junctions unless otherwise specified. Signal circuits shall be run without splices between instruments, terminal boxes, or panels.

Shields shall not be used as a signal conductor.

Common ground return conductors for two or more circuits are not permitted.

Unless otherwise specified, shields shall be bonded to the signal ground bus at the control panel and isolated from ground and other shields at other locations. Terminals shall be provided for running signal leads and shield drain wires through junction boxes.

Cable for communication, telephone, and fire alarm systems shall be installed and terminated in compliance with the equipment manufacturer's recommendations and applicable NEC requirements.



Cable for data circuits and operating at greater than 10 kHz, shall be run continuously from node to node without splices or intermediate terminal blocks unless otherwise specifically specified or shown.

Cable for low-level instrumentation circuits shall be run continuously between final terminations without splices or intermediate terminal blocks unless otherwise specifically shown or specified.

Spare circuits and the shield drain wire shall be terminated on terminal blocks at both ends of the cable run and be electrically continuous through terminal boxes. Shield drain wires for spare circuits shall not be grounded at either end of the cable run.

Terminal boxes shall be provided at instrument cable splices. If cable is buried or in raceway below grade at splice, an instrument stand shall be provided as specified with terminal box mounted approximately 3 feet above grade.

Fire alarm circuits shall be installed in accordance with NFPA-72.

INSTALLATION

Raceway fill shall be as scheduled, and shall not exceed NEC limitations.

Feeder, branch, control and instrumentation circuits shall not be combined in a raceway, cable tray, junction or pull box, except as permitted in the following: Where specifically indicated on the drawings. Where field conditions dictate and written permission is obtained from the Owner. Control circuits shall be isolated from the feeder and branch power and

instrumentation circuits but combining of control circuits with power is permitted as noted below. The combinations shall comply with the following:

12 VDC, 24 VDC and 48 VDC may be combined. 125 VDC shall be isolated from all other AC and DC circuits. All AC circuits shall be isolated from all DC circuits.

Instrumentation circuits shall be isolated from feeder and branch power and control circuits but combining of instrumentation circuits is permitted. The combinations shall comply to the following:

Analog signal circuits may be combined. Digital circuits may be combined but isolated from analog signal circuits

if digital circuits are AC. Multiple branch circuits for lighting, receptacle and other 120 VAC circuits are

allowed to be combined into a common raceway. Contractor is responsible for making the required adjustments in conductor

and raceway size, in accordance with all requirements of the NEC, including but not limited to: Up sizing conductor size for required ampacity de-ratings for the

number of current carrying conductors in the raceway. The neutral conductors may not be shared. Up sizing raceway size for the size and quantity of conductors.

Pulling wire and cable into conduit or cable trays shall be completed without damaging or putting undue stress on the cable insulation. Soapstone, talc, or UL listed pulling compounds are acceptable lubricants for pulling wire and cable. Grease is




not acceptable. Raceway construction shall be complete, cleaned, and protected from the weather before cable is placed.

Whenever a cable leaves a raceway, a cable support shall be provided. Conductors in panels and electrical equipment shall be bundled and laced at intervals not greater than 6 inches, spread into trees and connected to their respective terminals. Lacing shall be made up with plastic cable ties. Lacing is not necessary in plastic panel wiring duct. Conductors crossing hinges shall be bundled into groups not exceeding 12 and shall be so arranged that they will be protected from chafing when the hinged member is moved.

Slack shall be provided in junction and pull boxes, handholes and manholes. Slack shall be sufficient to allow cables or conductors to be routed along the walls of the box. Amount of slack shall be equal to largest dimension of the box. Where plastic panel wiring duct is provided for wire runs, lacing is not required. Plastic panel wiring duct shall not be used in manholes and handholes.

Do not exceed cable manufacturer's maximum recommended pulling tension. Use dynamometer or break-away swivel on pulls exceeding 150 feet.

Observe manufacturer's minimum recommended pulling and training radii.

Where data cables are installed in cable trays, provide barriers in the tray to separate data cables from power and/or control cables.

At each end of the run leave sufficient cable for termination. Coil sufficient cable in each manhole, handhole, or pull box to permit future splice.

In-line splices and tees are not allowed.

Splices shall not be permitted in any coaxial, twin-axial, or data cable runs.

Ground cable shields at one end only. Unless otherwise specified, ground the shields at the panel end.

Protect all cables against moisture during and after installation.

Install and ground token passing bus cable in accordance with IEEE 802.4. Attach trunk cable to walls and ceilings with PVC clamps with clamp backs at 4-foot intervals.

Install and ground Ethernet cable in accordance with IEEE 802.3. Attach trunk cable to walls and ceilings with PVC clamps with clamp backs at 4-foot intervals.

Signal and control cable suspended into the wet well shall be provided with heavy duty wire mesh cord grip of flexible stainless steel wire to take the tension from the cable termination. Strain relief system shall be suitably anchored.

Circuits provided under this Section shall not be direct buried.

TERMINATIONS

Terminations shall be on terminators as identified in Section 16010.

Each conductor shall be identified with a wire marker at each terminal to which it is connected. The marking system shall comply with Section 16010.

Stranded conductors shall be terminated as described in this Section, except where terminals will not accept such terminations. Compression lugs and connectors shall



be installed using manufacturer's recommended tools. Where terminal blocks will not accept lugged conductors, the conductors shall be tinned using 60 percent tin, 40 percent lead alloy non-corrosive resin core solder before insertion into pressure terminals.

Electrical spring connectors (wire nuts) shall not be used for any purpose on any cable specified under this Section except for receptacle and lighting circuits. Lugs and connectors shall be installed with a compression tool.

All splices and terminations are subject to inspection by the Owner prior to and after insulating.

Terminations at solenoid valves, 120 volt motors, and other devices furnished with pigtail leads shall be made using self-insulating forked compression connectors and terminal strips within a termination/junction box.

Provide tool-crimp N connectors at coaxial cable terminations except trunk runs.

Provide tool-crimp TRN connectors at twin-axial cable terminations.

Conductor and cable markers shall be provided at splice points.

Fiber Optic Connectors: Active and spare fiber optic cables fibers shall be provided with a breakout kit, and terminated with ST type terminations. ST connectors shall feature: Bayonet Style latch Keyed insertion Spring loading for positive contact

TESTING

GENERAL: The Contractor shall test conductors and cable in accordance with 16015.

Instrument and Data Cables shall be subjected to additional tests as specified in this section.

INSTRUMENT CABLE: Each signal pair or triad shall be tested for electrical continuity. Any pair or triad

exhibiting a loop resistance of less than or equal to 50 ohms shall be deemed satisfactory without further test. For pairs with greater than 50 ohm loop resistance, the Contractor shall calculate the expected loop resistance considering loop length and intrinsic safety barriers if present. Loop resistance shall not exceed the calculated value by more than 5 percent.

Each shield drain conductor shall be tested for continuity. Shield drain conductor resistance shall not exceed the loop resistance of the pair or triad.

Each conductor (signal and shield drain) shall be tested for insulation resistance with all other conductors in the cable grounded.

Instruments used for continuity measurements shall have a resolution of 0.1 ohms and an accuracy of better than 0.1 percent of reading plus 0.3 ohms. A 500 volt megohmmeter shall be used for insulation resistance measurements.

DATA CABLE: Test all data cables, including fiber-optic, with time-domain reflectometer prior to

installation.




Test all data cables, including fiber-optic, with time-domain reflectometer and transmission impairment analyzer after installation.

Test fiber-optic system PMD to FDDI requirements for the following: Transmit power levels AC extinction ratio Optical wave shape Duty cycle distortion Data dependent jitter Random jitter Transmit frequency Minimum optical input Receiver jitter tolerance

FIBER OPTIC TESTING: The Owner shall be notified a minimum of 5 days prior to tests and reserve the right to witness field tests.

TEST EQUIPMENT: Test equipment shall be traceable to NIST standards. Use the following to perform

the pre-installation and post-installation cable tests: Optical time domain reflectometer (OTDR) shall be laser precision, ALT, Inc. Model

5200 LRFL or equal.

PRE-INSTALLATION TESTS: Perform acceptance tests on the cable prior to installation to verify that the cable

conforms to the manufacturer's specifications, and is free of defects, breaks and damages by transportation and manufacturing processes. Perform tests on all reels of cable. Cable shall not be installed until the Owner has reviewed the test report.

Verify continuity and attenuation or loss for each fiber on each reel and document results of physical inspections to identify any cable and reel damage conditions, and any deviations from the manufacturer's specifications.

Notify the Owner 5 days prior to tests. Document test results and submit the report to the Owner for review. Documentation shall consist of both hard copy and electronic disk complete with application software.

POST-INSTALLATION TESTS: OTDR: Conduct the following tests on each cable segment with an OTDR each

optical fiber in the fiber cable. Tests shall be conducted at both 1310 and 1550 nm. No splice loss shall have a loss of 0.15 dB or greater with fiber attenuation measured in dB/km.

Excess Fiber Coefficient (EFC) Test shall be made as part of the cable testing. The following procedure shall be performed from both ends on each fiber provided. Prior to stripping the cable for splicing, record the meter marks to determine

the physical cable length. Record the fiber Index of Refraction (IOR) from the cable data submitted by

the Manufacturer. With the OTDR, set to the proper IOR and record the OTDR fiber length. Calculate the excess fiber coefficient (EFC) according to the following

formula: EFC = OTDR length/Sheath length.

OLTS FIBER ATTENUATION:



Measure the attenuation of each optical fiber in both directions using a with an Optical Loss Test Set (OLTS) at both 1310 nm and 1550 nm. Test shall be conducted per TIA/EIA 526-7. Provide a reference power level measured with a patch cord and connectors of the same types used on the fiber cable. Measure and record the reference power level of the Laser Light Source. Measure and record the received power level of each optical. Repeat the same measurements in the other direction.

The measured insertion loss shall be no greater than the loss calculated in the formula below:

IL = 2(Ls) + 2(Lc) + (La)(Length) + 0.5

where:

IL = Insertion Loss Ls = Splice losses at the pigtails (maximum 0.15 dB) Lc = Connector face loss (maximum 0.6 dB) La = Manufacturer’s cable attenuation (dB/km) Length = Fiber length (km)

CABLE ACCEPTANCE: Pigtail splices shall have a loss no greater than 0.15 dB, as determined by either a

Profile Alignment System (PAS) or Light Injection (LID) splice loss estimate, at the time the splice is made. Splices with an optical loss of greater than 0.15 dB shall be redone.

OTDR traces at both 1310 nm and 1550 nm wavelengths display no unexplained losses, reflectance events, or other discontinuities.

The insertion losses measured at both 1310 nm and 1550 nm wavelengths and in both directions do not exceed the maximum allowed values. After cable tests, the cable installation shall be subject to a physical inspection to verify the remaining fiber optic specification requirements have been met. If any test requirements are not met, or in the event of fiber test failure of one or more fibers, splice or replace cable as necessary until tests pass.

FIBER OPTIC SYSTEM ACCEPTANCE: Perform the inspection and establish a punch-list of the following:

Fiber splices: neatly organized. Connectors: capped and undamaged. Cabling: organized with no excessive bending. Specified coiled cable present in the splice cabinet. Cable entrances to the cabinets secured. Unused cable delivered to the Owner.

Identify cables with the directories installed in each fiber cabinet. Discrepancies found during the inspection of the fiber system installation shall be listed and provided on the punch-list. Inform the Owner upon resolution and completion of the punch-list items

CABLE SPECIFICATION SHEETS (CABLESPEC)

GENERAL: Conductor, wire, and cable types for different locations, service conditions and raceway systems are specified on individual cable specification sheets.




Scheduled and unscheduled conductors, wires, and cables shall be installed in accordance with the CABLESPEC SHEETS.

CABLESPEC SHEETS: The following CABLESPEC sheets are included in this section:

CABLESPEC Volts Product Purpose

MC 600 Multi-conductor power and control cable

Power and control conductors for use in conduit raceways and cable trays.

THWN 600 Single conductor cross-linked polyethylene power and control cable

Power and control conductors for use in conduit raceways.

INS 600 Single Pair/Triad #16/18 ST plus overall shield,

Instrumentation for use in conduit raceways and cable tray.

INS/M 600 Multiple Pair/Triad #16 STP plus overall shield,

Instrumentation for use in conduit raceways and cable tray.

FOT-MM

--

Fiber optic cable – multimode

Data Network

IT 300 350 MHz Enhanced Cat 6 Gigabit Ethernet, LAN cable.

CsCAN 300 Network Cable Data Network



Cable System Identification: MC Description: Multi-conductor power and control cable, approved for conduit and

cable tray installation. Voltage: 600V Conductor Material: Bare annealed copper; stranded in accordance with ASTM B8 Insulation: XHHW-2, 90 degree C dry, 75 degree C wet, crosslinked

polyethylene in accordance with UL1581. Assembly: Individual conductors cabled together with non-hydroscopic fillers

and binding tape. Jacket: 45 mil minimum, polyvinylchloride (PVC) in accordance with UL

1277 Flame Resistance: IEEE 383 Manufacturer(s): Okonite, X-Olene; or approved equal. Uses Permitted: Cable tray, conduit, Execution: Installation: Install in accordance with this Section.

Provide cable seals where required by NEC 501. Testing: Test in accordance with this Section and Sections 16010 and

16015.




Cable System Identification : THWN Description: Single conductor Cross-linked polyethylene power and control

cable for sizes No. 14 AWG and larger. Voltage: 600 volts Conductor Material: Bare annealed copper; stranded in accordance with ASTM B8 Insulation: THWN-2, 90 degree C dry, 75 degree C wet, heat and moisture

resistant polyvinyl chloride (PVC). Jacket: Nylon (polyamide). Flame Resistance: N/A Manufacturer(s): Okonite, X-Olene, Southwire; or equal Uses Permitted: Power, control, lighting, receptacle and appliance circuits Execution:

Installation: Install in accordance with this Section. Testing: Test in accordance with this Section and Sections 16010 and

16015.



Cable System Identification: INS Description: Single twisted, shielded pair or triad, 18 AWG, instrumentation cable,

rated for wet and dry locations. Voltage: 600 volts Conductor Material: Bare annealed copper; stranded in accordance with ASTM B8 Insulation: PVC/Nylon Shield: 100 percent, 1.35 mil aluminum-Polyester tape with 18 AWG 7-strand

tinned copper drain wire Jacket: 48 mil flame-resistance polyvinylchloride Flame Resistance: UL 1685, ICEA T-29-520 and IEEE 1202. Manufacturer(s): Single Pair: BELDEN 1120A, or equal. Single Triad: BELDEN 1121A, or

equal. Execution: Installation: Install in accordance with this Section. Testing: Test in accordance with this Section and Sections 16010 and 16015.




Cable System Identification: INS/M Description: Multiple twisted, shielded pairs or triads, instrumentation cable, rated for

wet and dry locations. Voltage: 600 volts Conductor Material: Bare annealed copper; stranded in accordance with ASTM B8 Lay: Length 2.5 inches Insulation: PVC/Nylon Shield: 100 percent, 1.35 mil aluminum-Polyester tape with 18 AWG 7-strand

tinned copper drain wire Jacket: 48 mil or 68 mil or 84 mil flame-resistance polyvinylchloride Flame Resistance: UL 1685and IEEE 1202. Manufacturer(s): 2 pair: BELDEN 1048A, or equal. 4 pair: BELDEN 1049A, or equal. 12

pair: BELDEN 1051A, or equal 4 triad: BELDEN 1093A, or equal. 12 triad: BELDEN 1095A, no equal.

Execution: Installation: Install in accordance with this Section. Testing: Test in accordance with this Section and Sections 16010 and 16015..



Cable Identification: FOT-MM Description: Multimode fiber-optic cable; Tight-buffer, Dual Layer, with 12-strand

fibers: Outdoor/Indoor; Riser Rated; Cable Tray Rated Loose tube construction. Optical fibers shall not adhere to the inside of the buffer tube. Fibers and buffer tubes shall be color coded with distinct and recognizable colors in accordance with EIA/TIA-598.

Jacket: Jacket: PVC extruded under high pressure directly over the cable core such as to produce cusped ridges that interlock with the subcables Color: Black Mark the exterior sheathing with the manufacturer's name, month and year of manufacture, and sequential meter or foot markings for easily determining the length of the cable at all points along the cable run.

Type:

OFNR with industrial cable tray rating and IEEE 383 Chapter 8 flame test rated Fiber Type: Multimode OM3 Clad Diameter: 125 ± 0.7 µm Coating Diameter: 245 ± 5 µm Core Diameter: 50 µm Attenuation: ≤ 0.35 db/km @ 1310 nm ≤ 0.25 db/km @ 1550 nm Operating Temperature Range: -50 to +75 Deg C Maximum Tensile Loading: 670/270 lbs (Installation/Operating) Minimum Cable Bending Radius: 5.7”/3.8” (Installation/Operating)




Manufacturers: Optical Cable Corporation BX-series or approved equal

(1) Fiber Optic cable shall be suitable for installation in conduit runs within buildings.

(2) Fiber Optic cable shall be suitable for installation between buildings in outdoor/concrete encased conduit runs which share vaults with medium voltage cable.

(3) The contractor shall use zip cord jumper cables between patch/breakout panels

and communications equipment.

(4) Fiber shall be terminated with ST style connectors unless otherwise shown on drawings or required by the manufacturer.

(5) Fiber Optic cables shall have number of fibers as shown in the documents.

(6) The cable that connects PLC to the Fiber Optic interface shall be Belden 9841 or

equal. Execution: Application: Data communication. Installation: Install in accordance with this Section and associated equipment manufacturer’s

instruction. Testing: Test in accordance with this Section.



Cable System Identification: IT Description: DataTwist Enhanced Category 6, gigabit Ethernet, 100BaseTX, 4

pair cable, non-armored Voltage: 300V rms Conductor Material: Bare copper 23 AWG solid. Insulation Material: Fluorinated Ethylene Propylene (FEP) Shield: Unshielded Jacket: Fluorinated Ethylene Propylene (FEP), 0.214-inch diameter Flame Resistance: UL 723, NFPA 262 Electrical Characteristics: 250 MHz, 32.8 dB/100 meters Manufacturer(s):Belden 7931A, or

approved equal. Uses Permitted: Conduit. Tray, Execution: Application: Data Network Communications – Ethernet. Installation: Install in accordance with this Section and associated equipment

manufacturer’s instruction. Testing: Test in accordance with this Section.




Cable System Identification: CsCAN Description: 5-wire multiconductor cable with two wires used as a transmission

line for network communications, two wires used to transmit network power, one conductor used as an EMI shield.

Voltage: 300V rms Conductor Material: Component I 18AWG Pair, shielded

Component II 15AWG Pair, shielded Drain Wire: 18 AWG

Insulation Material: Propylene Shield: Shielded Jacket: Pressure extruded Flexible XPbT 0.3-inch diameter Flame Resistance: UL 723, NFPA 262 Uses Permitted: Conduit, Execution: Application: Data Network Communications – CAN. Installation: Install in accordance with this Section and associated equipment

manufacturer’s instruction. Testing: Test in accordance with this Section.

END OF SECTION


16122 - 1 Medium Voltage Cable CNG Fueling Station

SECTION 16122

MEDIUM VOLTAGE CABLE

PART 1 - GENERAL


A. ASTM International (ASTM) Publication: 1. B3 Specifications for Soft or Annealed Copper Wire

B. Association of Edison Illuminating Companies (AEIC) Publication: 1. CS6 Specifications for Ethylene Propylene Rubber Insulated Shielded

Power Cables Rated 5 Through 69 kV

C. Federal Standard: 1. 228 Methods of Testing Insulated Cable and Wire

D. Institute of Electrical and Electronics Engineers (IEEE) Publication: 1. 48 Standard Test Procedures and Requirements for High-Voltage Alternating

Current Cable Terminations 2. 386 Separable Insulated Connection Systems for Power Distribution

Systems Above 600V 3. 404 Standard for Cable Joints for Use With Extruded Dielectric Cable

Rated 5,000 through 46,000 Volts, and Cable Joints for Use With Laminated Dielectric Cable Rated 2,500 through 500,000 volts

E. International Electrical Testing Association (NETA) Publication: 1. ATS Acceptance Testing Specifications

F. National Electrical Manufacturers Association (NEMA) Publication: 1. WC 8 Ethylene-Propylene-Rubber-Insulated Wire and (ICEA Cable for

the Transmission and Distribution of S-68-516) Electrical Energy

G. National Fire Protection Association (NFPA) Publication: 1. 70 National Electrical Code

1.02 SUBMITTALS

A. Submit material or equipment data in accordance with the submittal requirements of Section 01330.

B. Submit qualifications of MV Cable installer showing a minimum 10 years’ experience with MV cable splicing and terminations.

C. Submit factory test results as described below.

D. Submit field test results as described in Part 3.

1.03 DEFINITION

A. Medium voltage power cable shall mean all cables rated above 600 volts and below 34.5 Kv.

1.04 CABLE VOLTAGE RATING AND USE

A. Cables rated 25,000 volts, grounded neutral shall be used on a 15 kV, 60 Hertz, three phase system.

Medium Voltage Cable CNG Fueling Station



1.05 FACTORY TESTING

A. Certified evidence shall be submitted that the cable manufacturer has made factory tests on each factory reel length of cable. Copies of the test data shall be submitted to the Engineer for each length. Test shall include conductor resistance, partial discharge, and high voltage withstand all per AEIC CS6.

