NL Cypress- CN110801CYPRESS WATERS PHASE I LIFT STATION
Dallas Water Utilities — Contract No. XXXX
Technical Specifications
DIVISION 13 — SPECIAL CONSTRUCTION
Marty S. Paris, P.E:
Kimley-Horn and Associates, Inc.
DIVISION 16 - ELECTRICAL
Joe Kotrla, P.E.
McCreary and Associates, Inc.
I
This document is released for the purpose of interim review and markup under the
authority of Marty S. Paris, P.E., state license number 84766 on 8/26/2011. This
document is not to be used for construction, bidding, or permit purposes.
August 2011
Cypress Waters Phase I
Lift Station —Dallas, Texas August 2011
SECTION 13100 — SANITARY SEWER LIFT STATION
PART 1— GENERAL
1.01 SUMMARY
A. Contractor shall furnish all labor, materials, equipment and incidentals as shown, specified and
necessary to complete the sanitary sewer lift station and site work, including discharge piping,
coordination and installation of three phase power to the site, grading and all other work as shown
on the plans and described in these specifications.
B. The principal items of equipment for the lift station shall include three (3) electric motors, motor
controls, three (3) submersible sewage pumps, wet well level controls, all necessary plugs, check
valves, air release valves, plug valves, fittings, pipe supports, pipe for discharge lines, and guide
rail station.
C. The Contractor shall be responsible for setting and adjusting all controls of all units for proper
operation subject to the review of the Engineer.
D. An operation and maintenance manual and complete parts list shall be furnished.
1.02 REFERENCE STANDARDS
The Contractor shall comply with applicable provisions and recommendations of the following:
A. American Society for Testing and Materials (ASTM)
1. ASTM D 3033
2. ASTM D 3212
B. American National Standards Institute (ANSI)
C. American Waterworks Association (AWWA)
D. Texas Commission on Environmental Quality (TCEQ)
E. Texas Department of Transportation 2004, Standard Specification for Highways, Streets and
Bridges.
F. Hydraulic Institute (HI)
G. National Electric Code (NEC)
H. National Science Foundation (NSF)
I. Insulated Cable Engineers Association (ICEA)
J. National Electrical Manufacturers Association (NEMA)
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K. North Central Texas Council of Governments' Public Works Construction Standards (4"' Edition)
with latest City of Dallas Addendum.
1.03 SUBMITTALS
A. Product Data
1. Submit manufacturer's specifications for all materials to be installed under this contract.
2. Manufacturer's Product Data shall be clearly and specifically marked to indicate the specified
models or types intended for submittal.
3. Product Data which is unmarked or unclear as to exact intended submittal will be returned
un -reviewed to the Contractor.
4. Contractor shall submit performance data (pump curves, flow tests, etc.) for the pumps being
installed under this contract.
5. All submittal data shall be submitted at one time in a three ring hardback binder. Partial or
piecemeal submittals will not be allowed.
B. Operation and Maintenance Manual — submit three (3) sets. The O&M manual shall be provided
in both paper and electronic (Microsoft Word or Adobe PDF) format.
1.04 DELWERY, STORAGE AND HANDLING
A. Deliver, store and handle products in accordance with manufacturer's latest published
requirements and specifications.
PART2—PRODUCT
2.01 MATERIALS
A. Pumps
1. Requirements
Furnish and install three (3) submersible non -clog wastewater pump(s). The pumps shall be
ITT Flygt Model NP3153.181 HT or approved equal. Each pump shall be equipped with a 20
HP submersible electric motor, connected for operation on 460 volts, 3 phase, and 60 hertz.
The power cable shall be long enough to reach the pump controls without splicing and sized
according to NEC and ICEA standards and also meet with P-MSHA Approval. The pump
shall be supplied with a mating cast iron 6 -inch discharge connection and be capable of
delivering 1,250 GPM at 75 TDH and rated for 1755 RPM or less.
2. Pump Design
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The pump(s) shall be automatically and firmly connected to the discharge connection, guided
by no less than two type 316 stainless steel guide bars as specified in the plans, extending
from the top of the station to the discharge connection.
3. Pump Construction
Major pump components shall be of grey cast iron, ASTM A-48, Class 3513, with smooth
surfaces devoid of blow holes or other irregularities. All exposed nuts or bolts shall be of
stainless steel construction. All metal surfaces coming into contact with the pumpage, other
than stainless steel or brass, shall be protected by a factory applied spray coating of acrylic
dispersion zinc phosphate primer with a polyester resin paint finish on the exterior of the
pump.
Sealing design shall incorporate metal -to -metal contact between machined surfaces. Critical
mating surfaces where watertight sealing is required shall be machined and fitted with Nitrile
or Viton rubber O -rings. Fittings will be the result of controlled compression of rubber 0 -
rings in two planes and O-ring contact of four sides without the requirement of a specific
torque limit.
Rectangular cross sectioned gaskets requiring specific torque limits to achieve compression
shall not be considered as adequate or equal. No secondary sealing compounds, elliptical 0 -
rings, grease or other devices shall be used.
Each pump motor shall be sufficiently cooled by the surrounding environment or by
submergence in the pumped media.
4. Mix Flush Valve
At least two pumps shall be equipped with an automatically operating valve that will provide a
mixing action within the sump at the start-up of the pumping cycle.