B. Certified evidence shall also be submitted confirming sample testing of the cable which shall include mechanical integrity, bonding test, dissipation factor, power factor and a high voltage time test, all per AEIC CS6.

C. The results of these tests shall be submitted prior to shipment of the cable and shall be conducted in accordance with AEIC standards. Results shall include reel numbers.

1.06 SHIPMENT

A. Shipment of cable shall be made on reels in such a manner that the cable will be protected from mechanical damage.

B. Each end of the cable shall be hermetically sealed and securely attached to the reel.

C. Minimum diameter of the reel drum shall be 14 times the cable outside diameter.

PART 2 - PRODUCTS

2.01 CABLES

A. General: Provide Type MV-90 cable per NEC Article 328 and bearing the UL label. Wire or cable not specifically shown on the Drawings or specified, but required, shall be of the type and size required for the application and in conformance with the applicable code. All insulated conductors shall be identified with printing colored to contrast with the insulation or jacket color.

B. Cables shall be suitable for use in wet or dry locations, in metallic and non-metallic conduits, and in ducts.

C. Cables shall be able to operate continuously at 105°C conductor temperature and have an emergency rating of 130°C and a short circuit rating of 250°C.

D. Cables shall be single conductor type and shall have: stranded copper conductors; a semi-conducting material over the conductors (conductor screen); ozone-resistant insulation of ethylene-propylene-rubber (EPR); semi-conducting material (insulation screen); copper shield; and polyvinyl chloride jacket. Cable shall conform to NEMA Standard WC8 and AEIC Specification CS6.

E. All conductors shall be Class B stranded copper conforming to ASTM B3. Provide single conductor concentric round construction.

F. Conductor screen shall be an extruded layer of semiconducting EPR, easily removable from the conductor per AEIC.

G. Insulation shall be a flexible thermosetting dielectric based on an ethylene-propylene elastomer, colored to contrast with other cable components. It shall be resistant to heat, moisture, ozone, and corona.



H. Insulation screen shall be an extruded layer of semiconducting EPR easily removable from the insulation per AEIC.

I. Shield shall be a 5-mil-thick bare copper tape with a minimum overlap of 12.5%.

J. Jacket shall be an extruded layer of polyvinyl chloride having a minimum thickness per NEMA.

K. A pulling eye shall be installed by the manufacturer for each length of cable supplied.

L. Tray cable shall be composed of one or three conductors, a copper grounding conductor, ethylene-propylene rubber (EPR) insulation rated at 105 degrees C, interlocked aluminum armor, and PVC outer jacket. Insulation level shall be 133 percent, 115 mil.

2.02 SPLICES AND TERMINATIONS OF CONDUCTORS

A. Splices: Splices shall be rated to carry the full rated current of the mating cable and provide a fully submersible cable joint. Splices shall be Eaton or approved equal

B. Terminations: Medium Voltage Cable Terminations: Terminations shall consist of pre-assembled terminators and termination kits, suitable for the conductors, insulations, and jackets of the cables, and complying with IEEE Standard 48. They shall be 3M Company, G&W Electric Company, or equal. 1. Class 1: Porcelain insulator, and suitable for outdoor use. 2. Class 2: Porcelain or molded rubber insulator, and suitable for use inside an

outdoor enclosure. 3. Class 3: Porcelain or molded rubber insulator.

C. Tape used for terminations shall be compatible with the insulation and jacket of the cable and shall be of plastic material.

D. Cable identification shall be by stainless steel tags with 1/4-inch-high die stamped letters. Tags shall include circuit number, voltage and conductor size.

E. Insulation level shall be 133%.

F. Cables shall not support combustion for more than 3 seconds after application of flame or spark.

PART 3 - EXECUTION

3.01 CONDUCTOR INSTALLATION

A. Cable must be pulled in accordance with cable manufacturer's instructions. Exercise care in pulling wires and cables into conduit or wireways so as to avoid kinking, putting undue stress on the cables or otherwise abrading them. No grease will be permitted in pulling cables. Only soapstone, talc, or UL-listed pulling compound will be permitted. The raceway construction shall be complete and protected from the weather before cable is pulled into it. Swab conduits before installing cables and exercise care in pulling, to avoid damage to conductors.

B. Install feeder cables in one continuous length. Minimum radii shall be 12 times the cable O.D.




C. Provide grounding conductor, whether or not it is shown on the Drawings, in any raceway in which all or any portion of a run consists of non-metallic duct or conduit.

D. Prior to installation of cable in conduit, lubricate the conduit at the cable entry point thoroughly, using compressed air as necessary. Use only lubricants recommended by the cable manufacturer.

E. Use the factory-installed pulling eyes wherever possible. For those cable pulls where use of the manufacturer-installed pulling eyes is deemed by the Owner not to be feasible, attach the cable to the pull-line by means of a wire mesh cable grip (with swivel) which grips tighter as tension is put on the free end. First strip back the cable shield and sheathing and the conductor insulation. Then install the cable grip with all bare cable conductors protruding through the cable grip. Weave the bare conductor around the cable grip, without interfering with the swivel.

F. Apply liberal amounts of lubricant to the cable as it is fed into the conduit. Use care to avoid entry of dirt or other materials into the conduit. Make sure cable does not end-feed over the cable reel flanges. Do not kink the cable. If a cable is damaged, pull in a new cable.

G. General Pulling: 1. Cables shall be pulled through a flexible tube guide by means of a power

driven winch. Pulling force shall not exceed 1,000 pounds or a figure not exceeding 0.008 times the cable cross sectional area in circular mils, whichever is smaller. Cable pulling speed shall not exceed 50 feet per minute. Cable pulling by means of a vehicle is not acceptable.

2. Cable reel shall be set up so that reverse bending is not required. Cable shall be unreeled from the top of the reel. Cables cut in the field or pulled and not spliced the same day shall be immediately sealed rubber tape and protected with PVC tape. Cables for splicing shall be overlapped by a minimum of 2 feet. Cables shall be looped around the manhole or handhole circumference before exiting again

3.02 CONDUCTOR TERMINATIONS

A. General: 1. Pre-installation tests: Cable shall be tested for moisture prior to being pulled.

Contractor shall check conduit bend radii, conduit risers, pot heads and other fittings to ensure compliance with cable limitations and manufacturer's recommendations.

2. Cable personnel shall have a minimum of 10 years experience in cable splicing and terminations. Qualifications shall be submitted to the Engineer for review.

3. Once termination work has been started, work shall continue in one continuous work period until completed. Once a worker has started a termination, the work shall be completed by the same individual.

4. Under no conditions shall termination work be subjected to moisture. Tents shall be available at the Site to protect the area from rain.

B. Splices: Splices shall be made by personal with appropriate certifications and a minimum of 10 years of experience.

C. Terminations: 1. Built up stress relief cones shall be installed on all shield cable ends.



2. Outdoor terminations shall use wet process glazed electrical porcelain insulator factory pre-assembled kits installed in strict conformance with factory instructions.

3.03 CONDUCTOR IDENTIFICATIONS

A. Identify each wire or cable at each termination using numbered and lettered wire markers. All electrically common conductors shall have the same number. Each electrically different conductor shall be uniquely numbered. Identify other circuits as favorably reviewed by the Engineer.

B. Conductors between terminals of different numbers shall have both terminal numbers shown at each conductor end. The terminal number closest to the end of the wire shall be the same as the terminal number.

3.04 FIELD TESTS

A. The Contractor shall perform all tests required by NETA.

END OF SECTION




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16130 - 1 Junction and Device Boxes and Fittings CNG Fueling Station

SECTION 16130

JUNCTION AND DEVICE BOXES AND FITTINGS

PART 1 - GENERAL

1.01 Summary

A. Scope: This section provides specifications for all electrical junction boxes, device boxes, fixture support boxes, floor boxes, terminal cabinets and fittings.

B. Type: Unless otherwise listed, all junction boxes, device boxes, fittings, etc., shall be hot-dip galvanized cast ferrous alloy type. All exposed boxes and fittings shall be PVC coated.

1.02 References


Reference Title

ANSI C80.1 Electrical Rigid Steel Conduit

UL 1 Flexible Metal Conduit

UL 5 Surface Metal Raceway and Fittings

UL 6 Electrical Rigid Metal Conduit – Steel

UL 514B Conduit, Tubing and Cable Fittings

UL 651 Schedule 40 and 80 Rigid PVC Conduit and Fittings

NEMA RNI-2005 PVC Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit

NEMA TC-2-2003 Electrical PVC Tubing and Conduit

NEMA TC-3-2004 PVC Fittings for Use With Rigid PVC Conduit and Tubing

1.03 Submittals

A. Submittals shall comply with the provisions set forth in Sections 01330 and 16010.


A. The boxes and fittings shall be premium quality suitable for installation in a Wastewater or Water Facility.

PART 2 - PRODUCTS


A. Sheet Metal Boxes: Sheet metal boxes shall conform to UL 50, with a hot-dipped galvanized finish conforming to ASTM A123. Outlet boxes and switch boxes shall be

Junction and Device Boxes and Fittings CNG Fueling Station



designed for mounting flush wiring devices. Boxes and box extension rings shall be provided with knockouts. Boxes shall be formed in one piece from carbon-steel sheets. Outlet boxes shall not be less than 4 inches square and 1 1/2 inches deep. Ceiling boxes shall withstand a vertical force of 200 pounds for 5 minutes. Wall boxes shall withstand a vertical downward force of 50 pounds for 5 minutes. Gangable and through-wall types are not acceptable. Boxes shall conform to FS W J 800D and UL 514.

B. Cast Metal Boxes: Box bodies and cover shall be cast or malleable iron with a minimum wall thickness of 1/8 inch at every point, and not less than 1/4 inch at tapped holes for rigid conduit. Bosses are not acceptable. Mounting lugs shall be provided at the back or bottom corners of the body. Covers shall be secured to the box body with No. 6 or larger brass or bronze flathead screws. Boxes shall be provided with neoprene cover gaskets. Where only cast aluminum is available for certain types of fixture boxes, an epoxy finish shall be provided. Outlet boxes shall be of the FS types. Boxes shall conform to FS W C 586C and UL 514.

C. Non-metallic Boxes: Non-metallic boxes shall be hot-compressed fiberglass, one-piece, molded with reinforcing of polyester material, with minimum wall thickness of 1/8 inch.

D. Pull Boxes and Junction Boxes: Except where NEMA 4X fiberglass boxes are called for, all boxes shall be fabricated from carbon steel per UL 50. Boxes shall be welded construction with all seams or joints closed and reinforced. Boxes shall be galvanized after construction. Boxes intended for outdoor use shall be cast metal with threaded hubs and neoprene gasketed covers, or shall be of the fiberglass reinforced polyester type of 1/8 inch minimum thickness. Cover retention shall be by corrosion resistant stainless steel screws. 1. All boxes for wiring operating at 601 volts or higher shall be constructed without

hinges and shall be padlockable. 2. All boxes and cabinets shall be securely fastened to building structural members so

as to prevent movement in any direction. Boxes shall not be supported by lighting fixtures, suspended ceiling support wires or freely hanging rods. a. Covers of boxes and cabinets mounted in horizontal plane (top or bottom)

shall either weigh not more than 40 pounds or shall require not more than 40 pounds of force to open or close.

b. Covers of boxes and cabinets mounted in vertical plane (front, back, sides) shall either weigh not more than 60 pounds or shall require not more than 60 pounds of force to open or close. All covers over 30 pounds shall be furnished with angle support at bottom to carry weight of cover for assembly.

c. Covers of boxes and cabinets weighing more than 30 pounds shall be provided with lifting handles or some means of grasping other than edges.

E. Explosion-Proof Boxes and Fittings: In all Class I, Divisions 1 and 2, hazardous areas, boxes and fittings shall be explosion-proof and shall comply with Article 500 of the NEC. Seals for conduit systems in hazardous atmosphere locations shall be of hot-dip galvanized cast ferrous alloy, and each seal shall be of a suitable configuration for the individual circumstance. Sealing compound shall be UL listed for explosion-proof sealing fittings and shall be of the same manufacture as the fittings.

F. Boxes in Corrosive Areas: Boxes and fittings located in corrosive areas shall be NEMA 4X. This material shall be fiberglass reinforced polyester with minimum properties as follows: 1. Compressive strength: 28,000 psi 2. Flexural strength: 15,000 psi per ASTM D790 and D675


16130 - 3 Junction and Device Boxes and Fittings CNG Fueling Station

3. Tensile strength: 12,000 psi per ASTM D638 4. Flame-resistant and self-extinguishing per ASTM D635

G. All conduit entries shall use ferrous alloy hubs with 40 mil epoxy coating. All conduit entering plastic boxes and any exposed metal on plastic boxes which is not isolated from the interior of the box shall be bonded together with a suitable grounding conductor. Corrosive areas shall be as noted Section 16010 and/or as shown on the drawings.

PART 3 - EXECUTION

3.01 Installation

A. Outlet and switch boxes shall be located to provide ample clearance between fixtures and pipes, beams and ducts. The location shall be verified on the job to avoid conflict with other work. Boxes shall be accurately placed and shall be independently and securely supported. Wooden plugs inserted in masonry or concrete shall not be used as a base to secure boxes nor shall welding or brazing be used for attachment. Boxes shall be secured by galvanized brackets, expansion bolts, toggle bolts, or machine or wooden screws depending on the type of construction. 1. Provide fixture outlets with proper fixture connectors. 2. Box mounting height shall be dictated by the wiring device enclosed.

a. Switch boxes shall be mounted 48 inches above the floor. b. Unless otherwise indicated, receptacle boxes shall be mounted 12 inches

above the floor in offices and similar areas and 48 inches above the floor in all other areas.

3. Blanking covers shall be installed on all unused openings. 4. Sheet metal boxes shall be used in dry non-corrosive locations where the conduit

system is routed concealed in the walls and ceilings. 5. Cast metal or molded non-metallic surface mounted boxes shall be used in exterior

and/or in all wet locations. 6. Bonding jumpers shall be used around all concentric or eccentric knockouts. 7. Boxes shall be securely mounted to the building structure independent of conduits

entering or exiting the boxes

B. Boxes in corrosive atmospheres or wet locations shall be PVC or PVC coated cast steel with threaded hubs.

C. Junction Boxes and Pull Boxes: 1. Boxes shall be installed where required and where indicated on the Drawings. 2. Boxes shall be readily accessible. 3. Boxes shall not be installed in finished areas. 4. Pull boxes shall be provided at least every 300 feet on long straight conduit runs.

Spacing shall be reduced by 50 feet for each 90 degree bend. See Section 26 05 33 for maximum bends in conduit systems.

5. Box dimensions shall be in accordance with size and quantity of conductors and conduits entering and leaving box per NEC Article 370 requirements.

6. All boxes, both new and existing, for medium voltage systems shall be permanently marked "High Voltage" on all surfaces with red letters which are at least 4 inches high.

END OF SECTION

Junction and Device Boxes and Fittings CNG Fueling Station



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16140 - 1 Wiring Devices CNG Fueling Station

SECTION 16140

WIRING DEVICES

PART 1 - GENERAL

1.01 SUMMARY

A. SCOPE: This Section specifies wiring devices consisting of receptacles, plugs, switches and appurtenances.





Reference Title NEMA 250 Enclosures for Electrical Equipment (1000 volts maximum)

NEMA WD-1 General Requirements for Wiring Devices

NEMA WD-6 Wiring Devices - Dimensional

NFPA 70 National Electrical Code (NEC)

ANSI C73 Plugs and Receptacles

ANSI C73a Plugs and Receptacles

FS W-C-596 D/E General Specifications for Cable Outlet Electrical Connector

FS W-C-896 D/E General Specifications for Flush Mounted Toggle and Lock Switches

UL 20 General-Use Snap Switches

UL 498 Attachment Plugs and Receptacles

UL 514A Metallic Outlet Boxes

UL 894 Switches For Use In Hazardous (Classified) Locations

UL 943 Ground-Fault Circuit Interruptors

UL 1010 Receptacle-Plug Combinations for Use in Hazardous (Classified) Locations

1.03 SUBMITTALS

A. PROCEDURES: Section 01330

Wiring Devices CNG Fueling Station





2. Catalog cuts of equipment, devices, and materials installed under this section. Catalog information shall include technical specifications and application information, including electrical ratings, dimensions, weight, etc. Catalog cuts shall be edited to show only the items, model numbers, and information which apply.

PART 2 - PRODUCTS

2.01 GENERAL

A. Wiring devices shall be UL approved for the current and voltage specified and shall comply with NEMA WD-1. Devices shall contain provisions for back wiring and side wiring with captive binding screws.

B. Provide devices colored to conform to manufacturer’s or industry standard for special use such as orange for isolated ground receptacles, blue for surge suppression receptacles, and red for emergency power receptacles. Unless shown otherwise on the Drawings or Schedules, normal use devices shall be brown, except those located in finished areas shall be ivory.

2.02 RECEPTACLES AND PLUGS

A. GENERAL: Receptacles shall be grounding type.

B. 120V RECEPTACLES: 1. INDOOR, CLEAN AREAS: Unless shown otherwise on the Drawings or

Schedules, receptacles shall be duplex 20 amp, NEMA 5-20R, and shall accept NEMA 5-15P and 5-20P plugs. Where the manufacturer of cord connected equipment requires an isolated ground, a receptacle with isolated ground shall be provided. a. Manufacturers: Hubbell 5362, 5362-AI or equal. b. Isolated ground receptacle manufacturers: Hubbell IG-5362, Arrow-Hart

IG5362, or equal. c. Receptacles shall be white in occupied areas with white faceplate. d. Receptacles shall be grey in un-occupied areas with chrome faceplate. e. Receptacles shall be mounted at 18” above floor unless otherwise

indicated on plan drawings. 2. METERING PUMPS: Each 120VAC metering pump and 120VAC transfer

pump shall have a dedicated switch and GFCI receptacle, 20 amp, NEMA 5-20R, and shall accept NEMA 5-15P and 5-20P plugs. Switch shall disconnect power to receptacle and shall be industrial grade two position, maintained contact, single throw, 2-pole, single-phase toggle switch.

3. OUTDOOR, PROCESS OR CORROSIVE AREAS: Receptacle shall be duplex, 20 ampere, NEMA 5-20R, IP65/66/67, and shall accept NEMA 5-15P and 5-20P plugs. Receptacle and plug shall be corrosion resistant, watertight, marine duty with yellow polycarbonate weatherproof lift covers. a. Manufacturers: Hubbell 60W33H/15W33H, 52CM62 or approved equal.

4. GFI Receptacles:



a. Device shall be rated 20 ampere, 2-pole, 3-wire, 120 volt, conforming to NEMA WD1.10 configuration. Face shall be nylon composition meeting UL 498 test standards. Unit shall have test and reset push buttons. Reset push button shall have a visible indicator band to indicated tripped condition.

b. GFCI component shall meet UL 498 Class A standards with a tripping time of 1/40 second at 5 milliamperes current unbalance. Operating range shall extend from 31°F to 158°F. Unit shall have transient voltage protection and shall be ceramic encapsulated for protection against moisture.

c. Provide Hubbell GFR 5253, Arrow-Hart equivalent, or equal.

C. 250V RECEPTACLES: Receptacles shall be duplex 20 amp, NEMA 6-20R, and shall accept NEMA 6-20P plug caps. Receptacles shall be Hubbell 60W48H, or approved equal.

D. 480V RECEPTACLES: Receptacles shall be 30A, Type 3R, IP54/IP55. IP55 on the receptacle when the lid is latched closed. Receptacle shall be Meltric, DS30, blue metal with latch cover and angle mount. Receptacle shall match existing sump pump plug. 1. Provided complete with angle adapter, gaskets, and a gasketed screw-type,

weathertight cap with chain fastener. 2. Provide each receptacle with one plug

E. LUG CAPS: Male plug caps for 120 volt and 250 volt receptacles shall be of the cord grip armored type with heavy phenolic housing, of the same manufacture as the receptacle. Plug caps shall be rated 15 amps. One plug cap shall be provided for every four receptacles furnished, with a minimum of two plug caps being provided. Plug caps shall be delivered to the Owner.

F. RECEPTACLES FOR HAZARDOUS AREAS: Receptacles for use in hazardous areas shall be rated in accordance with NEC for the area in which they are to be located and shall be factory sealed. Receptacles shall be designed so the plug must be inserted and turned before load is energized. Receptacles shall be provided with mounting box, sealing chamber, and compatible plug. Voltage and current ratings shall be 120 Vac, 20-ampere. 1. Manufactures: Appleton "U-Line," Crouse-Hinds "Ark-Gard 2," or equal.

2.03 SWITCHES

A. Line Voltage Types: Switches shall be rated 20 amperes at 120 or 277 Volts ac only. Units shall be flush mounted, self-grounding, quiet operating toggle devices. Handle color shall be brown in industrial areas and white or ivory in office and laboratory areas. Units shall conform to Federal Specifications W-S-896 D and E, UL 20, and NEMA WD1 standards.

B. Low Voltage Types: Switches shall meet all of the requirements listed in Item A above except to be rated at 15 amperes for switching 24 Volts dc. Devices shall be three-position, momentary contact, spring return, center "off" configuration.




C. GENERAL PURPOSE (INDOOR, OCCUPIED AREAS): General purpose switches shall be rocker type, quiet AC type, specification grade, back and side wired, and shall be provided in accordance with rated capacities as required or as indicated on Drawings or Schedules. Switches shall match receptacles in color. Voltage and current ratings shall be 120VAC, 20 ampere. 1. Manufactures: Leviton, Hubbell, or Owner accepted substitute.

D. GENERAL PURPOSE (INDOOR, UN-OCCUPIED AREAS): General purpose industrial switches shall be toggle type, quiet AC type, specification grade, back and side wired, and shall be provided in accordance with rated capacities as required or as indicated on Drawings or Schedules. Switches shall match receptacles in color. Voltage and current ratings shall be 120VAC, 20 ampere. 1. Manufactures: Leviton, Hubbell, or Owner accepted substitute.

E. SWITCHES FOR EXPLOSION PROOF: Units shall conform to the standards listed in Item A above, but in addition shall have UL listings for use in hazardous areas classified as Class 1, Division I or II, and Class 2, Division I. Units shall be factory sealed devices. Material shall be copper-free aluminum for metallic types. Provide Killark FSK, Seal X Series; Crouse-Hinds; or equal. Provide fiberglass or polyamide for non-metallic types.

F. SWITCHES FOR OUTDOOR AND CORROSIVE AREAS: Switches shall be 20-ampere with weatherproof/ corrosion resistant neoprene plate. Switches shall be mounted in "FD" type cast ferrous or cast ferrous PVC-coated boxes as specified. 1. Manufactures: Hubbell or Arrow-Hart as follows:

Hubbell

with 17CM50 plate Arrow-Hart with 2881 plate

Single pole 1281 2991

Double pole 1282 2992

3-way 1283 2993

4-way 1284 2994

2.04 DEVICE PLATES

A. RECEPTACLES AND SWITCHES (Occupied areas): Device plates shall be oversized, white, thermoplastic provided with switches. Lighting and exhaust fan switches located on the same wall shall share device plate.

B. RECEPTACLES AND SWITCHES (Un-Occupied areas):

1. In non-corrosive un-occupied indoor areas, device plates shall be made of sheet steel, zinc electroplated with chrome finish as manufactured by Crouse-Hinds, Appleton, or equal.

2. In corrosive indoor areas device plates shall be corrosion-resistant/marine-duty type. Plates shall have weather protective double doors. Material of manufacture shall be die-cast aluminum for metallic plates or nylon for non-metallic plates. Plates shall be of the same manufacturer as the receptacle or switch.

3. In outdoor or wet areas receptacle covers shall provide while-in-use protection, rated NEMA 3R with cover closed. Covers shall be powder-coated



cast zinc, with self-closing lid and stainless steel hinges as manufactured by Leviton M5979 or equal.

4. Device plates for explosion-proof equipment shall be factory provided with the equipment.

5. Cast Metal: Plates shall be cast or malleable iron covers with gaskets so as to be moisture resistant or weatherproof.

6. Stainless Steel: Plates shall be 0.035 inches thick with beveled edges and shall be manufactured from No. 302 alloy having a brushed or satin finish.

7. Blank Plates: Cover plates for future telephone or television outlets shall match adjacent device wall plates in appearance.

C. Device plates shall be provided with engraved laminated phenolic nameplates with 1/8- inch white characters on black background. 1. Nameplates for switches shall identify panel and circuit number and area

served (if remotely switched). 2. Nameplates for receptacles shall identify circuit and voltage if other than 120

volts, single phase.

2.05 PRODUCT DATA

A. In accordance with Section01330, the Contractor shall provide catalog cuts for all materials provided under this section.

PART 3 - EXECUTION

3.01 GENERAL

A. Boxes shall be independently supported by galvanized brackets, expansion bolts, toggle bolts, or machine or wood screws as appropriate. Wooden plugs inserted in masonry or concrete shall not be used as a base to secure boxes, nor shall welding or brazing be used for attachment.

B. Receptacles and switches installed in sheet steel boxes shall be flush mounted. Flush mounted receptacles shall be located 18 inches above the floor unless otherwise indicated. Switch boxes shall be mounted 48 inches above the floor. Receptacles installed in cast device boxes shall be located 48 inches above the floor.

C. Wiring devices shall be tested for correct connections.

D. Damp or Wet Interior Locations: Install only wiring devices approved for outdoor service. Adjust boxes so that front edge will be 1/4-inch beyond the rear edge of the finished wall. Use metal tubing sleeves to bring device mounting straps flush with the front edge of the finished wall.

E. Receptacles; 1. Receptacles shall be grounded by a grounding conductor, not by a yoke or

screw contact. 2. Receptacles shall be oriented so that the grounding slot is located at the top

of the outlet. 3. Receptacles shall be installed with connections pigtailed (spliced) to the

branch circuit wiring so that removal of the receptacle will not lose neutral continuity and branch circuit power will not be lost to other receptacles on the same circuit.




3.02 INSTALLATION OF WALL PLATES

A. General: Plates shall match the style of the device and shall be plumb within 1/16-inch of the vertical or horizontal.

B. Interior Dry Locations: Install plates so that all four edges are in continuous contact with the finished wall surfaces. Plaster filling will not be permitted. Do not use oversize plates or sectional plates.

C. Exterior and/or Wet Locations: Install plates with gaskets on wiring devices in such a manner as to provide a raintight weatherproof installation. Cover type shall match box type.

D. Future Locations: Install blanking cover plates on all unused outlets.

3.03 TESTS

A. Receptacles: 1. Receptacles shall be tested for blade and ground plug tension prior to

installation. Do not install any receptacle having less than 16 ounce individual blade retention.

2. After installation of receptacles, circuits shall be energized and each receptacle tested for proper ground continuity, reversed polarity, and/or open neutral condition.

3. GFI receptacles shall be tested with the circuits energized. Devices shall be tested with a portable GFI receptacle tester capable of circulating 7.5 milliamperes of current, when plugged in, between the "hot" line and "ground" to produce tripping of the receptacle. Resetting and tripping shall be checked at least twice at each GFI receptacle.

END OF SECTION


16160 - 1 Panelboards CNG Fueling Station

SECTION 16160

PANELBOARDS

PART 1 - GENERAL

1.01 Summary

A. Scope: This section provides specifications for all panelboards. Furnish and install panelboards as indicated on the panel schedule, in the drawings, and in this specification. 1. Panelboards connected to data cabinets, analyzer cabinets, remote I/O panels,

equipment controls panels, and network system cabinets (fire alarm, intrusion, door access) shall have surge protective devices.

1.02 References


Reference Title

IEEE C62.1 Surge Arrestors for Alternating Current Power Circuits

IEEE C62.11 Standards for Metal-Oxide Surge Arrestors for AC Power Circuits

NECA 407 Recommended Practive for Installing and Maintaining Panelboards

NEMA 250 Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA 289 Application Guide for Ground Fault Circuit Interrupters

NEMA AB 1 Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit Breaker Enclosures

NEMA KS 1 Enclosed Switches

NEMA LA 1 Surge Arrestors

NEMA PB 1 Panelboards

NEMA PB 1.1 General Instructions for Proper Installation, Operation, and Maintenance of Panelboards Rated 600 Volts or Less

NFPA 70 National Electrical Code

UL 67 Standard for Panelboards

UL 98 Standard for Enclosed and Dead-Front Switches

UL 486E Standard for Equipment Wiring Terminals for use with Aluminum and/or Copper Conductors

UL 489 Standard for Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit Breaker Enclosures

UL 508 Standard for Industrial Control Equipment

Panelboards CNG Fueling Station



Reference Title

UL 943 Standard for Ground-Fault Circuit Interrupters

1.03 Submittals

A. Submittals shall comply with Sections 01330 – Submittals Procedures, and 16010- General Electrical Provisions.

B. Shop Drawings: For each panelboard, submit manufacturer's name and data as required: 1. Panelboard Type 2. Main bus and terminal connection sizes. 3. Location of line connections. 4. Cabinet dimensions. 5. Gutter space. 6. Gauge of boxes and fronts. 7. Finish data. 8. Voltage rating. 9. Breaker types, trip ratings, and interrupting ratings


A. Each panelboard shall comply with applicable standards of the Underwriter's Laboratories, Inc.

PART 2 - PRODUCTS

2.01 Manufacturers

A. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in their entirety. Products in compliance with the specification and manufactured by others not named will be considered only if pre-approved by the Engineer ten (10) days prior to bid date. 1. Eaton 2. Allen Bradley 3. Square D 4. Or equal


A. Service Conditions 1. NEMA 1 gasketed, mounting as indicated on plans.

B. Ratings 1. As shown on the drawings. 2. Minimum short circuit rating: As required to meet the Short Circuit Study and

Protective Device Evaluation and Coordination Study as specified in specification section 16020 but not less than 22,000 symmetrical rms Amperes.

C. Construction


16160 - 3 Panelboards CNG Fueling Station

1. Cabinets: Code gauge steel cabinets, dead front panels and doors. Fasten dead front panels to cabinets with concealed trim fasteners concealed front door hinges.

2. Locks: Flush door locks, keyed alike for all panelboards.

D. Distribution Panelboards: Distribution panelboards shall be rated 480Y/277 volts, 4-wire, with bus ratings as shown on the Drawings. They shall meet the requirements of Federal Specification W-P-115 for Type I, Class 1 panelboards with circuit breakers meeting Federal Specification W-C-375 for Class 2d and 3a circuit breakers. Distribution panelboards shall be large enough for double branch mounting of branch circuit breakers up to 600 amp and shall be surface mounted. Circuit breakers shall have minimum interrupting ratings of 22,000 RMS symmetrical amperes at 480 volts.

E. Lighting Panelboards: Lighting panelboards shall be rated as shown on the Drawings. Panelboards shall meet the requirements of Federal Specification W-P-115 for Type I, Class 1 panelboards with circuit breakers. Lighting panelboards shall have front doors with key latch, common keying and a typed directory card and holder. Panelboard circuits shall be arranged with odd numbers on the left and even numbers on the right with number of circuit breakers shown in Contract drawings.

F. Finish 1. All painted steel work shall be treated with a primer coat and finish coat of the

manufacturer's standard gray color.

2.03 Components and Accessories

A. Bussing 1. Bussing shall be rectangular cross section copper or full length silver or tin-plated

aluminum. 2. Each panelboard shall be equipped with a ground bus secured to the interior of the

enclosure. The bus shall be equal to the panelboard neutral bus and shall have a separate lug for each ground conductor. Not more than one conductor shall be installed per lug.

B. Circuit Breakers 1. As required in Section 16180. 2. Manufacturer shall be the same as the panelboard, motor control center, or

switchgear in which they are mounted. 3. Where two pole breakers occur in the panels, they shall be common trip units.

Single pole breakers with tie-bar between handles will not be accepted.

C. Breakers shall have toggle, quick-make, and quick-break operating mechanisms with trip-free feature to prevent contacts being held closed against overcurrent conditions in the circuit. Trip position of the breakers shall be clearly indicated by movement of the operating handles to the center position.

D. Nameplates and Directory 1. Each panel shall have a neatly typewritten directory with the name and number of

the room or the equipment served by each circuit breaker which shall correspond with the final circuit arrangement. Spaces in directories for spare circuit breakers shall be neatly marked "Spare" in pencil. The directory shall also indicate the panel designation, voltage, and phase at the top. Each directory shall be mounted in metallic index cardholder behind a clear plastic window.

Panelboards CNG Fueling Station



PART 3 - EXECUTION

3.01 INSTALLATION

A. All equipment shall be installed so that it is readily accessible for operation and maintenance.

3.02 MOUNTING HEIGHTS

A. Lighting and distribution panelboards shall be mounted with the top of the box 6-feet-6-inches above the floor. Panelboards shall be plumb within 1/8-inch. The highest breaker operating handle shall not be higher than 72 inches above the floor.

3.03 FIELD TESTS

A. Insulation Resistance Tests: Perform insulation resistance tests on circuits to be energized with a line-to-neutral voltage of 120 volts or more. Make these tests after all equipment has been connected, except that equipment, which may be damaged by the test voltage, shall not be connected. Test the insulation with a 500 Vdc insulation resistance tester with a scale reading 100 megohms. The insulation resistance shall be 20 megohms or more. Submit results for review.

B. Grounding: Panelboard grounding shall conform to Section 16450.

C. Continuity: Panelboard circuits shall be tested for continuity prior to energizing. Continuity tests shall be conducted using a dc device with a bell or buzzer.

3.04 ADJUSTING/ CLEANING/ PROTECTION

A. All circuits shall be tested and verified for correct connections.

END OF SECTION


16180 - 1 Overcurrent Protective Devices CNG Fueling Station

SECTION 16180

OVERCURRENT PROTECTIVE DEVICES

PART 1 - GENERAL

1.01 Summary

A. Scope: This section provides specifications for all molded case overcurrent protective devices including circuit protective devices, ground fault circuit interrupters, and motor circuit protectors.

B. Type: The overcurrent protective devices shall be molded case type with adjustable trip settings.

1.02 References


Reference Title

FS W-C-375 Federal Standard – Circuit Breakers, Molded Case, Branch Circuit and Molded Case Switches

NEMA AB 1 Molded Case Circuit Breakers

1.03 Submittals

A. Submittals shall comply with the provisions set forth in Section 16000.


A. Performance Requirements 1. The frame sizes for overcurrent protective devices shall be as indicated on the

contract drawings. The overcurrent protective devices shall be either thermal magnetic or fully magnetic depending on whether the device is protecting a feeder or a motor starter.

2. The main circuit breakers at the motor control centers shall be of the frame sizes indicated and have adjustable trip settings.

3. Molded case circuit breakers shall be provided with current ratings and pole combinations as indicated on the contract drawings.

4. The molded case circuit breakers for protecting feeders shall be thermal magnetic type that provides inversed time delay overload and instantaneous short circuit protection. The molded case circuit breakers in combination type starters shall be fully magnetic type that provides instantaneous short circuit protection. In addition, the circuit breakers shall be ambient temperature compensated. The minimum interrupting rating of the breakers shall be at least equal to the available short circuit current at the line terminal.

B. Operating Requirements: The interrupting ratings for circuit breakers shall be in accordance and meet or exceed the minimum requirements established by the Short Circuit Study as indicated in specification section 16020. Lighting panel circuit breakers

Overcurrent Protective Devices CNG Fueling Station



shall have an interrupting rating of no less than 65,000 amperes rms (symmetrical) at the applied voltage. All other molded case circuit breakers shall be rated at 600 volts, shall meet or exceed the minimum requirements established by the Short Circuit Study and provide the selective coordination requirements demonstrated by the Protective Device Evaluation and Coordination Study as indicated in specification section 16020. For any circuit breakers not covered by Protective Device and Coordination Study, the following minimum interrupting ratings shall be met:

Frame Designation (b) Maximum

Continuous Amperes

Minimum Interrupting Rating

AB E at 480 volts sym.

ampsat 240 volts sym.

Amps

140G-H 140G-I 140G-I 140G-K 140G-M 140G-N 140G-R

HFD HFD HFD HLD HMC HNC PB

100 150

225(a) 400(a) 800(a)

1,200(a) 1,600(a)

65,000 65,000 65,000 65,000 65,000 65,000

100,000

100,000 100,000 100,000 100,000 100,000 100,000 100,000

Notes: Interchangeable trips shall be provided. Frame sizes as shown are Allen Bradley (AB), Eaton (E), or equal

PART 2 - PRODUCTS


A. Molded Case Circuit Breakers 1. Molded case circuit breakers shall be fully enclosed in a molded case and circuit

breakers with non-interchangeable trips shall have their covers sealed. Contacts shall be made from a non-welding silver alloy. Arc extinction shall be accomplished by means of arc chutes that consist of a metal grid mounted in an insulated support.

2. Molded case circuit breakers with current limiting fuses shall be one complete assembly consisting of a molded circuit breaker and current limiting fuse. The above current limiting fuses shall be coordinated with the circuit breaker element for selective operation. The circuit breaker shall not reset until current limiters which have functioned have been replaced and covers fastened. The current limiters shall have visual indicators to indicate which unit needs replacement.

3. The fully magnetic type circuit breakers shall be adjustable trip magnetic type designed to meet NEC requirements for such devices. The adjustment shall provide instantaneous trip settings in the range of 700 percent to 1300 percent of the lowest full load current for which the unit is rated. Each unit shall be adjusted to the circuit breaker manufacturer's recommended setting for the particular motor full load current. All other characteristics shall be in accordance with the specifications


16180 - 3 Overcurrent Protective Devices CNG Fueling Station

for molded case circuit breakers. The interrupting rating shall be not less than 65,000 amperes symmetrical. Where short circuit current exceeds 65,000 amperes an integrally mounted current limiter shall be provided. Refer to one-line diagrams for available short circuit duties.

B. Circuit Breakers (magnetic only): 1. Magnetic circuit breakers shall be molded-case equipped with toggle type handle,

quick-make, quick-break over center switching mechanism that is trip-free so that breaker cannot be held closed against short circuits and abnormal currents. The tripped position shall be clearly indicated by breaker handle maintaining a position between "ON" and "OFF." All poles shall open, close, and trip simultaneously. Minimum short circuit capacity shall be 65,000 amps symmetrical

C. Ground Fault Circuit Interrupters 1. Ground fault circuit interrupters (labeled GFI on diagrams) shall be provided in the

locations as shown in the panelboards. The circuit interrupters shall be UL listed for the application and shall trip at 5 milli-amperes to protect personnel from electrical shock hazard. The unit shall be of the plug-in type and shall be of the same manufacturer and shall match the other circuit breakers in the panelboard in space requirements and general appearance, except that a test pushbutton shall be provided on the face of each unit and be accessible from the front (similar to the accessibility of the circuit breaker toggle handle).

2. The neutral for each circuit that is ground fault protected shall be individually brought back with the live leg of the circuit and connected to the neutral pigtail or terminal of the interrupter unit. All wiring in GFI circuits shall be 3/64-inch insulated THWN/XHHW No. 12 AWG minimum. In general, the GFI monitored circuits will be those feeding receptacles in the shop, laboratory, restrooms, operating and outdoor areas of the plant or station and as otherwise noted.

PART 3 - EXECUTION

3.01 Installation

A. Testing: After the completion of installation, each protective device shall be individually tested to ensure that the device is properly installed, connected and operates as specified and as required.

END OF SECTION

Overcurrent Protective Devices CNG Fueling Station



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16402 - 1 Underground Electrical Work CNG Fueling Station

SECTION 16402

UNDERGROUND ELECTRICAL WORK

PART 1 - GENERAL

1.01 SECTION INCLUDES:

A. Provisions: Applicable provisions of Division 16 become a part of this Section as if repeated herein.

1.02 APPLICABLE STANDARDS

A. 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. 1. Federal Specifications (Fed. Spec.):

a. RR-F-621C Frames, Covers, Gratings, Steps, Sump and Catch Basin, Manhole

b. RR-G-661D Grating, Metal, Bar Type (Floor, except for Naval Vessels) 2. American Concrete Institute (ACI) Publication:

a. 318 Building Code Requirements for Reinforced Concrete 3. American Society of Testing and Materials (ASTM) Publications:

a. A36 Structural Steel b. A153 Specifications for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware c. A615 Deformed and Plain Billet - Steel Bars for Concrete

Reinforcement d. C33 Concrete Aggregates e. C139 Concrete Masonry Units for Construction of Catch Basins and

Manholes, Specification for f. C150 Portland Cement g. C478 Precast Reinforced Concrete Manhole Sections, Specification for h. C857 Recommended Practice for Minimum Structural Design Loading

for Underground Precast Concrete Utility Structures i. C858 Standard Specification for Underground Precast Concrete Utility

Structures 4. American Association of State Highway and Transportation Officials

(AASHTO) Publication: a. HB-13 Standard Specifications for Highway Bridges

5. American National Standard Institute (ANSI) Publication: a. C2 National Electrical Safety Code

6. National Fire Protection Association (NFPA) Publication: a. 70 National Electrical Code (NEC)

7. Pacific Gas and Electric Company (PG&E) Standard: a. Drawing Primary Electric Underground Equipment 062000 enclosures.

1.03 SUBMITTALS

A. Submit material or equipment data in accordance with the Product Review category of the General Conditions and the submittal requirements of Division 16.

B. Manufacturer's Data and Shop Drawings:

Underground Electrical Work CNG Fueling Station



1. Manhole and Handhole - Include a table of dimensions which shows proposed size of each manhole and handhole.

2. Manhole Frame and Cover 3. Handhole Frame and Cover 4. Sealing Material for Precast Manhole and Handhole Joints

C. Certificates 1. Test Reports: Submit for approval 30 days before the materials are used,

copies of laboratory test reports for the following: a. Arc-proofing test for cable fireproofing materials.


A. Seismic design requirements: 1. All raceway systems to be furnished under this Section shall be designed and

constructed to meet the seismic requirements of Section 01330.

PART 2 - PRODUCTS

2.01 GENERAL

A. Materials and equipment shall conform to the respective specifications and standards and to the specifications herein. Electrical ratings shall be as indicated.

B. Conduit: Provide per Section 16110.

C. Wire and Cable: Provide per Section 16120 & 16122

2.02 CAST-IN-PLACE AND PRECAST MANHOLES

A. Cast-in-place concrete manholes shall have a smooth trowel finish for floors and horizontal surfaces. Concrete shall conform to Division 3. Precast concrete manholes, risers and tops shall conform to ASTM C478, except that the spacing of manhole steps or ladder rungs shall not exceed 16 inches. Precast units (ACI 318) shall be the product of a manufacturer regularly engaged in the manufacture of precast concrete manholes and handholes. Manholes shall be the type noted on the drawings and shall be constructed in accordance with the applicable details as indicated. Top, walls, and bottom shall consist of reinforced concrete. Walls, bottom and top of manholes shall be of monolithic concrete construction; sectionalized construction is not acceptable. Duct entrances and windows shall be located near the corners of structures to facilitate cable racking. Covers shall fit the frames without undue play. Steel and iron shall be formed to shape and size with sharp lines and angles. Castings shall be free from warp and blow holes that may impair their strength or appearance. Exposed metal shall have a smooth finish and sharp lines and arises. Provide all necessary lugs, rabbets, and brackets. Set pulling-in iron shall be installed in the wall opposite each duct line entrance. The words "ELECTRICAL" shall be cast in the top face of all manhole covers. Cable racks, including rack arms and insulators, shall be adequate to accommodate the cable. Cable racking hardware shall be non-metallic and corrosion resistant as manufactured by Pacific Utilities Supply, or equal.

B. Metal Frames, Covers and Gratings: Provide steel or malleable iron frames, covers and gratings conforming to Federal Specification RR-G-661, Type I.



C. Manhole Doors: 1. Covers: Prior to galvanizing, the covers shall have letters applied, "E" for

power manholes and "S" for signal manholes. Letters shall be not less than 5 inches high formed by means of a welding bead in the center of the cover.

2. Manhole doors shall be hot-dipped galvanized steel after fabrication with spring operated hinged doors. Traffic doors shall be rated for HS 20-44 wheel loading as given in AASHTO HB-13 [, with I-beam removable base supports.

D. Complete manholes shall be rated for HS 20-44 wheel loading as given in AASHTO HB-13.

2.03 HANDHOLES

A. Provide handholes of reinforced precast concrete, or injection molded composite plastic material. Handholes shall include a base, a body, extensions, and a cover. Handholes with a perimeter of 10 feet or more (e.g., 3 feet by 2 feet) shall have both pulling irons and cable racks. All hardware shall be stainless steel, or hot-dip galvanized after fabrication; cable racking hardware, however, shall be non-metallic and corrosion resistant as manufactured by Pacific Utilities Supply (415) 495-4940 or equal. If no handhole size is shown on the Drawings, size units per NEC or provide 12 inches by 24 inches by 18 inches deep, whichever is larger. Structure shall be fabricated in accordance with ACI 318.

B. Aggregate used in pre-cast handholes shall conform to the specifications given in ASTM C33.

C. Cement used shall be Type 11, low alkali Portland cement and shall meet ASTM C150, Type 11.

D. Reinforcing bars shall be intermediate grade billet steel conforming to ASTM A615.

E. Design wheel loads for handhole covers and roof structures shall be HS 20-44 as given in AASHTO HB-13.

PART 3 - EXECUTION

3.01 GENERAL

A. Check the approximate locations of raceway system components shown on drawings for conflicts with openings, structural members, and components of other systems and equipment having fixed locations. In the event of conflicts, consult the Engineer. Make modifications and changes required.

B. Protection during construction: 1. In addition to the requirements of Division 01, prior to installation, store all

products in a dry location. Following installation, protect products from the effects of moisture, corrosion, and physical damage during construction. Keep openings in conduit and tubing capped with manufactured seals during construction. Cover PVC conduit, elbows, and PVC coated rigid steel conduit, nipples, elbows, and fittings from exposure to sunlight.

C. Material and equipment installation: 1. Follow manufacturer's installation instructions explicitly, unless otherwise

indicated. Wherever any conflict arises between manufacturer's installation instructions, codes and regulations, and these contract documents, follow




Engineer's decision. Keep copy of manufacturer's installation instructions on the jobsite available for review at all times.

3.02 TRENCHING, BACKFILL, AND COMPACTION

A. See Section 02301

3.03 WIRE AND CABLE INSTALLATION

A. See Sections 16120 and 16130.

3.04 UNDERGROUND RACEWAYS WITH CONCRETE ENCASEMENT

A. All underground raceways shall be encased in concrete unless otherwise specifically shown otherwise on the Drawings. 1. Concrete encasement shall be minimum of 3 inches around outer walls of

raceways and minimum of 2 inches between raceways. Conduits shall be PVC Type EB.

2. Concrete shall be portland cement type with 4 sacks cement per cubic yard of concrete, maximum coarse aggregate size of 3/8-inches and shall have minimum strength of 2,000 psi after 28 days. Amount of water shall not exceed slump required for placement. Five pounds red lead oxide shall be added per cubic yard of concrete for medium voltage raceway encasement only.

3. Underground raceways shall slope toward manholes, pullboxes, etc., at minimum rate of 3 inches per 100 feet unless indicated otherwise on Drawings. Raceway entrances in manholes, handholes, etc., shall be by means of bell ends and shall be sealed against entry of silt, debris, rodents, etc., into raceways.

4. Top of concrete encasement shall be minimum of 24 inches below grade. 5. Minimum radius of all horizontal bends in underground duct banks shall be

25 feet. Bends shall be formed of factory made sweeps or continuous assembly of bend segments or curved segments, except that polyvinyl chloride conduits may be field formed. Minimum radius of all vertical bends in underground raceways shall be ten times nominal size of conduit. Vertical bends shall be made of rigid steel or permanently coated aluminum conduit.

6. Underground raceways within roadways shall be run parallel or perpendicular to road centerline.

7. Pull wires left in underground raceways shall be 1/8-inch nylon rope or 3/16-inch polypropylene.

8. Terminate conduits in end-bells where duct lines enter manholes and handholes. Provide structural support for concrete encased duct banks at the point where they terminate. Separators shall be of precast concrete, high impact polystyrene, steel, or any combination of these. Stagger the joints of the conduits by rows and layers so as to provide a duct line having the maximum strength. During construction, protect partially completed duct lines from the entrance of debris such as mud, sand and dirt by means of suitable conduit plugs. As each section of a duct line is completed, draw a brush through having the diameter of the duct, and having stiff bristles until the conduit is clear of all particles of earth, sand, and gravel; then immediately install conduit plugs.

B. Connections to Existing Ducts: Where connections to existing duct lines are indicated, excavate the lines to the maximum depth necessary. Cut off the lines



and remove loose concrete from the conduits before new concrete encased ducts are installed. Provide a reinforced concrete collar, poured monolithically with the new duct line, to take the shear at the joint of the duct lines. Remove existing cables that constitute interference with the work. Abandon in place those used ducts and cables that do not interfere with the work.

C. Removal of Ducts: Where duct lines are removed from existing manholes, close the openings to waterproof the manhole. Chip out the wall opening to provide a key for the new section of wall.

D. Separation and Support: 1. Separate ductbanks no less than 4 feet 0 inches for power ductbanks

between adjacent sides and 2 feet 0 inches for signal ductbanks except where shown otherwise.

2. Separate signal and power ductbanks with minimum 2 feet 0 inches clear spacing.

3. At 90 degree ductbank crossings regardless of ductbank type, maintain 2 feet 0 inches clear spacing.

4. Support raceways installed in fill areas to prevent accidental bending until backfilling is complete. Tie raceways to supports, and raceways and supports to the ground, so that raceways will not be displaced when concrete encasement or earth backfill is placed.

5. Separate parallel runs of two or more raceways in a single trench with preformed, nonmetallic spacers designed for the purpose.

E. Arrangement and Routing 1. Where other utility piping systems are encountered by means of potholing or

being installed along a raceway route, maintain a 12-inch minimum vertical separation between raceways and other systems at crossings. Maintain a 12-inch minimum separation between raceways and other systems in parallel runs. Do not place raceways over valves or couplings in other piping systems. Refer conflicts with these requirements to the Engineer for instructions before further work is done.

2. Duct bank alignments shown on drawings are diagrammatic. Actual alignments shall contain no sharp bends and shall be installed with minimum radius bends as required in the CEC.

3. In multiple conduit runs, stagger raceway coupling locations so that couplings in adjacent raceways are not in the same transverse line.

4. All conduits shall enter handholes, buildings, and structures at right angles. Patch all duct knockouts and openings in handholes with non-shrink grout

F. See Section 16110 for additional requirements.

3.05 UNDERGROUND RACEWAYS WITHOUT CONCRETE ENCASEMENT

A. Provide raceways without concrete encasement only if specifically shown on the Drawings, otherwise, provide concrete encasement as above.

B. Provide sand backfill three inches all around the raceway.

C. Construct raceways per the applicable provisions above for underground raceways with concrete encasement.

D. See Section 16110 for additional requirements.




3.06 MANHOLES AND HANDHOLES

A. Provide manholes and handholes complete with all accessories, as indicated provide additional handholes as needed so that the spacing between handholes does not exceed 300 feet. Identify each casting by having the manufacturer’s name and address cast into an interior face or permanently attached thereto. Stencil manhole number in the neck with 3-inch-high yellow letters.

B. Manhole, Handhole, or Concrete Pullbox Grounding: Ground rods installed in electrical distribution system manholes, handholes, or concrete pullboxes shall be properly connected to the cable shielding, metallic sheath, and armor at each cable joint or splice by means of No. 4 AWG or equivalent braided tinned copper wire. Connections to metallic cable sheaths shall be by means of tinned terminals soldered to ground wires and to cable sheaths. Care shall be taken in soldering not to damage metallic cable sheaths or shields. Ground rods shall be protected with a double wrapping of pressure-sensitive plastic tape for a distance of 2 inches above and 6 inches below concrete penetrations. Ground wires shall be protected with a double wrapping of pressure-sensitive plastic tape for a distance of 2 inches above and 6 inches below concrete penetrations. Ground wires shall be neatly and firmly attached to manhole and handhole walls and the amount of exposed bare wire shall be held to a minimum.

C. Installation of Cable in Manholes and Handholes: Do not install cables utilizing the shortest route, but route along those walls providing the longest route and the maximum spare cable lengths. Form all cables to closely parallel walls, not to interfere with duct entrances, and support on brackets and cable insulators at a maximum of 18 inches. In existing manholes, handholes and vaults where new ducts are to be terminated or where new cables are to be installed, provide cable supports and grounding as required for a neat and workmanlike installation with all cables properly arranged and supported. Support cable splices in underground structures by racks, leaving top space open for future cables, except as otherwise indicated for existing installations. Provide one spare three-insulator rack arm for each cable rack in each underground structure. Provide additional cable racks in each existing underground structure through which new cable is run.

D. Fireproofing (Arc Proofing) of Cables in Manholes, Handholes and Vaults: All wire and cables which will carry current at 2,200 volts or more in manholes, handholes, and vaults shall be fireproofed. 1. Arc-proofing Test for Cable Fireproofing Materials: Test one sample

assembly consisting of a 3-inch diameter lead tube with a 1/4-inch wall thickness, fireproofed as specified. Make tests at three different points. At each point the testing shall consist of an arc magnetically blown against the test assembly until melting occurs at the point of arc contact. The arc shall be struck between two 7/8-inch electrodes located one inch from the sample assembly. Electrodes must be electrodes located one inch from the sample assembly. Electrodes must be squared off after each test run. Arc current shall be between 195 and 210 amperes at 40 vdc. For each test the fireproofing shall prevent damage to the lead for at least 25 seconds at any point and an average time of no less than 30 seconds for the test. In lieu of the above test, the Contractor may submit copies of the report of such a test previously made for the manufacturer, with certification that the material supplied for this project is the same as that used in the test. Test elements and requirements shall be essentially as specified in the test above.



2. Fireproofing Tape: Strips of fireproofing tape approximately 1/16-inch thick by 3 inches wide shall be wrapped tightly around each cable spirally in half-lapped wrapping, or in two butt-joined wrappings with the second wrapping covering the joints in the first. The tape shall be applied with the coated side toward the cable and shall extend one inch into the ducts. To prevent unraveling, the fireproofing tape shall be random wrapped the entire length of the fireproofing with pressure sensitive glass cloth tape. The fireproofing tape shall consist of a flexible, conformable fabric having one side coated with flame retardant, flexible, polymeric coating and/or a chlorinated elastomer not less than 0.050-inch thick and shall weigh not less than 2.5 pounds per square yard. The tape shall be noncorrosive to cable sheath, shall be self-extinguishing, and shall not support combustion. The tape shall not deteriorate when subjected to oil, water, gases, salt water, sewage and fungus.

E.

END OF SECTION




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16405 - 1 Switchboards CNG Fueling Station

SECTION 16405

SWITCHBOARDS PART 1 - GENERAL 1.01 SECTION INCLUDES

A. Provisions: Applicable provisions of Section 16010 become a part of this Section as if repeated herein.

1.02 APPLICABLE STANDARDS

A. American National Standard Institute (ANSI) Publications: 1. C57.13 Requirements for Instrument Transformers

B. International Electrical Testing Association (NETA) Publications: 1. ATS Acceptance Testing Specifications for Electric Power Distribution

Equipment and Systems

C. National Electrical Manufacturers Association (NEMA) Publication: 1. PB2 Deadfront Distribution Switchboards

D. National Fire Protection Association (NFPA) Publication: 1. 70 National Electrical Code (NEC)

E. Underwriters Laboratories (UL) Publication: 1. 891 Deadfront Electrical Switchboards

1.03 SUBMITTALS

A. Submit material or equipment data in accordance with the Product Review category of the General Conditions and the submittal requirements of Section 16010.

B. Shop Drawings: Submit shop drawings which shall include: complete layout of

equipment and devices; front and end elevations and floor plan to scale with major dimensions; structural details and overall weights; complete nameplate data and ratings of all devices; material, sizes, locations, and short circuit bracing rating of all buses; nameplate schedules; and circuit breaker time-current curves.

C. Regarding the seismic anchorage requirements refer to Section 01612 for

equipment certification and anchorage design.

D. Factory Test Report: Include the results of the applicable production tests as required in NEMA PB2.

E. Manuals: Provide in conformance with Section 16010.

Switchboards CNG Fueling Station



PART 2 - PRODUCTS 2.01 SWITCHBOARDS

A. Standards: Design, build and test the switchboard in accordance with applicable portions of NEMA PB2 and UL 891, and comply with the NFPA 70.

B. Switchboards shall be as shown on the Drawings. C. Provide service entrance switchboards with dedicated pull section and metering

enclosure as shown on the drawings, and in accordance with PG&E requirements D. Structure: The switchboard shall be a NEMA 1 completely self-supporting structure

of the required number of vertical sections bolted together to form one metal-enclosed switchboard approximately 90 inches high. Sides, top and rear covers shall be code gauge steel, bolted to the switchboard structure. The frame structure members shall be die-formed 12 gauge steel bolted together and reinforced at external corners with rugged gussets both internal and external to the structure members. The switchboard frame shall be suitable for use as floor sills. Structure shall be for indoor use. Switchboard shall be constructed so that when installed on the concrete pad (see Part 3) the unit complies with the NFPA 70 6'-7" rule. Access shall be from the front.

E. Devices: The switchboard shall include all the devices shown on the Drawings.

Devices with operating handles or control knobs or switches shall have the handles, knobs or switches externally accessible without opening any inner doors or covers.

F. Buses:

1. Main buses shall be tin-plated copper supported with high impact non-tracking insulation material, and braced to withstand mechanical forces exerted during short circuit conditions of 65,000 RMS symmetrical amperes. The continuous current density of the buses shall not exceed 1,000 amperes per square inch of cross section for copper or 750 amperes per square inch for aluminum. Continuous current ratings shall be as shown on the Drawings. Bus arrangement shall be A-B-C (left-to-right, top-to-bottom, front-to-rear) throughout.

2. Bus bar shall be bare main and feeder sections. 3. Ground bus shall be copper, not less than 1/4-square-inch in cross section.

Secure to the vertical section. 4. Neutral bus shall be copper and not less than 50% of the rating of the main bus.

Bus shall be insulated from the structure. Provide removable link between neutral and ground bus.

G. Wiring: Factory install all wiring within the switchboard and neatly cable and secure

to supporting surfaces. Provide terminal lugs for all external wiring. Small wire shall be Type SIS.

H. Provision for Future: Arrange horizontal main buses for convenient future extension

as shown on the Drawings. Provide vertical buses to the spaces shown on the Drawings for future devices, arranged to accept future mounting bolts and bus connecting straps.



I. Ambient Temperature: Base device ratings on operation in an ambient temperature

not exceeding 40°C. J. Connections: Cable connectors and device lugs shall be compression type and

suitable for use with copper or aluminum cables. K. Hardware: All hardware used on conductors shall have high tensile strength and

suitable protective finish. L. Handling Means: Provide the switchboard with adequate lifting means and make

switchboard capable of being rolled or moved into position and bolted directly to the floor without the use of floor sills.

M. Finish: Chemically clean and treat all steel surfaces, providing a bond between

paint and metal surfaces to help prevent the entrance of moisture and the formation of rust under the paint film. Finish the switchboard exterior with ANSI 61 light gray paint, not less than 2 mils thick.

N. Provide group mounted main and feeder circuit breakers. O. Main Circuit Breaker:

1. Insulated type, 3-pole, motor operated, 600 Vac, 100% rated, 65,000RMS symmetrical amperes interrupting capacity at 480 volts. Frame and trip ratings shall be as shown on the Drawings. It shall have an integral current sensor in each pole and an integral solid state self-powering programmable trip unit with 3 fault indicators. Motorized Breaker shall have stored energy operator, 120 Vdc motor-operated charging mechanism, and shunt trip. The trip unit shall provide the following tripping characteristics, all adjustable: a. Sensor Rating b. Sensor Setting Range c. Long Time Delay e. Short Time Delay f Ground Fault

2. Manufacturer: Eaton Magnum DS with Digitrip RMS Trip unit; or equal. P. Feeder Circuit Breakers:

1. Insulated or molded case type, 3-pole, motor operated, 600 Vac, 100% rated, 65,000 RMS symmetrical amperes interrupting capacity at 480 volts. Each breaker shall have an integral current sensor in each pole and an integral solid state self-powering programmable trip unit with 3 fault indicators. Breaker shall have stored energy operator, 120 Vdc motor-operated charging mechanism, and shunt trip. The trip unit shall provide the following tripping characteristics, all adjustable: a. Sensor Rating. b Sensor Setting Range. c. Long Time Delay. d. Short Time Delay. e. Instantaneous. f. Ground Fault




2. Manufacturer: Eaton Series JD, KD, and RD Series with Seltronic Trips; or equal.

P. Current Transformers: Provide three current transformers in accordance with

ANSI C57.11, 600 volt, 10 kV BIL, with ANSI metering accuracy class of 0.3 at burden B-0.1 and continuous thermal rating factor of 2.0.

Q. Power meter : Provide a microprocessor-based power monitor to measure electrical

parameters such as current, voltage, kW, power factor, frequency, and KWH. Power monitor shall include a keypad and a data port for Ethernet communications and/or DeviceNet or Modbus connected to the programmable logic controller as specified in Section 17330. Data shall be made available for display on the SCADA system. Provide Eaton IQ Series, Allen Bradley Power Monitor 3000, Power Monitor II, or equal.

R. Switchboards shall be listed and labeled as service entrance equipment if the

switchboard is used as service entrance. S. Ground Connections: Provide binding post type lugs for attachment of ground

cables to sheet steel enclosures. Lugs shall be of the binding post type, shall accommodate a range of stranded copper cable from #2 AWG to #2/0 AWG, shall have a 1/2 to 13 NC stud size and shall be attached to enclosures using a threaded or tapped boss welded to the sheet steel. These lugs shall be Burndy Type KC, Anderson Type KS, or equal. Provide bolted pressure connectors for all other ground connections. Provide one lug for each outgoing circuit.

T. Nameplates: Nameplates shall be provided for each control component. The

nameplate shall be phenolic, black background with white lettering. All nameplates shall be fastened by stainless steel screws.

U. Arc Flash Labels: Provide Arc Flash warning labels in addition to Arc Flash hazard

labels specified in Section 16020. V. Provide 120 Vdc battery charger and lead acid batteries, complete with al conduit

and wire as required for operating the circuit breakers. W. Switchboard shall be Eaton Powerline Series, or equal.

PART 3 - EXECUTION 3.02 SWITCHBOARD INSTALLATION

A. Mount the switchboard and anchor to a 3-inch concrete pad. Doors shall open and close freely and all manually operated device handles and controls shall operate properly.

3.04 FIELD TESTING

A. Test switchboard and circuit breakers in accordance with applicable NETA Publication ATS.



END OF SECTION




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16442 - 1 Padmount Sectionalizers CNG Fueling Station

SECTION 16442

PADMOUNT SECTIONALIZERS PART 1 - GENERAL 1.01 SECTION INCLUDES

A. Work Included:

1. Provide padmount fused sectionalizers. 2. Provide equipment pads where shown on the Drawings. 3. Provide ground connections to the pad grounding system installed per

Section 16450. 4. Provide underground conduit per Sections 16110 and 16402.


A. ASTM International (ASTM) Publications: 1. D117 Method of Testing and Specification for Electrical Insulating Oils of

Petroleum Origin 2. D877 Test Method for Dielectric Breakdown Voltage of Insulating Liquids

Using Disk Electrodes 3. D92 Test Method for Flash and Fire Points by Cleveland Open Cup

B. Institute of Electrical and Electronic Engineers (IEEE) Publication: 1. 386 Separable Insulated Connectors for Power Distribution Systems above

600V 2. C57.12.28 Pad-Mounted Equipment - Enclosure Integrity 3. C57.12.38 Pad-Mounted-Type, Self-Cooled, Single-Phase Distribution (Parking

Stands Only).

C. International Electrical Testing Associates (NETA): 1. ATS Acceptance Testing Specification

1.03 SUBMITTALS

A. Submit the following in accordance with Section 01300: B. Catalog Information: Submit manufacturer's descriptive literature. C. Shop Drawings:

1. Furnish detailed plan and elevation drawings giving equipment dimensions, anchoring information, and weights for each configuration shown on the Drawings, and giving ratings of fuses.

2. Provide drawings showing size of medium voltage insulated separable connectors and cable termination data.

3. Provide single line diagram and schematics for each configuration.

Padmount Sectionalizers CNG Fueling Station



D. Seismic Anchorage Design in accordance Division 3 including layout and calculations, signed and sealed by a Professional Civil or Structural Engineer registered in the State of California.

E. Affidavits: Submit affidavits from the manufacturer stating that the equipment has

been properly installed and tested and is ready for full-time operation in accordance with Section 01650, paragraph 1.04.

F. Factory Tests: Furnish manufacturer's certified standard test reports. G. Operation and Maintenance Manual: Provide in accordance with Section 01300,

paragraph 1.07. PART 2 - PRODUCTS 2.01 GENERAL

A. Sectionalizer configurations may be “3-way,” “4-way,” or “5-way” as shown on the Drawings. A “way” is defined as a connection from the exterior (either a source or a tap) to the interior switchgear bus that may be a direct electrical connection or a connection via switch or a fuse. The total number of “ways” is the sum of all sources and taps. The configuration for each shall be as follows: 1. 3-way: Two junctions for incoming and outgoing distribution, and one junction

for fused feeder. 2. 4-way: Two junctions for incoming and outgoing distribution, and two junctions

for fused feeders. 3. 5-way: Two junctions for incoming and outgoing distribution, and three

junctions for fused feeders. 2.02 CONSTRUCTION

A. Enclosure: The sectionalizing enclosure shall be suitable for outdoor use, and must be continuous seam-welded and manufactured of 12-gauge HRPO mild steel. All hardware must be stainless steel for corrosion resistance. Enclosure shall meet the finish requirements as defined in IEEE Std. C57.12.28 and be painted to match existing equipment.

B. Enclosure shall include a top hinged removable cover and allow one person

operation. Cover must also include a wind stop to prevent accidental closing. Enclosure shall include a deep angled recessed door with low sill for easy accessibility.

C. Enclosure shall include universal mounting plates painted light grey or white for

optimum visibility of cable terminations and must accept the following: 1. 200 A, 15 kV, three-position dead break junctions on fused feeders.

D. Enclosure shall include “parking lot” parking stand design providing multiple options

for parking of accessories. Enclosure shall provide a minimum of 1 parking stand pocket per phase. Enclosure shall include a minimum of one grounding provision per phase.


16442 - 3 Padmount Sectionalizers CNG Fueling Station

E. Enclosure must include provisions for lifting. F. Enclosure must include a recessed lock pocket, padlock hasp and pentahead bolt

for security. G. Units shall be Trinetics; Eaton Cooper; or equal.

2.03 FUSES

A. Provide Class E 15kV fuses, with ratings as shown on the Drawings. B. Spares: Provide 3 spare fuses of each ampere rating shown on the Drawings.

PART 3 - EXECUTION 3.01 GENERAL

A. Install padmount sectionalizers in conformance to the manufacturer's shop drawings and mounting instructions, including securing it to the concrete slab by at least four anchor bolts. Complete installation shall conform to the requirements of ANSI C2.

3.02 SIGNS

A. In addition to the name plates required in other Sections, sectionalizers shall also be outfitted with "DANGER - HIGH VOLTAGE" signs in accordance with Section 10400 on each accessible side of the sectionalizer.

B. Provide nameplate with the sectionalizer number.

3.03 FIELD TESTS

A. The Contractor shall perform all tests required by Section 16015.

END OF SECTION

Padmount Sectionalizers CNG Fueling Station



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16450 - 1 Grounding System CNG Fueling Station

SECTION 16450

GROUNDING SYSTEM

PART 1 - GENERAL

1.01 SUMMARY

A. SCOPE: This section specifies the system for grounding electrical distribution and utilization equipment, including but not limited to cabinets, motor frames, manholes, instrumentation, metal surfaces of process/mechanical equipment that contain energized electrical components, metal structures and buildings, outdoor metal enclosures, fences and gates.

B. SYSTEM REQUIREMENTS: 1. Provide equipment grounding conductors in all electrical raceways. The

conductors shall be sized in accordance with the National Electrical Code. 2. Underground, rebar, and building steel ground connections shall be via

exothermic weld. 3. Bond building’s rebar and building steel attributes to form a ground mat. Bond

all site ground mats via exothermic welds. 4. Provide cable tray grounding and bonding in accordance with these project

Specifications and the Drawings.

C. SIZING: The minimum size of the Equipment Grounding Conductors installed with the circuit conductors shall be per the National Electrical Code Table 250.122. The circuit grounding conductor size routed with a feeder or branch circuit conductors is as shown on the Drawings.

1.02 QUALITY ASSURANCE:




Reference Title

IEEE 81

Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System

IEEE Std 81.2-1991 Guide to Measurement of Impedance and Safety Characteristics of Large, Extended or Interconnected Grounding Systems

NETA - ATS Inter-National Electrical Testing Association Inc. - Acceptance Testing Specifications

NFPA 70 National Electric Code (NEC) Article 250

Grounding System CNG Fueling Station



1.03 SUBMITTALS:




2. Marked product literature for ground rods, test wells, and equipment ground plate.

3. Grounding system test data.

PART 2 - PRODUCTS

2.01 PROCESS EQUIPMENT GROUNDS

A. The Contractor shall coordinate with the equipment supplier to provide an equipment ground lug and contractor provided ground cable and terminations to bond the equipment to the grounding electrode system. Ground cable shall be sized in accordance with this specification. Provide cables, exothermic welds, and equipment bolted connections as necessary. Use of conduit as a grounding connection is not acceptable.

2.02 GROUND CONDUCTORS

A. The System Ground Conductor shall be soft-drawn, bare annealed copper, concentric stranded, as specified. The minimum sizes shall be as follows, where American Wire Gage (AWG) conductor sizes are not shown or specified: 1. 480V MCC and switchboards - 4/0 AWG 2. Cable tray - 2/0 AWG 3. Lighting & Power panels - #2 AWG 4. Exposed metal cabinets - #2 AWG 5. Electrical & Process equipment - #2 AWG 6. Buildings and enclosure - #2 AWG 7. Motors 25 hp to 250 hp - #2 AWG 8. Motors 1 hp to 25 hp - #6 AWG

2.03 GROUND RODS

A. Ground rods shall be copper covered steel, 3/4-inch diameter and 10-feet long. Rods shall have threaded type removable caps so that extension rods of same diameter and length may be added where necessary.

2.04 CONNECTORS

A. COMPRESSION CONNECTORS: Compression connections shall be irreversible, cast copper as manufactured by Thomas and Betts, or equal.

B. BOLTED CONNECTORS: Bolted connectors shall be Burndy, O.Z. Gedney, Thomas and Betts, or equal.

C. WELDED CONNECTORS: Exothermic welding products shall be Erico’s Cadweld Plus system with a remotely operated battery powered electronic ignition device and moisture resistant weld metal cup for the required mold, or equal.



2.05 TEST WELLS

A. CONCRETE BOXES: 1. Material: High density reinforced concrete box with non-settling shoulders

positioned to maintain grade and facilitate back filling with steel checker plate screw down cover.

2. Product and Manufacturer: Provide box assembly from one of the following: a. Concrete Box:

1) Christy Concrete Products, Inc. Model #B1017. 2) Or Approved Equal.

b. Steel Cover: 1) Christy Concrete Products, Inc. Model # B1017-51JH labeled

“GROUND”. 2) Or Approved Equal.

B. EXTERIOR TEST WELL: Provide concrete test well with cover and connect the ground grid extension using a removable connector.

C. INTERIOR TEST WELL: Provide concrete ground test wells for measuring the ground resistance of each separately derived system prior to terminating in equipment. Provide 18” ground conductor slack loop in each well. Route ground conductor from test well to equipment in PVC conduit.

2.06 EQUIPMENT GROUND BARS

A. Ground bars required in power distribution equipment shall be tin plated copper and sized in accordance with manufacturer’s standard.

2.07 EQUIPMENT GROUND BARS

A. Copper equipment ground bars shall be Erico Eritech EGB Series or equal, sized as required for the installation.

B. Ground bars specified in electrical rooms or adjacent to electrical equipment shall be tin plated copper and shall be wall mounted at 18 inches above finished floor on isolation standoffs. Unless otherwise specifically sized the ground bars shall be 30 inches long, 4 inches tall, and ¼ inches thick. Bars shall have pre-drilled 7/16” holes for termination of lugged conductors. Ground bars shall be Storm Copper, Alpha Equipment Company isolated ground bar assembly, or approved equal.

PART 3 - EXECUTION

3.01 GENERAL

A. Embedded and buried ground connections shall be made by exothermic weld connectors. Above grade ground connection shall be made by exothermic weld or by utilizing diamond or hexagon dies and a hand compression tool for wire sizes 2 AWG and smaller and a hydraulic pump and compression head for wire sizes 2/0 AWG and larger. Tools and dies shall be approved for this purpose; dimple compressions are not acceptable. Compression connections shall be prepared in accordance with the manufacturer's instructions. Exposed ground connections to equipment shall be made by bolted clamps unless otherwise specified. No solder shall be used in any part of the ground circuits.




B. Embedded ground cables and fittings shall be exothermically bonded to concrete reinforcing steel. Ground wires shall also be securely attached to concrete reinforcing steel with tie wires and prevented from displacement during concrete placement.

C. Grounding conductors, which are extended beyond concrete surfaces for equipment connection, shall be extended a sufficient length to reach the final connection point without splicing. Minimum extension shall be 3 feet. Grounding conductors, which project from a concrete surface, shall be located as close as possible to a corner of the equipment pad, protected by non-metallic conduit, or terminated in a flush grounding plate. Exposed grounding conductors shall be supported by noncorrosive metallic hardware at 4-foot intervals or less. Grounding conductors for future equipment shall be terminated using a two-hole copper flush mounted grounding plate.

D. Ground conductors, except signal conductor shields, entering enclosures shall be bonded together to the enclosure if it is metallic and to metallic raceways within or terminating at the enclosure. Prior to making ground connections or bonds, the metal surface at the point of connection shall be cleaned.

E. Compression-type lugs shall be used in accordance with manufacturer's recommendations.

F. Grounding conductor shall not be used as a system neutral.

G. Metallic sheaths or shields of shielded power cable shall be terminated by a copper grounding strip provided with cable connection for connection to the grounding system. Grounding strip shall be sized to withstand available fault current for specimen to be terminated.

H. Grounding system shall be provided in compliance with the NEC.

I. Bond building service piping systems to ground within three feet of entering the building.

3.02 RACEWAY GROUND

A. All service, feeder and branch circuit raceways shall contain a green insulated ground conductor sized per applicable NFPA 70 National Electrical Code (NEC) tables: 1. Table 250.66 - Grounding Electrode Conductor for Alternating-Current

Systems or 2. Table 250.122 - Minimum Size Equipment Grounding Conductors for

Grounding Raceways and Equipment.

B. Metallic conduits terminating at concentric knock-outs or reducing washers shall be bonded using insulated grounding bushings. Grounding bushings shall be connected to the grounding system using conductors sized in compliance with NEC.

C. Provide equipment grounding conductors in all power and control circuit raceways.

3.03 CABLE TRAY GROUNDING

A. Cable trays shall have 2/0 bare copper ground conductor run on the outside of each tray or tray group of tiered cable tray. Conductor shall be connected to each section or fitting using an approved ground-clamp and supported at 5 foot intervals.



3.04 EQUIPMENT AND ENCLOSURE BONDING

A. Electrical distribution and utilization equipment enclosure ground bus, motor frames, manholes, metal structures and buildings, outdoor metal enclosures, fences and gates shall be bonded to the grounding system with conductor sizes as specified.

B. Connect the conductor to the metal enclosure using a UL listed connector, where the enclosure does not contain an internal ground bus

C. Non-electrical equipment with metallic enclosures, that are located outdoor and without a cover or a shade, shall be connected to the grounding system.

3.05 ISOLATED GROUNDING

A. An isolated ground system shall be installed where required by an equipment manufacturer. The isolated ground conductor shall have green insulation with a yellow stripe and shall be run in the same raceway as the power and neutral conductors. The isolated ground bus shall be kept isolated from neutral and grounding buses.

B. Where specifically directed by the Owner and required by an equipment manufacturer, the Contractor shall provide an additional isolated ground conductor from the service or separately derived system to an isolated ground bus bar at each associated distribution point.

C. The neutral conductor from the ultra-isolation transformers shall be grounded only at the single point ground bus in the automatic transfer switch.

3.06 SERVICE AND SEPARATELY DERIVED SYSTEM BONDING

A. A neutral bonding jumper shall be installed in only one location for each service or separately derived system. The bonding jumper shall be located at the service source or the first immediate distribution point downstream from the source. The neutral and ground buses shall be kept isolated from each other accept where the bonding jumper is installed.

3.07 GROUNDING SYSTEM TESTS

A. The Contractor shall test the grounding system at each switchgear, switchboard and panelboard via the grounding electrode conductor to determine the ground resistance. The grounding test shall be performed using a calibrated Fluke 1625 Earth/Ground test meter or per IEEE Standard 81 using the NETA Fall-of-Potential procedure. Ground resistance readings shall be recorded and the Owner shall be notified within three (3) days if any reading exceeds 25 ohms.

B. Use of salts, water, or compounds to attain the specified ground resistance is not acceptable.

END OF SECTION




PAGE INTENTIONALLY

LEFT BLANK


16460 - 1 Padmount Transformers CNG Fueling Station

SECTION 16460

PADMOUNT TRANSFORMERS

PART 1 - GENERAL

1.01 SECTION INCLUDES

A. Work Included: 1. Provide padmount transformers. 2. Provide equipment pads where shown on the Drawings. 3. Provide ground connections to the pad grounding system installed per

Section 16450.


A. American National Standards Institute (ANSI) Publications: 1. C2 National Electrical Safety Code 2. C57.12.90 Test Code for Liquid-Immersed Distribution, Power and

Regulating Transformers 3. C57.12.27 Conformance Standard for Liquid-Filled Distribution Transformers

Used in Padmount Installations including Unit Substations 4. Z35.1 Accident Prevention Signs

B. ASTM International (ASTM) Publications: 1. D117 Method of Testing and Specification for Electrical Insulating Oils of

Petroleum Origin 2. D877 Test Method for Dielectric Breakdown Voltage of Insulating

Liquids Using Disk Electrodes 3. D92 Test Method for Flash and Fire Points by Cleveland Open Cup

C. Institute of Electrical and Electronic Engineers (IEEE) Publication: 1. C57.12.00 – Standard for Standard General Requirements for Liquid-

Immersed Distribution, Power, and Regulating Transformers. 2. C57.12.28 – Pad-Mounted Equipment - Enclosure Integrity. 3. C57.12.34 – Standard Requirements for Pad-Mounted, Compartmental-Type,

Self-Cooled, Three-Phase Distribution Transformers. 4. C57.12.90 – Standard Test Code for Liquid-Immersed Distribution, Power,

and Regulating Transformers and IEEE Guide for Short-Circuit Testing of Distribution and Power Transformers.

5. C57.12.91 – Guide for Loading Mineral-Oil-Immersed Transformers.

D. International Electrical Testing Associates (NETA): 1. ATS Acceptance Testing Specification

E. National Electrical Manufacturers Association (NEMA) Publication: 1. LA1 Surge Arresters 2. TR 1 Transformers, Regulators and Reactors, Table 0-2 Audible Sound

Levels for Liquid-Immersed Power Transformers. 3. 260 Safety Labels for Pad-Mounted Switchgear and Transformers

Sited in Public Areas.

1.03 SUBMITTALS

A. Submit the following in accordance with Section 01330:

Padmount Transformers CNG Fueling Station



B. Catalog Information: Submit manufacturer's descriptive literature.

C. Shop Drawings: 1. Furnish drawings giving equipment dimensions, anchoring information, and

weights for each rating shown on the Drawings, and giving ratings of transformers, switches, fuses and breakers.

2. Provide drawings showing size of high-voltage insulated separable connectors and cable termination data.

D. Seismic Anchorage Design in accordance with Section 01612 including layout and calculations, signed and sealed by a Professional Civil or Structural Engineer registered in the State of California

E. Factory Tests: Furnish manufacturer's certified standard test reports for the transformer ratings shown on the Drawings and for the tests specified herein.

F. Operation and Maintenance Manual: Include information for the transformers and instruction bulletins on the high-voltage cable terminator kit.

PART 2 - PRODUCTS

2.01 GENERAL

A. The high-voltage and low-voltage compartments, separated by a metal barrier, shall be located side-by-side on one side of the transformer tank. When viewed from the front, the low-voltage compartment shall be on the right for one of the two transformer and the other the low-voltage compartment shall be on the left. Each compartment shall have a door that is constructed so as to provide access to the high-voltage compartment only after the door to the low-voltage compartment has been opened. There shall be one or more additional fastening devices that must be removed before the high-voltage door can be opened. Where the low-voltage compartment door is of a flat panel design, the compartment door shall have three-point latching with a handle provided for a locking device. Hinge pins and associated barrels shall be constructed of corrosion-resistant material, passivated ANSI® Type 304 or the equivalent.

B. A recessed, captive, penta-head or hex-head bolt that meets the dimensions per IEEE Std C57.12.28 shall secure all access doors.

C. The compartment depth shall be in accordance with IEEE Std C57.12.34, unless additional depth is specified.

D. The tank base must be designed to allow skidding or rolling in any direction. Lifting provisions shall consist of four lifting lugs welded to the tank.

E. The tank shall be constructed to withstand 7 psi without permanent deformation, and 15 psi without rupture. The tank shall include a 15 psig pressure relief valve with a flow rate of minimum 35 SCFM.

F. The tank shall be complete with an anodized aluminum laser engraved nameplate. This nameplate shall meet Nameplate B per IEEE Std C57.12.00.


16460 - 3 Padmount Transformers CNG Fueling Station

2.02 TRANSFORMER

A. Unit shall be a dead front, three-phase, two winding, 60 Hertz, 65°C rise unit with mineral oil liquid insulation system. Self-cooled 300 KVA ratings as noted on the Drawings. High-voltage shall be 15 kV Delta with two 2-1/2% taps above and below normal. BIL shall be 95 kV. Impedance shall not be less than 5%. Low-voltage shall be 480Y/277 Volts, 4 wire grounded Wye. The external tap changer handle shall be located in the high-voltage compartment and shall be operable only with the transformer de-energized. Insulating liquid shall not contain any PCB chemicals.

B. Primary Compartment: Provide the following equipment as a minimum: 1. One gang-operated load break primary disconnect switch rated 15 kV at 200

amperes for radial feed operation. 2. Three oxide film gapless 15 kV lighting arresters. 3. Three drawout type current limiting primary fuse elements in transformer dry

wells. 4. Three radial feed load break insulated high-voltage inserts complete with

matching transformer dry wells and parking clips. 5. External tap changing handle operable only when the transformer is de-

energized.

C. Low-Voltage Compartment: Provide the following equipment as a minimum: 1. Liquid level gauge-dial type. 2. Thermometer-dial type. 3. Oil filling connection. 4. Drain and oil sample valves. 5. Pressure relief valve. 6. Neutral ground strap-removable. 7. Key interlock to high-voltage compartment door. 8. Nameplate in conformance with ANSI C57.12.26 except that the number of

gallons of coolant shall be shown. 9. Transformer case grounding pad.

D. Low Voltage Bushings and Terminals: The transformer shall be provided with tin-plated spade-type bushings for vertical takeoff. The spacing of the connection holes shall be 1.75 inch on center, per IEEE Std C57.12.34.

E. FINISH: Unless otherwise specified, electrical equipment shall be painted by the manufacturer 1. Exterior shall be painted to match existing equipment. 2. Prior to shipment, the completed assemblies shall be given an exterior finish

coat of air drying paint 2 mils minimum thickness.

F. Factory Test: Perform the following factory tests: 1. Routine Factory Tests-ANSI C57.12.00 Section 8.1.

G. Units shall be Eaton; Square D; or equal.

Padmount Transformers CNG Fueling Station



PART 3 - EXECUTION

3.01 GENERAL

A. Install padmount transformer in conformance to the manufacturer's shop drawings and mounting instructions, including securing it to the concrete slab by at least four anchor bolts. Complete installation shall conform to the requirements of ANSI C2.

B. Lace secondary conductors to resist short circuit forces. Follow manufacturer's recommendations.

3.02 SIGNS

A. In addition to the name plates required in other Sections, transformers shall also be outfitted with "DANGER - HIGH VOLTAGE" signs on each accessible side of pad mounted transformers.

B. Provide nameplate with the transformer number

3.03 FIELD TESTS 1. The Contractor shall perform all tests required by NETA.

3.04 OPERATING TEST

A. Energize the transformer and adjust the output voltage to the specified value. After the transformer has been energized 48 hours, operate each high-voltage fused cutout then retest and adjust the output voltage if required.

END OF SECTION


16500 - 1 Luminaires CNG Fueling Station

SECTION 16500

LUMINAIRES

PART 1 - GENERAL

1.01 SUMMARY

A. SCOPE: This section specifies luminaries (lighting fixtures) features and installation.

B. S PECIFICATIONS REFERENCED 1. 16120: Low Voltage Conductors 2. 16110: Raceways, Boxes, and Fittings

C. DEFINITIONS: Terminology used in this Section conforms to the following definitions: 1. Lighting terminology used herein is defined in IES RP-16.




Reference Title

NFPA 70 National Electrical Code (NEC)

IESNA LM 79 Electrical and Photometric Measurements of Solid-State Lighting Products

IESNA LM 80 Measuring Lumen Maintenance of LED Light Sources

UL 844 Electric Lighting Fixtures for Use in Hazardous (Classified) Locations

B. SPECIAL WARRANTY: Provide a Special Warranty for LED luminaires. The Special Warranty shall include as a minimum the following: 1. A written 5-year on-site replacement material, fixture finish and workmanship.

On-site replacement includes transportation, removal, and installation of new products. Finish warranty must include warranty against failure or substantial deterioration such as blistering, cracking, peeling, chalking or fading.

2. A written 5-year replacement material warranty for defective or non-starting LED source assemblies.

3. A written 5-year replacement material warranty on all power supply units (PSU).

Luminaires CNG Fueling Station



4. A written 5-year replacement warranty for luminaires producing inadequately maintained illuminance levels at the end of the warranty period, as prorated from levels expected at end of useful life.

5. The Owner may request an optional 10-year replacement warranty for inadequately maintained illuminance levels, finish of luminaire, PSU, or defective LED source assemblies. The terms of the extended warranty will be negotiated by the Owner and the luminaire manufacturer for an additional cost.

6. The warranty period shall begin on the date of Substantial Completion. The Contractor shall provide the Owner with appropriate signed warranty certificates. The Owner shall have received these certificates prior to final payment.

1.03 SUBMITTALS




2. Manufacturer's descriptive catalog literature for all fixtures and accessories being installed under this section. Information shall include manufacturer, wattage, voltage, mounting configuration, and lamp type. Catalog cuts shall be edited to show only the items, model numbers, and information which apply.

3. Applicable operation and maintenance items as specified in Division 1. 4. Catalog information describing fixture make, materials, and dimensions.

PART 2 - PRODUCTS

2.01 GENERAL

A. Unless otherwise specified, lighting materials, including fixtures, accessories, and hardware, shall conform to the detailed requirements specified on the Drawings. Lighting fixtures shall be provided where specified on the drawings. The drawing’s light fixture placement is diagrammatical in nature. The actual installation and fixture layout shall be coordinated with the various trades and equipment.

B. Light Fixtures shall comply with UL 57, and be UL classified and labeled for intended use. Fixtures for use in hazardous locations shall be UL listed per UL Standard 844.

2.02 EXTERIOR LIGHTING POLES

A. GENERAL: Provide lighting poles with pole cap and the necessary fixture mounting hardware.

B. TYPE: Poles shall be square, galvanized steel, marine-grade painted, with hand holes.


16500 - 3 Luminaires CNG Fueling Station

2.03 LED LUMINAIRES (LED)

A. LED luminaires shall be a complete functioning unit with all components including light source, lamps, power supply, control interface and any additional components needed for operation shall be assembled by the luminaire manufacturer.

B. Luminaires shall comply with ANSI chromaticity standard for classifications of color temperature. Luminaire shall be UL or ETL listed and labeled.

C. Luminaire testing shall be per IESNA LM-79 AND LM-80 procedures.

D. Useful Life Requirements: The useful life of the luminaire in terms of lumen output must be specified by one of the following two methods: 1. Simplified L70 threshold: A minimum of 50,000 operating hours before

reaching the L70 lumen output degradation point, accounting for individual LED lumen depreciation and catastrophic failures. Fifty percent of the sample population must reach the 50,000 hour point – this is known as B50. Only 10 percent of the LED lamps can have failed in a conventional sense – this is known as F10.

E. Provide shop drawings showing illumination levels with LED systems based on lumen output at 70 percent lumen depreciation for white LEDs and 50 percent for colored LEDs. Initial lumen output for all LEDs shall be listed individually.

F. LED drivers 1. Drivers shall have reversed polarity protection, open circuit protection and

require no minimum load. 2. Drivers shall operate at a minimum 85 percent efficiency and have a class A

noise rating. 3. LED driver shall be solid state unit mounted within fixture and shall be

adequately ventilated and match the LED fixture rating in watts and voltage.

G. Where LED systems are required to be dimmable, the LED system shall be capable of full and continuous dimming.

2.04 LIGHTING CONTROLS

A. Type of lighting control and sensors in each equipment areas. Provide lighting control systems for each equipment area space as shown on the Contract Drawings.

B. General: Contractor shall work with lighting control manufacturer representative to provide equipment necessary to meet intent of control shown on the Contract Drawings. Contractor shall submit site plans, floor plans and wiring diagrams for approval by engineer as part of the submittal process.

C. Time Switch 1. Digital electronic time switch shall have a Form C dry contact, output rated for

6 amps at 120 VAC. Time switches shall have the minimum following set of features. a. Time out setting ranging from 5 minutes to 12 hours. b. 5-minute time resolution up to 1 hours, then 15-minute time resolution

up to 12 hours. c. Visual warning feature that flashes lights at 5 minutes and 1 minute

prior to time-out. d. Compatible with LED and motor loads

Luminaires CNG Fueling Station



e. Manufacturer: Tork, Paragon Electric Company, or approved equal.

D. Exterior Photocell: 1. Automatic ON/OFF switching photo control 2. Housing: Self-contained, die-cast aluminum, unaffected by moisture,

vibration, or temperature changes 3. Setting: ON at dusk and OFF at dawn 4. Time delay feature to prevent false switching 5. Field adjustable to control operating levels 6. Manufacturers: Tork, Paragon Electric Company, or approved equal.

PART 3 - EXECUTION

3.01 GENERAL

A. The location and type of fixtures are shown on the drawings. Lighting circuit raceways and conductors shall be sized by the contractor. Raceways and wire shall be provided from the fixtures and switches to the lighting panel in accordance with the NEC. Raceways shall be provided in accordance with Section16110. Wire shall be provided in accordance with Section 16120.

B. Fixtures labeled to require conductors with a temperature rating exceeding 75 degrees C shall be spliced to circuit conductors in a separately mounted junction box. Fixture shall be connected to junction box using flexible conduit with a temperature rating equal to that of the fixture.

C. Photoelectric cells, where specified, shall be oriented toward the north.

D. Labels and marks, except the UL label, shall be removed from exposed parts of the fixtures. Fixtures shall be cleaned when the project is ready for acceptance.

E. Where recessed fixtures are required, the fixture shall be provided with mounting hardware for the ceiling system specified. Catalog numbers given on the Drawings shall not be used for selection of mounting hardware, but only as a reference to the type of fixture required. A concealed latch and hinge mechanism shall be provided to permit access to the lamps and ballasts and for removal and replacement of the diffuser without removing the fixture from ceiling panels. Fixtures recessed in concrete shall have protective coating of bituminous paint.

F. Fixtures shall be aligned and directed to illuminate an area as specified. Fixtures shall be directly and rigidly mounted on their supporting structures. Unless otherwise specified, conduit system shall not be used to support fixtures. Where brackets or supports for lighting fixtures are welded to steel members, the welded area shall be treated with rust-resistant primer and finish paint.

G. Underground and outdoor wire splices shall be in accordance with Section 16120.

END OF SECTION


17010 - 1 Instrumentation and Controls, General Requirements

CNG Fueling Station

SECTION 17010

INSTRUMENTATION AND CONTROLS, GENERAL REQUIREMENTS PART 1 - GENERAL 1.01 SECTION INCLUDES

A. Work Included: 1. Provide all tools, equipment, materials, and supplies and be responsible for all

labor required to complete the installation, startup and operational testing of a complete and operable Instrumentation and Control (I&C) System as indicated on the Drawings and as specified herein.

2. Provide all the necessary equipment components and interconnections along with the services of manufacturers' engineering representatives necessary to ensure that the Owner receives a completely integrated and operational I&C system as herein specified.

3. Provide all terminations for wiring at field mounted instruments, equipment enclosures, alarm and status contacts.

4. Provide all Instrumentation and Control wire required for a fully functioning Instrumentation and Controls System as shown on the Drawings except for wire specifically specified in Division 16. See Section 16010.

B. Work Specified in Other Divisions or Work done by Others

1. Process piping, installation of inline instrumentation, chemical pumps and other mechanical work and equipment as specified in Divisions 11, 13, and 15.

2. Division 16 work, including all instrumentation and controls conduit, and only that wire specified in Division 16. Refer to Division 16 Specifications for specific requirements for wire, conduit, grounding, and other electrical equipment.

3. Final control elements as specified in Section 15050 4. General mechanical requirements as specified in Section 11001.


A. American National Standard Institute (ANSI) Publications: 1. Y14.15a Drafting Practice 2. C62.1 Surge Arrestors

B. Instrumentation Society of America (ISA) Publications: 1. S5.4 Instrument Loop Diagrams 2. S20 Specification Forms for Process Measurement and Control

Instruments, Primary Elements and Control Valves 1.03 I&C SUBCONTRACTOR QUALIFICATIONS

A. An I&C Subcontractor shall be an electrical contractor who has demonstrated experience in purchasing, calibrating, fabricating, installing and testing the Instrumentation and Control (I&C) products listed in this Specification Section.

Instrumentation and Controls, General Requirements CNG Fueling Station



1.04 I&C SUBCONTRACTOR SYSTEM RESPONSIBILITIES

A. General: The I&C equipment as specified in this Division shall be considered an integrated system. Entire system installation including calibration, verification, startup, operation testing, and training shall be performed by qualified personnel, possessing all the necessary skills and equipment, and who have had experience performing similar installations. Instrumentation and control systems drawings are diagrammatic only; it is the responsibility of the Contractor to obtain technical data, determine performance requirements, develop instrumentation detail installation designs, and coordinate the selection of specified equipment with Contractor supplied equipment to meet the design conditions stated.

1.05 SUBMITTALS

A. Refer to Specification Section 01300 for required method of preparation and transmittal, and conform to requirements herein.

B. Shop Drawings: Submit shop drawings (diagrams) for review in complete bound

sets indexed by Specification number, with exterior tabs marked by subject. Submit manufacturer's catalog cuts for each item for which shop drawings are not required. Manufacturer's catalog cuts, specifications or data sheets shall be clearly marked to delineate the options or styles to be furnished. Show dimensions, physical configurations, methods of connecting instruments together, mounting details, and wiring schematics. Drawings shall be complete with device tag numbers, wire numbers and terminal board numbers. Submit fabrication details, nameplate legends, and control panel internal wiring and piping schematic drawings. Submit panel graphic drawings where applicable. Include material lists and/or bills of material. 1. Elementary Diagrams: Submit an elementary diagram (also known as a

schematic diagram - (see Sketch 40 90 00-3) for control, protection, and monitoring circuits. Elementary diagrams are not required for lighting, communications and those systems clearly defined on the single line diagram. Show all interconnections between power sources, apparatus, and device elements of a particular system or equipment, and all interlocks with other systems in a manner, which fully indicates circuit function and operation. Refer to the Drawings for functional and operational requirements.

C. Specification Forms:

1. Submit completed Specification Forms per ISA S20, including those instrumentation and control components directly related to process control, but specified in other Divisions of these Specifications.

2. Include on each form the assigned tag numbers, manufacturer's part numbers, and device data. More than one tag numbered item may be included on a sheet.

D. As-Built Drawings: Submit a revised set of shop drawings that incorporates all

change orders and modifications made during performance of the work. In addition to updated loop diagrams, interconnect diagrams and elementary diagrams, submit equipment and device wiring diagrams (see Sketch 40 90 00-4) and other drawings as necessary to depict the "as-built" condition of equipment. Include all installed field and panel conduit and piping/tubing runs and routing, tray systems, supports,



CNG Fueling Station

mounting details, interconnection diagrams with cable, wire, tube and termination numbers. Coordinate all drawings with the conductor identification requirements in Section 16000. Submit a copy of CAD produced drawings on magnetic media in AutoCAD DWG format.

E. Operation and Maintenance Manuals: Furnish Operation and Maintenance Manuals,

including Instruction Manuals and Part Lists, for equipment provided under Division 40 as required by the Special Provisions and Section 01300. Obtain data from manufacturers, and format and bind as specified. Obtain distribution method instructions from the Owner or his representative. 1. Schedule: Deliver two (2) copies of manuals in 2-inch, 3-ring (D-ring) binders,

Wilson-Jones #386-44W, or equal, not later than the equipment shipment date. 2. Contents: Include in manuals not less than the following information, as

applicable, for each instrument, equipment, subsystem and/or control loop: a. General, introduction and overall description, purpose, functions, simplified

theory of operations, etc. b. Specifications (including equipment specification data sheet as described

above under Shop Drawings), sufficiently detailed for reordering exact duplicates of the original items.

c. Installation instructions, procedures, sequences, tolerances, and precautions.

d. Operational procedures. e. Shutdown procedures. f. Maintenance, calibration, and repair instructions. g. Parts list and spare parts recommendations. h. Calibration curves, rating tables, and any other data showing the

relationship of the variable inputs and the calibrated output of all measuring devices and controlled equipment.

3. Format: a. Use drawings and pictorials to illustrate the text to the extent necessary to

insure a clear, concise presentation. If manuals have been written to cover a family of similar instruments or equipment, strike out inapplicable information in a neat fashion or emphasize applicable portion by heavily weighted arrows, circles or boxes; whichever provides the clearest and neatest presentation.

b. Group manuals by system. Where identical instruments are used in more than one control loop or subsystem, include only one instruction manual, per panel grouping; however, an index by tag number for all instruments shall identify its location in that manual.

c. Provide control loop and/or subsystem operational descriptions to identify the function of each instrument and its relation to the other instruments in the loop.

4. Binding: Bind each manual in a cover which indicates the panel or process area to which it applies, manufacturer's name, local address and telephone number, and year of purchase. Punch and bind manuals in standard three ring binders and include system name and subcontractor's name on binding.

F. Accessory and Maintenance Materials: Submit data for the following items:

1. Special Tools and Accessories: Special tools, instruments, and accessories for maintaining instruments and equipment requiring periodic repair and




adjustment as specified elsewhere herein. Also, furnish special lifting and handling devices for equipment requiring such devices.

2. Maintenance Materials and Spare Parts: Submit a list of manufacturer recommended spare parts for each item specified. Refer to other sections of these Specifications.

G. Test Reports: Submit the following test reports as described herein: Instrument

Calibration Data Sheets


A. Standard of Quality: The Contractor shall provide equipment of the types and sizes specified which has been demonstrated to operate successfully. Provide equipment which is new and of recent proven design.

1.07 INSPECTIONS

A. The Design Engineer may inspect the fabricated equipment at the factory before shipment to job site. Provide the Engineer with sufficient prior notice so that an inspection can be arranged at the factory.

B. Inspection of the equipment at the factory by the Design Engineer will be made after

the manufacturer has performed satisfactory checks, adjustments, tests and operations.

C. Favorable review of the equipment at the factory only allows the manufacturer to

ship the equipment to the project site. The Contractor shall be responsible for the proper installation and satisfactory startup operation of the equipment to the satisfaction of the manufacturer and the Design Engineer.

1.08 DRAWINGS

A. Drawings: The Instrumentation Drawings are diagrammatic; exact locations of instrumentation products shall be determined in the field by the Engineer. Except where special details are used to illustrate the method of installation of a particular piece or type of equipment or material, the requirements or descriptions in this Specification shall take precedence in the event of conflict. 1. Locations of equipment, inserts, anchors, motors, pull boxes, conduits, stub-

ups, fittings and ground wells are approximate unless dimensioned; verify locations with the Engineer prior to installation. Field verify scaled dimensions on Drawings.

2. Review the Drawings and Specification Divisions of other trades and perform the instrumentation work that will be required for the installations.

3. Should there be a need to deviate from the Instrumentation Drawings and Specifications, submit written details and reasons for all changes to the Design Engineer for favorable review.

4. Resolution of varying interpretations of the Contract Documents shall conform to the Special Provisions.

5. The Drawings provide details of installation and supersede the manufacturer's recommendation where a conflict exists.



CNG Fueling Station

1.09 PRODUCT DELIVERY, STORAGE, AND HANDLING

A. Box, crate, or otherwise enclose and protect instruments and equipment during shipment, handling, and storage. Keep all equipment dry and covered from exposure to weather, moisture, corrosive liquids and gases or any element that could degrade the equipment. Protect painted surfaces against impact, abrasion, discoloration, and other damage. Notify the engineer in writing in the event that any equipment or material is damaged. Obtain prior favorable review by the Engineer before making repairs to damaged products.

1.10 INSTRUMENT SCHEDULE

A. See Appendix A for Instrument Schedule.

PART 2 - PRODUCTS 2.01 MATERIALS AND STANDARD SPECIFICATIONS

A. Provide instruments, equipment and materials suitable for service conditions and meeting standard specifications such as ANSI, ASTM, ISA, and SAMA. The intent of this Specification is to secure instruments and equipment of a uniform quality and manufacture throughout the plant. All instruments in the plant of the same type shall be made by the same manufacturer.

2.02 NAMEPLATES

A. For each piece of equipment, provide a manufacturer's nameplate showing his name, location, the pertinent ratings and the model designation.

B. Identify each piece of equipment and related controls with a rigid laminated

engraved phenolic nameplate. Engrave nameplates with the inscriptions indicated on the Drawings and, if not so indicated, with the equipment name. Securely fasten nameplates in place using two stainless steel screws or, where favorably reviewed by the Engineer, with epoxy cement. Where no inscription is indicated on the Drawings, furnish nameplates with an appropriate inscription furnished by the Engineer upon prior request by the Contractor.

C. Each control device, including pushbuttons, control switches, and indicating lights,

shall have an integral legend plate or nameplate indicating the device function. These shall be inscribed as indicated on the Drawings or as favorably reviewed by the Engineer.

D. Provide CAUTION or SAFETY nameplates to alert operators of special conditions

that may result in faulty equipment operations. Devices containing batteries that must be replaced periodically must be clearly identified. Nameplates are not required if the device senses and displays a low battery warning.




2.03 NAME TAGS

A. All instrumentation and equipment items or systems shall be identified by nametags. Field equipment shall be tagged with the assigned instrumentation tag number on the Drawings.

B. Name tags shall be stainless steel with engraved or stamped black characters of

3/16-inch minimum height. Tags shall be attached to equipment with a tag holder and stainless steel band with a worm screw clamping device. Use 20-gauge stainless steel wire where banding is impractical. For field panels or large equipment cases use stainless steel screws; however, such permanent attachment shall not be on an ordinarily replaceable part.

2.04 FIELD-MOUNTED EQUIPMENT

A. All instrument and control equipment mounted outside of protective structures shall be equipped with suitable surge arresting devices to protect the equipment from damage due to electrical transients induced in the interconnecting lines from lightning discharges or nearby electrical devices. Protective devices used on 120 Vac inputs to field mounted equipment shall be secondary valve surge protectors conforming to the requirements of ANSI C62.1.

2.05 EQUIPMENT OPERATING CONDITIONS

A. All equipment shall be rated for normal operating performance with varying operating conditions over the following minimum ranges: 1. Electrical Power: 120 Vac ±10%, 60 Hz, unregulated, except where specifically

stated otherwise on the Drawings or in the Specifications, or when two-wire, loop-powered devices are specified.

2. Field Instruments: a. Outdoor Protected Areas: Ambient Temperature: +15°F to +104°F Ambient Relative Humidity: 5% to 95% Weather: Rain, sleet, snow and ice b. Indoor Unheated Areas: Ambient Temperature: +40°F to +104°F Ambient Relative Humidity: 5% to 95%, non-condensing c. Indoor Environmentally Controlled Areas: Ambient Temperature: +60°F to +104°F

2.06 EQUIPMENT LOCATIONS

A. Provide equipment and materials suitable for the types of locations in which they are located as defined under Division 26. All equipment specified for field mounting shall be weatherproof and splash proof as a minimum. If electrical or electronic components are contained within the equipment, they shall be housed in NEMA 4 cases, unless noted otherwise on the Drawings.



CNG Fueling Station

2.07 ANALOG SIGNAL INDICATED UNITS

A. For all instruments with local or remote indicators, provide indicators scaled in actual engineering units, i.e., gallons per minute, feet, psi, etc., rather than 0 to 100%, unless noted otherwise on the Drawings.

2.08 SIGNAL TRANSMISSION

A. Analog: 1. Signal transmission between electric or electronic instruments shall be 4-20 mA

and shall operate at 24 Vdc. Signal output from all transmitters and controllers shall be current regulated and shall not be affected by changes in load resistance within the unit's rating. Where practical, milliampere signals from the field shall be converted to a voltage signal at the external terminals of each panel, and all instruments within a panel shall be parallel wired.

2. Nonstandard transmission systems such as impulse duration, pulse rate, and voltage regulated will not be permitted except where specifically noted otherwise or shown on the Drawings. When transmitters with nonstandard outputs do occur, their output shall be converted to 4-20 mA prior to transmission.

B. Discrete: All alarm and status signals shall be 24 VDC unless specified otherwise.

Proprietary data highway or serial bit transmissions such as RS232C shall be allowed to the extent shown on the Drawings.

2.09 PAINTING

A. Factory paint all instruments and equipment except where installed in pipelines. Where instrument panels are installed adjacent to electrical control panels provided under Division 16, provide instrument panels of identical color to that of electrical control panels. Paint as required in Division 9 for structural supports, brackets, etc. Repair damaged factory paint to satisfaction of the Engineer. Feathering, priming and painting shall produce a reasonable match to the surrounding paint work.

2.10 FASTENERS

A. Fasteners for securing equipment to walls, floors and the like shall be either hot-dip galvanized after fabrication or stainless steel. Provide stainless steel fasteners in corrosive locations. When fastening to existing walls, floors, and the like, provide capsule anchors, not expansion shields. Size capsule anchors to meet load requirements. Minimum size capsule anchor bolt is 3/8-inch.

2.11 TUBING, PIPE, FITTINGS AND SUPPORTS

A. General: Instrument tubing listed below is required for all instruments and control valves. Select the appropriate tubing materials to satisfy service conditions except where specifically shown on Installation Detail Drawing.




1. Fittings: a. Copper Tube: Solder joint fittings shall be seamless wrought copper per

ASTM B75. Compression fittings shall be Brass equal to Imperial or Swagelok.

b. Stainless Steel Tube: Weld joint fittings shall be Type 304 stainless. Compression fittings shall be Type 316 stainless steel equal to Imperial or Swagelok.

c. Supports for Tubing: Supports located in areas exposed to the weather or corrosive atmosphere shall be Type 304 stainless steel Unistrut or equal or made of steel conforming to ASTM A276. Supports not exposed to the weather or corrosive atmosphere shall be carbon steel painted.

d. Weld joint fittings shall be permitted for header and branch service only. Instrument and valve connections shall be compression-type only. Use unions on as necessary to simplify instrument removal.

2. Valves: a. Pipe, Pipe Fittings and Valves: Main-line piping material and root valves for

instrumentation shall be as specified in Section 15050. b. Instrument valves shall be 1/4-inch, 3/8-inch or 1/2-inch from Whitey or

Hoke to match tubing material and size. 2.12 INSTRUMENT CALIBRATION

A. Each field instrument shall be calibrated at 0%, 25%, 50%, 75% and 100% of span using test instruments to simulate inputs and read outputs that are rated to an accuracy of at least 5 times greater than the specified accuracy of the instrument being calibrated. Such test instruments have accuracies traceable to the National Institute of Standards and Technology (NIST).

B. Submit a written report to the Engineer on each instrument. This report shall include

a laboratory calibration sheet or the manufacturer's standards calibration sheet on each instrument and calibration reading as finally adjusted within tolerances.

C The Contractor may, at his option, choose to perform calibration on an instrument by

acquiring the services of an independent test lab, or by obtaining the required test instruments and performing the calibration.

PART 3 - EXECUTION 3.01 MOUNTINGS

A. Mount and install equipment as indicated. Mount field instruments on pipe mounts or other similar means in accordance with suppliers' recommendation. Where mounted in control panels, mount according to requirements of that section.

B. Equipment specified for field mounting shall be suitable for direct pipe mounting or

surface mounting, surface-mounted indicators and equipment with calibration adjustments or requiring periodic inspection shall be mounted not lower than 3 feet-6 inches nor higher than 6 feet above walkways, platforms, catwalks, and the like.



CNG Fueling Station

C. Note that applicable specifications require detail drawings showing seismic sway bracing design and anchorage requirements for their equipment. Seismic zone requirements are specified in Division 1.

D. All devices shall be accessible to operators for servicing, operating, reading, etc.

Provide permanent platforms to assure devices are continuously accessible. 3.02 PROCESS CONNECTIONS

A. Terminate connection to process lines or vessels in a service rated roof valve, provided under other Divisions, that will permit closing off the impulse line or removal of the element without requiring shut down of the process. Include blowdown of drip legs and valves for terminations of impulse lines at the instruments.

B. Process vessels, line penetrations, and root valves shall be furnished and installed

under other Divisions of these Specifications. Instrument tubing and valve manifolds are installed as part of this Specification.

3.03 FIELD WIRING

A. Ring out signal wiring prior to termination and perform surge withstand tests where required (see Section 16015, Part 3 for methods). Verify wire number and terminations are satisfactory as designated on the Loop and Interconnect Diagrams. Verify all terminations are tight and shields are uniformly grounded at one location.

3.04 ELECTROMAGNETIC INTERFERENCE (EMI)

A. Construction shall proceed in a manner which minimizes the introduction of noise (RFI/EMI) into the I&C System.

B. Cross signal wires and wires carrying ac power or control signals at right angles. C. Separate signal wires from wires carrying ac power or switched ac/dc control

signals within control panels, terminal cabinets, telemetry equipment, multiplexer cabinets, and data loggers as much as possible. Provide the following minimum separations within such equipment unless indicated otherwise on the Drawings:

Power Wiring Capacity Separation (Inches)

120 volts ac or 10 amps 240 volts ac or 50 amps 480 volts ac or 200 amps 4,160 volts ac or 800 amps

12 18 24 48

3.05 PREPARATION

A. Ensure that installation areas are clean and that concrete or masonry operations are completed prior to installing instruments and equipment. Maintain the areas in a broom-clean condition during installation operations.




B. Panels shall be protected during construction to prevent damage to front panel devices and prevent dust accumulation in the intervals. Other protective measures (lamp, strip heaters, etc.) shall be included as weather conditions dictate.

3.06 FIELD TESTING

A. General: The purpose of the field testing is to verify instruments are calibrated and operationally performing their intended function. Provide the services of factory trained and experienced engineers to perform verification and operational testing as prescribed below. Since the initial calibration of instruments may not satisfy the final operation of system, perform recalibration or adjust setpoints as required to satisfy the performance requirements of the system. Notify the Engineer and Owner in writing a minimum of 48 hours prior to the proposed date for commencing final operational testing and acceptance.

B. System Verification Testing: Verify that each instrument shown on the Drawings is

operating and calibrated by simulating inputs at the primary element in each system loop and verify performance at loop output devices (i.e. recorder, indicator, alarm, etc., except controllers). Simulate inputs at 0%, 25%, 50%, 75%, and 100% of span or with on-off inputs, as applicable. During system verification: 1. Make initial or provisional settings on levels, alarms, etc. listed in the Instrument

Schedule. 2. Verify controllers by observing that the final control element moves in the

proper direction to correct the process variable as compared to the set point. 3. Cause malfunctions to sound alarms or switch to standby to check system

operation. 4. Check all loop instruments thoroughly for correct operation. 5. Immediately correct all defects and malfunctions disclosed by tests. 6. Submit a report certifying completion of verification of each instrument system.

This report shall include a data sheet on each instrument tested that indicates instrument tolerances, instrument calibration verification, data and initial settings made to devices.

C. Final Operational Testing: Upon completion of instrument verification, test all

systems under process conditions in the presence of the Engineer or designated representative. The intent of this test is to demonstrate and certify the operational interrelationship of plant instrumentation and control systems. This testing shall include, but not be limited to: 1. Making final adjustments to levels, alarms, etc. 2. Checking all alarms, failure interlocks, and operational interlocks. 3. Verifying all computer input and outputs and CRT displays are fully functional. 4. Immediately correcting all defects and malfunctions and retesting.

3.07 INSTRUCTION OF OWNER'S PERSONNEL

A. In accordance with Specification Section 01640, provide the services of a factory trained and field experienced instrumentation engineer to conduct group training of the Owner's designated personnel in the operation of each instrument system. This training shall be for the time period of one-half working day and shall be performed during the operational testing period. Include instruction covering basic system theory, operating principles and adjustments, routine maintenance and repair, and



CNG Fueling Station

"hands on" operation. The text for this training shall be the Operation and Maintenance Manuals furnished under these Specifications.

3.07 WARRANTY


END OF SECTION




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17120 - 1 Flow Measurement CNG Fueling Station

SECTION 17120

FLOW MEASUREMENT

PART 1 - GENERAL

1.01 SECTION INCLUDES

A. Requirements of Division 01 and Sections 16000 form a part of this Section. This Section specifies flow measurement devices for process instrumentation, auxiliary equipment and supplies directly related to the installation of and operation of these flow measurement devices, to perform the required functions in conjunction with information and equipment specified in other sections.

1.02 SUBMITTALS

A. Shop drawings to be submitted in this Section shall be made in one package under the Product Review Category of Shop Drawings.

B. Shop Drawings: 1. Submit shop drawings which include: supply voltage and frequency, electrical

load, accuracy, description of operation, operating instructions, and calibration procedure.

2. Furnish Shop Drawings for each item of mechanical equipment presenting sufficient data to determine compliance to these Specifications. Submit completed ISA S20 forms for each device and physical dimensions. Also submit manufacturer's recommended upstream and downstream straight piping lengths, recommended location of any pressure taps, and estimates of pressure losses through the device.

C. Installation Method: The proposed method of mounting sensors and instruments shall accompany all shop drawings.

D. Parts List: Submit a Parts List with current net prices and a list of recommended spares.

E. Factory Testing and Calibration: 1. All meters shall be factory tested. Perform a factory test and/or provide

certification of calibration from an independent test laboratory. Calibration curves based on factory and/or laboratory testing (see option below) shall be provided for the Engineer's favorable review. Furnish calibration curves in units of output

Flow Measurement CNG Fueling Station



(inches or rpm/gpm) versus measured flow. Upon receipt of the Engineer's favorable review, the Contractor may have the meters shipped to the job site.

2. As an option to laboratory testing each meter, the calibration curves of six (6) "like devices" may be substituted provided the calibration data is available from at least one identical device (pipe size, flow range, and type plus accessories such as extension registers).

3. The flow tube supplier shall provide laboratory calibration data to the transmitter supplier or, where practical, test the flow tube and transmitter as an integral assembly. The integral test shall be accomplished at no extra cost to the customer.

F. Manuals: Furnish manufacturer's installation, lubrication, operation and maintenance manuals, bulletins, and spare parts lists.

G. Affidavits: Furnish affidavits from the manufacturers stating that the meters have been properly installed and tested and each is ready for full time operation.


A. Manufacturer: In addition to the requirements of Section 17010, flow measurement devices furnished shall be manufactured by firms regularly and currently engaged in the design and manufacture of similar equipment. All equipment furnished shall be new and of current design.

B. Maintainability: All equipment shall be designed for ease of maintenance and repair, and access to critical parts shall not require a major disassembly. Internal field adjustments where permitted or required herein shall be easily accessible upon removal of a panel or cover.

C. Materials and Installation: Materials and installation shall comply with the requirements of the current editions of referenced electrical codes and standards, and the codes and standards referred to shall be used for establishing the minimum quality of the materials and equipment supplied and installed. All equipment of the same type shall be products of the same manufacturer. Capacities of all equipment shall not be less than that indicated on the Drawings or as specified.

1.04 SEISMIC PROTECTION

A. Seismic restraint for metering devices, which are integral with piping, shall be as specified for the piping system in which they are installed. Seismic design certification and anchorage descriptions are specified in Section 01612.


17120 - 3 Flow Measurement CNG Fueling Station

1.05 INDICATING UNITS

A. Provide flow indication in LBPM, GPM, CFS, MGD, etc. Do not use indicators, which read 0 to 100%, 4-20 mA, etc.

1.06 SERVICE CONDITIONS

A. Provide process fluid description that includes type of liquid or gas, pH, density, viscosity, suspended solids concentration, temperature, mixed liquid/gas or air entrainment to support flow device materials. Consider flow device applications in: 1. Wastewater 2. Digester (gases)

PART 2 - PRODUCTS

2.01 MASS FLOWMETER - GAS

A. General: Mass flowmeters are used to measure gas flow composed of methane and carbon dioxide. These meters provide a direct measurement of gas flow that is independent of pressure, temperature and specific gravity, thus eliminating the need to make many independent measurements and calculations. The mass flowmeter shall be designed for insertion mounting and utilize hot-wire method.

B. Provide a sensor designed for insertion into a pipe. Include all accessories as needed so that the sensor can be removed through a full port valve without shutting down the gas system. Mating flanges shall be 150 pound ANSI raised face flange. All materials shall be designed for use in the intended service. Electrical connections shall meet NEC, Article 500 for Class 1, Division 1, Groups C and D for hazardous service. Turndown ratio shall be at least 5:1. Accuracy shall be 1% of actual flow rate or less.

C. A remote electronic indicating transmitter and integral totalizer shall produce a 4-20 mAdc signal that is proportional to linearized flow. The indicator shall be calibrated in LBPM in the range indicated in the Instrument Index. The transmitter/sensor distance shall be up to 500 feet or may be co-located provided hazardous service requirements are observed. Furnish a cable between the sensor and the transmitter that is at least 25 feet in length. This length may be reduced depending upon the actual location of the transmitter. The transmitter shall be supplied by 120 Vac and include a 24 Vdc power supply capable of supplying current to a 600 ohm load.

Flow Measurement CNG Fueling Station



D. Manufacturer: Unit shall be from FCI, Inc., Model ST98; Kurz Series 454FTB-WGF; or equal.

E. Special Tools: Provide calibrator for field calibration of the instrument.

F. Equipment Location and Tags:

Description Tag Reference Drawing

Digester Gas Treatment Flow FIT2210 22-I-02

Off Gas Flow FIT2212 22-I-02

PART 3 - EXECUTION

3.01 INSTALLATION

A. Provide installation, testing, calibration, verification, and startup instructions in accordance with Sections 16010 and 17010.

3.02 FIELD TESTING

A. All flow devices are to be field tested against a secondary standard at the normal (or expected) process flow rates.

B. The contractor may select at his option to either install a second flow device of known calibration in the line to verify flow device calibration.

END OF SECTION


17150 - 1 Pressure Measurement CNG Fueling Station

SECTION 17150

PRESSURE MEASUREMENT PART 1 - GENERAL 1.01 SECTION INCLUDES

A. Requirements of Division 1 and Section 17010 form a part of this Section. This Section specifies pressure measurement devices for process instrumentation, auxiliary equipment and supplies directly related to the installation of and operation of these pressure measurement devices, to perform the required functions in conjunction with information and equipment specified in other sections of Division 17.

1.02 SUBMITTALS

A. Shop drawings to be submitted in this section shall be made in one package under the Product Review Category of Shop Drawings.

B. Shop Drawings: In addition to the requirements of Section 17010, shop drawings

shall include for each type of instrument: supply voltage and frequency, electrical load, accuracy, description of operation, operating instructions, and calibration procedure.

C. Installation Method: The proposed method of mounting sensors and instruments

shall accompany all shop drawings. D. Parts List: Submit a Parts List with current net prices and a list of recommended

spares. 1.03 QUALITY ASSURANCE

A. Manufacturer: In addition to the requirements of Section 17010, pressure measurement devices furnished shall be manufactured by firms regularly and currently engaged in the design and manufacture of similar equipment. All equipment furnished shall be new and of current design.

B. Maintainability: All equipment shall be designed for ease of maintenance and

repair, and access to critical parts shall not require a major disassembly. Internal field adjustments where permitted or required herein shall be easily accessible upon removal of a panel or cover.

C. Materials and Installation: Materials and installation shall comply with the

requirements of the current editions of referenced electrical codes and standards, and the codes and standards referred to shall be used for establishing the minimum quality of the materials and equipment supplied and installed. All equipment of the same type shall be products of the same manufacturer. Capacities of all equipment shall not be less than that indicated in the Instrument Index.

Pressure Measurement CNG Fueling Station



PART 2 - PRODUCTS 2.01 PRESSURE TRANSMITTERS - ELECTRONIC

A. General: 1. Electronic indicating-type pressure transmitters shall convert a gauge or

absolute pressure measurement to a 4-20 mAdc linear electrical output signal capable of transmission into at least a 600 ohm maximum load at 24 Vdc or less. Signal and power transmission shall be provided on a single pair of wires. Operating ambient temperature limits shall be at least -40° to +82°C.

2. Range shall be as indicated in the Instrument Index. Overrange protection shall be at least 1-1/2 times span without degradation of accuracy. Reference accuracy shall be ±1/2 percent or better.

B. Construction:

1. The transmitter enclosure shall be NEMA 4X rated except where explosion-proof is required as noted on the Drawings. The process connection for clean liquid service shall be 1/4-inch NPT. Enclosure and wetted surface material shall be corrosion resistant and suitable for the process fluid.

2. Transmitters shall be liquid-filled employing diaphragm where shown on the Drawings. Use optional remote seal with capillary length selected to suit installation needs, such as location, elevation, or orientation. Standard seal flange shall be a 3-inch 150-pound USAIS lap joint flange. A mating transmitter ANSI flange shall be provided with each transmitter per Section 15050.

C. Hazardous Locations: Transmitters shall be intrinsically safe or protected by barrier

or explosion-proof enclosure for applications in hazardous locations. See Electrical Drawings.

D. Manufacturers: Rosemount, Model 1151; Fischer & Porter; or equal.

2.02 PRESSURE GAUGES

A. Pressure and Vacuum Gauges: Pressure and vacuum gauges shall be of the local mounting type unless panel mounted type is shown on the Drawings.

B. Construction: 1. Gauges shall be of the bourdon tube or bellows type with 270 degrees C.W.

pointer travel. Dials shall be white with black numerals. Panel-mounted gauges shall have round bezels for flush mounting and rear connection. Others shall have a stem mounting bottom connection, cast iron case, plastic lens, and blowout protection. Accuracy shall be 1% of full-scale maximum and readable to 1%. Connection for all gauges shall be male 1/4-inch NPT with square wrench flats. Provide diaphragm seals on corrosive fluid and gas lines and those lines having large amounts of

2. Refer to Section 15050 for additional requirements for snubbers, dampening, pressure limiting, and material requirements.

3. Pressure indicators on Digester Gas Piping shall be provided where shown. Pressure indicator shall be well-type manometers with red indicating oil with


17150 - 3 Pressure Measurement CNG Fueling Station

range to 20 inches water column. Indicator shall have venting petcock at inlet to permit calibration. Pressure indicators shall be Varec Series 217, Groth Model 8170, or equal.

2.03 DIAPHRAGM PRESSURE SEALS

A. General: 1. Units shall consist of corrosion-resistant lower housing and diaphragm, and

instrument mounting upper housing. Lower housing shall have a 1-inch NPT female process and a 3/8-inch flushing connection terminated with a 3/8-inch hose bibb and shall be Type 316 stainless steel. Diaphragm shall be Type 316 stainless steel, unless otherwise noted. Upper housing shall have bleed screw, NPT female instrument connection, and shall be steel, unless otherwise noted. Filling fluid shall be suitable for a temperature range of -17° to +260°F.

2. Where noted on the Drawings, capillary assembly shall be furnished to connect diaphragm seal to instrument.

B. Manufacturer: Units shall be Mansfield & Green, Type SG; Ashcroft, Type 101; or

equal. 2.04 INSTRUMENT MANIFOLDS

A. General: Test valve manifolds shall be used with all pressure and differential pressure transmitters installed in clean liquid (no entrained solids) service. Test manifolds shall be corrosion resistant with integral 2-valve assembly (or block and bleed) for pressure transmitters and 3-valve assemblies (block and bypass with manometer ports) for differential pressure transmitter installation.

B. Provide manifold(s) with the following hardware, performance features and ratings:

1. Traditional mount manifold type. Two-valve or three-valve. 2. Direct mount manifold type. Two-valve. 3. Coplaner manifold type. Three-valve integral. 4. Process connection. 1/2-14 MNPT. 5. Material: Body, Bonnet, Stem, Drain/Vent Plug, 316 SST. 6. Packing material: Grafoil. 7. Calibration tap or adapter.

C. Manufacturer: Provide Rosemount Model 305AT traditional mount, 306AT direct

mount, or 305AC coplaner flange; or equal. PART 3 - EXECUTION 3.01 INSTALLATION

A. On systems requiring diaphragm seals, the Contractor shall order (or assemble) a completely filled system. The filling fluid shall be silicone oil [or glycerin]. Interconnecting piping shall be kept short. The filled system shall retain the same calibration requirements of the individual components.

Pressure Measurement CNG Fueling Station



B. Installation, testing, calibration, validation, startup and instruction shall be in accordance with Section 17010.

END OF SECTION


17300 - 1 Control Strategies CNG Fueling Station

SECTION 17300

CONTROL STRATEGIES

TITLE: System Configuration A. General: This strategy describes the configuration of the Programmable Logic

Controllers (PLCs) and associated SCADA computers (HMI). B. Packaged Controls: There are 3 packaged control systems each provided with a

control panel and PLC controllers. Each packaged system controls include an HMI to allow local monitoring and control of the particular process. The package controls shall be integrated to the existing Plant PLC and SCADA systems to read data as shown on the drawings and specified herein. A fiber optical Ethernet cable is used to connect these packages to the existing PLC/SCADA network at PLC-3 at the Boiler building using Modbus-over-Ethernet protocol The packaged controls include:

Gas Treatment (Bio CNG) Vehicle Fuel Equipment Controls

C. Existing Programmable Logic Controller PLC-3: PLC-3 shall be programmed by the

City’s programmer to control and monitor new signals as part of this project. Contractor shall coordinate with the City’s Programmer for direction on where to land new signals in the cabinet for PLC-3.

E. SCADA System: The existing Plant SCADA system software shall be configured to

provide overall monitoring and control of all plant functions by the City’s programmer. The SCADA system shall integrate all PLC data over the existing PLC/SCADA Ethernet network.

DESCRIPTION 1.00 – GENERAL FUNCTIONS

1.1 GENERAL FUNCTIONS

A. Functions fall in to the categories of hardwired functions, programmed functions within package PLC’s, and associated displays, and programmed functions within Plant PLC’s and associated Plant Supervisory Control and Data Acquisition (SCADA).

B. For all programmed functions within Plant PLC’s and SCADA, the work will be accomplished by the City’s Programmer. The work shall conform to the City’s standards (published and defacto) and practices, in all areas including the following:

1. Alarm latching and disables 2. Alarm remote notification procedures 3. Communications from Plant PLC to Plant or packaged PLC 4. Communications from PLC to SCADA

Control Strategies CNG Fueling Station



5. Control system master time 6. Equipment call order/fail over techniques 7. Equipment speed or position discrepancy alarms 8. Fail-to-respond to commanded state alarms 9. Out-of-range alarms 10. I/O processing 11. Initialization routines 12. PLC program structure/organization 13. PLC programming software selection and version 14. Remote network access 15. Runtime and start counters 16. Totalizers 17. Supervisory Manual/Auto Control 18. SCADA alarm priorities/SCADA graphics standards 19. SCADA historian details or standards 20. SCADA navigation details 21. SCADA screen content 22. SCADA security logins/access 23. SCADA software selection and version 24. SCADA trending 25. Tagname standards

DESCRIPTION 1.10 – Digester Gas Storage (FUTURE)

DESCRIPTION 1.11 – Digester Gas Treatment System

A. REFERENCES:

1. Process Area: 22. 2. P&ID Drawings: 22-I-02 3. Plant PLC: 3 4. Package PLC: PLC Gas Treat. (Furnished and programmed by manufacturer) 5. SCADA Screen: Digester Gas Treatment

B. MECHANICAL EQUIPMENT

Tag Number Equipment Name

22-CH-101 Chiller

22-GCP-101 Gas Treatment Compressor

FCV371 Product Gas Flow Control Valve

FCV372 Off-Gas Flow Control Valve



C. INSTRUMENTATION

Tag Number Instrument Name

FIT2210 Digester Gas Flow Meter

PIT2210 Digester Gas Inlet Pressure

AIT371 Product Gas Analyzer

FIT2211 Product Gas Flow Meter

FIT2212 Off-Gas Flow Meter

ZT371 Product Gas Flow Control Valve Position Indication

ZT372 Off-Gas Flow Control Valve Position Indication

D. SYSTEM OVERVIEW

1. Functions listed below are controlled by PLC GAS TREAT.

2. PLC GAS TREAT initiates the gas treatment system start-up sequence after receiving a start signal from Vehicle Fuel System controller. Start signal is a hard wire connection.

3. Digester gas flows to the gas treatment system when the Gas Treatment Compressor 22-GCP-101 is started by PLC GAS TREAT. The compressor is started after PLC GAS TREAT starts the chiller, and the chiller reaches its operating temperature set point.

4. Hydrogen sulfide is first removed from the digester gas by H2S Removal system 22-DGS-101.

5. After treatment by 22-DGS-101, the gas flows to gas treatment skid for compression, moisture removal, siloxane removal, and carbon dioxide removal.

6. Product gas control valve FCV371 and off gas control valve FCV372 are modulated to maintain a Product Gas flow setpoint, and to maintain a methane concentration in the product gas. The methane concentration is measured by AIT371.

7. Vary the digester gas flow through the gas treatment system based on digester gas pressure inputs (PIT1582 or PIT15282) accessible from PLC3.

E. LOCAL CONTROLS AND INSTRUMENTATION:

1. Local control is available using the panels below.

2. Gas Treatment Control Panel HMI (furnished by Gas Treatment vendor)

3. Chiller Control Panel (furnished by Gas Treatment vendor)




F. MCC CONTROLS AND INSTRUMENTATION:

1. None

G. PACKAGE PLC/OIS FUNCTIONS:

1. The Gas Treatment Control Panel contains PLC Gas Treat that controls the gas treatment components furnished by the vendor. PLC Gas Treat is programmed by the vendor.

2. An HMI in the Gas Treatment Control Panel is configured to allow monitoring and local control of the gas treatment system. The gas treatment system should be operated in the Auto Mode only.

3. PLC Gas Treat transmits and receives signals from the Chiller Control Panel to control and monitor the chiller.

4. PLC Gas Treat receives and transmits inputs and output with the Plant PLC network and SCADA system using Ethernet communications.

5. PLC Gas Treat initiates the gas treatment system start-up sequence after receiving a start signal from Vehicle Fuel System controller.

6. PLC Gas Treat transmits a signal to PLC Vehicle Fuel when the gas treatment system has started.

7. PLC Gas Treat varies the digester gas flow through the gas treatment system based on digester gas pressure inputs available at PLC3. The control strategy for this function is specified as Description 1.14, Gas Pressure Control.

8. PLC Gas Treat receives inputs from the Waste Gas Burner Control Panel for monitoring and alarming of the Waste Gas Burner on the Waste Gas Burner SCADA Screen.

9. There is no remote control of the gas treatment system via the Plant SCADA system.

H. PLANT PLC/OIS FUNCTIONS

1. Plant PLC 3 shall be programmed as needed to allow PLC Gas Treat to access its registers to read inputs via Ethernet.

2. Plant SCADA system shall be configured to receive input and output signals from PLC Gas Treat via Ethernet for alarming and for use on the Gas Treatment SCADA system display.

3. Screen Indicators and Alarms (Gas Treatment SCADA Screen):

1) Digester Gas Treatment Flow (FIT2210) 2) Digester Gas Inlet Pressure (PIT2210)



3) Compressor Inlet Pressure (PT330) 4) Compressor Outlet Pressure (PT331) 5) Product Gas Pressure (PT371) 6) Product Gas Valve Position (ZT371) 7) Off Gas Pressure (PT372) 8) Off Gas Valve Position (ZT372) 9) Gas Analyzer – Methane (AIT371M) 10) Gas Analyzer – Carbon Dioxide (AIT371C) 11) Product Gas Flow (FIT2211) 12) Off Gas Flow (FIT2212) 13) Gas Treatment System Run 14) Gas Treatment System Fault 15) Existing Waste Gas Burner Inlet Pressure (PIT15121 16) Chiller Run

4. Screen Indicators and Alarms for the Waste Gas Burner SCADA Screen are

listed in Description 3.13, Section H.2

DESCRIPTION 1.12 – Vehicle Fuel System

1.2 TEMPLATE

A. REFERENCES

1. Process Area: 23 2. P&ID Drawings:23-I-01 3. Plant PLC 3 4. Package Control: PLCs within the equipment control panels are furnished and

programmed by the manufacturer. 5. SCADA Screen: Vehicle Fuel



23-DGD-501 Inlet Gas Dryer

23-GCP-101 CNG Compressor No. 1

23-GCP-201 CNG Compressor No. 2

23-GCP-301 Natural Gas Booster Compressor

23-PCP-401 Priority Panel

C. INSTRUMENTATION


PT23101 Compressor No. 1 Inlet Pressure

PT23102 Compressor No. 1 Outlet Pressure




PT23201 Compressor No. 2 Inlet Pressure

PT23202 Compressor No. 2 Outlet Pressure

PIT23301 Vehicle Fuel System Inlet Pressure

FIT23301 Natural Gas Flow Meter

PT23401 CNG Supply Pressure

FIT23401 CNG Flow

D. SYSTEM OVERVIEW

1. The vehicle fuel system dries and compresses RNG or NG to create CNG, and then stores the CNG.

2. The Priority Fill panel controls the CNG pressure and distributes the CNG to the CNG storage vessels.

3. The CNG is dispensed to a mobile fueling vehicle that transports the CNG to the Petaluma Refuse and Recycling site. The CNG may also be dispensed to City vehicles

4. PLCs within the equipment control panels are furnished and programmed by the manufacturer. The control panel PLCs communicate via Ethernet using a Vehicle Fuel Communications Panel, which is used to route communications with the Plant SCADA network using Modbus-over-Ethernet proctocol.


1. Local control is available in the manufacturer furnished panels below. HMI’s in the panels are configured and programmed by the Vehicle Fuel System vendor.

a. Inlet Dryer Control Panel

b. Compressor No. 1 Control Panel

c. Compressor No. 2 Control Panel

d. Priority Panel

e. Natural Gas Booster Compressor Control Panel


1. None




1. The PLCs in the equipment panels are programmed by the vehicle fuel system manufacturer to complete the functions described below locally only.

2. Controls and monitors CNG pressure in the CNG storage system.

3. When the CNG pressure decreases below the low pressure set point, send a signal to PLC Gas Treat to initiate the gas treatment start up sequence.

4. Upon receipt of a signal from PLC Gas Treat that the gas treatment system has started, shall start the lead CNG compressor.

5. If the Vehicle Fuel System Inlet Pressure (PIT23301) falls below a low pressure setpoint when any CNG compressor is operational, then the Vehicle Fuel controller shall start the NG Booster Compressor.

6. Receives and transmits inputs and output with the Plant PLC network using Ethernet communications.

7. There is no remote control of the Vehicle Fuel System via the Plant SCADA system.


1. The Plant SCADA system receives input and output signals from the Vehicle Fuel Communications Panel via Ethernet for alarming and for use on the Vehicle Fuel SCADA system display.

2. Screen Indicators and Alarms (Gas Treatment SCADA Screen):

1) Inlet Dryer On-Off 2) Inlet Dryer Fault 3) CNG Compressor No.1 On-Off 4) CNG Compressor No. 1 Fault 5) CNG Compressor No. 1 Inlet Pressure 6) CNG Compressor No. 1 Outlet Pressure 7) CNG Compressor No.2 On-Off 8) CNG Compressor No. 2 Fault 9) CNG Compressor No. 2 Inlet Pressure 10) CNG Compressor No. 2 Outlet Pressure 11) Priority Panel On-Off 12) Priority Panel Fault 13) CNG Flow 14) CNG Pressure

DESCRIPTION 1.13 Waste Gas Burner System

1.3 TEMPLATE

A. REFERENCES




1. Process Area: 22 2. P&ID Drawings: 22-I-02 3. Plant PLC: 3 4. Package PLC: Waste Gas Burner Controller 5. SCADA Screen: Waste Gas Burner



22-FLR-201 Waste Gas Burner

SV-2213 Pilot Solenoid Valve-Digester Gas

SV-2214 Pilot Solenoid Valve-Natural Gas

22-MV-101 Upper Burner Ring Flow Valve

22-MV-102 Middle Burner Ring Flow Valve

C. INSTRUMENTATION


TE-22201 Waste Gas Burner Stack Temperature

PIT22201 Waste Gas Burner Inlet Pressure

D. SYSTEM OVERVIEW

1. The waste gas burner combusts the off gas from the gas treatment system.

2. The pilot for the waste gas burner is will be started when the gas treatment system begins its start-up sequence.

3. Burner ring flow valves 22-MV-101 and 22-MV-102 shall be opened and closed by the Waste Gas Burner controller based on pressure indicating transmitter PIT22201.

4. Flare stack temperature TE-22201 shall be monitored by the Plant SCADA System.


1. Waste Gas Burner Control Panel (furnished by Waste Gas Burner vendor)


1. None




1. The Waste Gas Burner controller controls the operation of the pilot solenoid valves. This is local control only.

2. The Waste Gas Burner controller opens and closes the Burner Ring control valves based on inlet pressure to the Waste Gas Burner.

3. The Waste Gas Burner controller receives a remote start signal from the PLC Gas Treatment to start the pilot flame.

4. There is no remote control of the waste gas burner system by the SCADA system


1. The Plant SCADA System receives input signals from Waste Gas Burner Control Panel via PLC Gas Treat for alarming and for use on the Waste Gas Burner SCADA system display.

2. Screen Indicators and Alarms (Waste Gas Burner SCADA Screen)

1) Waste Gas Burner – Power On 2) Waste Gas Burner – Ready 3) Waste Gas Burner - Run 4) Waste Gas Burner – Fault 5) Pilot On 6) Upper Burner Ring – Open/Close 7) Middle Burner Ring – Open/Close 8) Stack Temperature 9) Inlet Pressure

DESCRIPTION 1.14 Digester Gas Pressure Control

General

1. The Gas Treatment System manufacturer (Unison Solutions), will program PLC Gas Treat to vary its Product Gas production rate based on digester gas pressure at either Digester 1 or 2. Following is a general description of the control strategy.

Control Strategy Description

1. Unison to program PLC Gas Treat to vary the Product Gas (PG) Flow setpoint based on operator selectable digester gas pressure device (PIT 1582 for Digester 1 or PIT 15282 for Digester 2). Variation of the PG setpoint will cause the compressor to vary its speed, and will vary the digester gas flow to the gas treatment system. Flow setpoint and selectable digester gas pressure device shall also be adjustable via a Plant SCADA screen.

2. VFD for the gas treatment compressor shall operate with digester gas inlet flow range of 50 to 100 cfm




3. Control shall be based on gas pressure in the digesters, when the gas pressure is within a range of 7 to 11 inches w.c.

4. Permissives to start a. Digester gas pressure above 9 inches w.c. (PIT 1582 used for the descriptions

below.) b. Flow to existing waste gas burner (FIT 15121) at a minimum of 60 scfm for 60

minutes. The minimum flow setting shall be adjustable via a Plant SCADA screen.

c. Call to run from the CNG controller. This initiates the gas treatment start up sequence that may take up to 20 minutes. (Depends upon length of time for gas treatment chiller to reach target temperature.)

5. Control after gas treatment system starts (Gas treatment compressor starts at minimum speed)

a. After TDR1 of 60 seconds i. If PIT1582 pressure is between 7 and 10 inches w.c. maintain PG flow

setpoint. (Gas treatment compressor remains at minimum flow of 50 cfm, PG setpoint is approx. 20 cfm)

ii. If PIT 1582 is between 10 and 11 inches w.c., increase setpoint of PG Flow by 2 cfm. (2 cfm of PG flow is approximately equal to 5 cfm of digester gas flow)

iii. If PIT 1582 is greater than 11 inches w.c, increase setpoint of PG flow by 5 cfm

iv. Start TDR2 b. After TDR2 of 60 seconds

i. If FIT 15121 is greater than 10 cfm, adjust the PG setpoint as described above in 5.a.i

ii. If FIT 15121 is between 0 and 10 cfm, maintain PG flow setpoint and set TDR3

c. After TDR3 of 60 seconds i. If PIT 1582 is less than 7 inches w.c., decrease PG flow setpoint to

minimum (gas treatment compressor flow at 50 cfm) ii. If PIT 1582 pressure is between 8 and 9 inches w.c, decrease PG flow

setpoint by 2 cfm. iii. If PIT1582 pressure is between 9 and 11 inches w.c. maintain PG flow

setpoint. iv. If PIT 1582 is greater than 11 inches w.c, increase setpoint of PG flow

by 2 cfm v. Reset TDR3 and repeat

6. Gas Treatment System shutdown i. PIT1582 pressure decreases below 2 inches w.c. after gas treatment

system has started ii. Gas Treatment System inlet pressure (PIT2210) decreases below ___

inches w.c. (Determined by Unison.)



DESCRIPTION 1.15 Existing Waste Gas Burner Pressure Monitoring

1. Program PLC3 to include PIT15121 as an input. 2. Configure the Plant SCADA software to monitor the digester gas pressure to the existing

waste gas burner on a Plant SCADA screen using PIT15121. 3. This pressure shall be used as an input to manually tune the setpoints in the Digester

Gas Pressure Control Strategy.




I/O List

Description PLC Notes

Digester Gas Storage System FUTURE

Gas Treatment System

Digester Gas Treatment Flow FIT2210 AI Gas Treat Instrument by contractor

Digester Gas Inlet Pressure PIT2210 AI Gas Treat Instrument by Unison, installed by

contractor

Compressor Inlet Pressure PT330 AI Gas Treat Instrument by Unison on skid

Compressor Outlet Pressure PT331 AI Gas Treat Instrument by Unison on skid

Product Gas Pressure PT371 AI Gas Treat Instrument by Unison on skid

Product Gas Valve Position ZT371 AI Gas Treat Instrument by Unison on skid

Off Gas Pressure PT372 AI Gas Treat Instrument by Unison on skid

Off Gas Valve Position ZT372 AI Gas Treat Instrument by Unison on skid

Gas Analyzer ‐ Methane AIT371M AI Gas Treat Instrument by Unison on skid

Gas Analyzer ‐ Carbon Dioxide AIT371C AI Gas Treat Instrument by Unison on skid

Product Gas Flow FIT2211 AI Gas Treat Instrument by Unison, installed by

Contractor

Off Gas Flow FIT2212 AI Gas Treat Instrument by Contractor

Gas Treatment System Run XI22101 DI Gas Treat Signal from Unison PLC

Gas Treatment System Fault XA22101 DI Gas Treat Signal from Unison PLC

Gas Treatment Start HS22101 DI VF comm Hard wire from VF Comm (need to

check source of DO)

Chiller Run XI101 DI GasTreat Chiller Run

Vehicle Fuel System

Inlet Gas Dryer ‐ On/Off HS23501 DI VF Comm Equipment by vehicle fuel

manufacturer



I/O List


Inlet Gas Dryer ‐ Fault XA23501 DI VF Comm Equipment by vehicle fuel

manufacturer

Compressor 23‐GCP‐101 ‐ On/Off HS23101 DI VF Comm Equipment by vehicle fuel

manufacturer

Compressor 23‐GCP‐101 ‐ Fault XA23101 DI VF Comm Equipment by vehicle fuel

manufacturer

Compressor 23‐GCP‐101 ‐ Inlet

Pressure

PT23101 AI VF Comm Instrument by vehicle fuel

manufacturer

Compressor 23‐GCP‐101 ‐ Outlet

Pressure


manufacturer

Compressor 23‐GCP‐102 ‐ On/Off HS23202 DI VF Comm Equipment by vehicle fuel

manufacturer

Compressor 23‐GCP‐102 ‐ Fault XA23202 DI VF Comm Equipment by vehicle fuel

manufacturer

Compressor 23‐GCP‐102 ‐ Inlet

Pressure


manufacturer

Compressor 23‐GCP‐102 ‐ Outlet

Pressure


manufacturer

Priority Panel ‐ On/Off HS23401 DI VF Comm Equipment by vehicle fuel

manufacturer

Priority Panel ‐ Fault

XA23401

DI VF Comm Equipment by vehicle fuel

manufacturer

CNG Total – Fuel Master

AI VF Comm Instrument by vehicle fuel

manufacturer

CNG Pressure

PT23401


manufacturer

Gas Treatment Start DO VF Comm Hard wire from vehicle fuel controller

NG Booster Compressor 23‐GCP‐301 ‐

On/Off HS23301


manufacturer




I/O List



Fault XA23301


manufacturer


NG Flow FIT23301


manufacturer

Vehicle Fuel System Inlet Pressure PIT23301 AI VF Comm Instrument by Contractor

Waste Gas Burner (WGB)

Power On

XI22201

DI WGB CP Hard wired from WGB control panel

to PLC Gas Treat

Ready

YI22201


to PLC Gas Treat

Fault

XA22201


to PLC Gas Treat

Pilot On

MA22201


to PLC Gas Treat

Upper Burner Ring ‐ Open/Close

MV22101


to PLC Gas Treat

Middle Burner Ring ‐ Open/Close

MV22102


to PLC Gas Treat

Stack Temperature

TI22201

AI WGB CP Hard wired from WGB control panel

to PLC Gas Treat

WGB Inlet Pressure

PI22201

AI WGB CP Hard wired from WGB control panel

to PLC Gas Treat

Existing Waste Gas Burner

Waste Gas Burner Inlet Pressure PIT15121 3 Hard wired to PLC3.

END OF SECTION