This valve shall be mounted directly on the pump volute and shall direct a portion of the
pumpage into the sump to flush and re -suspend solids and grease by the turbulent action of its
discharge. The turbulent action caused by the flow shall also provide some sump aeration
benefits. The valve shall be mounted on the pump volute so that it can be removed from the
sump along with the pump during normal and routine maintenance checks and shall be
positioned on the volute to provide for non -clogging operation. The valve shall be equipped
with an adjustable, wear -resistant discharge nozzle which shall be used to direct flow from
the valve to optimize mixing action within the sump.
The valve shall not require any external power source or control to operate, neither electric
nor pneumatic. The use of the external power source is not acceptable. The valve shall be
suitable for use in Class I, Division 1 hazardous locations.
The valve shall open at the beginning of each pumping cycle and shall automatically close
during pump operation after a pre -selected time of operation. The valve shall operate
automatically by differential pressure across the valve and shall be actuated through a self-
contained hydraulic system which uses and environmentally safe fluid. A method of
adjusting the valve operating time shall be provided.
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B. Motor
August 2011
1. The pump motor shall be a NEMA B design, induction type with a squirrel cage rotor, shell
type design, housed in an air filled, watertight chamber. The stator windings shall be
insulated with moisture resistant Class H insulation rated for 180°C (356°F). The stator shall
be insulated by the trickle impregnation method using Class H monomer -free polyester resin
resulting in a winding fill factor of at least 95%. The motor shall be inverter duty rated in
accordance with NEMA MGI, Part 31.The stator shall be heat -shrink fitted into the cast iron
stator housing. The use of multiple step dip and bake -type stator insulation process is not
acceptable. The use of pins, bolts, screws or other fastening devices used to locate or hold
the stator and that penetrate the stator housing are not acceptable. The motor shall be
designed for continuous duty while handling pumped media of up to 1047. The motor shall
be capable of withstanding at least 15 evenly spaced starts per hour. The rotor bars and short
circuit rings shall be made of aluminum. Three thermal switches shall be embedded in the
stator end coils, one per phase winding, to monitor the stator temperature. These thermal
switches shall be used in conjunction with and supplemental to external motor overload
protection and shall be connected to the motor control panel. The junction chamber shall be
sealed off from the stator housing and shall contain a terminal board for connection of power
and pilot sensor cables using threaded compression type terminals. The use of wire nuts or
crimp -type connectors is not acceptable. The motor and the pump shall be produced by the
same manufacturer.
2. The motor service factor (combined effect of voltage, frequency and specific gravity) shall be
1.15. The motor shall have a voltage tolerance of +/- 10%. The motor shall be designed for
continuous operation in up to a 46°C ambient and shall have a NEMA Class B maximum
operating temperature rise of 80° C. A motor performance chart shall be provided upon
request exhibiting curves for motor torque, current, power factor, input/output kW and
efficiency. The chart shall also include data on motor starting and no-load characteristics.
Motor horsepower shall be sufficient so that the pump is non -overloading throughout its
entire performance curve, from shut-off to run -out. The motor and cable shall be capable of
continuous submergence underwater without loss of watertight integrity to a depth of 70 feet
or greater.
C. Bearings
The integral pump/motor shaft shall rotate on two bearings. The motor bearings shall be sealed
and permanently grease lubricated with high temperature grease. The upper motor bearing shall
be a two row angular contact ball bearing. The lower bearing shall be a two row angular contact
ball bearing to handle the thrust and radial forces. The minimum LIO bearing life shall be 50,000
hours at any usable portion of the pump curve.
D. Mechanical Seals
Each pump shall be provided with a positively driven dual, tandem mechanical shaft seal
system consisting of two seal sets, each having an independent spring. The lower primary
seal, located between the pump and seal chamber, shall contain one stationary and one
positively driven rotating corrosion resistant tungsten -carbide or silicon carbide ring. The
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upper secondary seal, located between the seal chamber and the seal inspection chamber, shall
contain one stationary and one positively driven rotating corrosion resistant tungsten -carbide
or silicon carbide seal ring. All seal rings shall be individual solid sintered rings. Each seal
interface shall be held in place by its own spring system. The seals shall not depend upon
direction of rotation for sealing. Mounting of the lower seal on the impeller hub is not
acceptable. Shaft seals without positively driven rotating members or conventional double
mechanical seals containing either a common single or double spring acting between the upper
and lower seal faces are not acceptable. The seal springs shall be isolated from the pumped
media to prevent materials from packing around them, limiting their performance.
2. Each pump shall be provided with a lubricant chamber for the shaft sealing system. The
lubricant chamber shall be designed to prevent overfilling and shall provide capacity for
lubricant expansion. The seal lubricant chamber shall have one drain and one inspection plug
that are accessible from the exterior of the motor unit. The seal system shall not rely upon the
pumped media for lubrication.
3. The area about the exterior of the lower mechanical seal in the cast iron housing shall have
cast in an integral concentric spiral groove. This groove shall protect the seals by causing
abrasive particulate entering the seal cavity to be forced out away from the seal due to
centrifugal action.
4. A separate seal leakage chamber shall be provided so that any leakage that may occur past the
upper, secondary mechanical seal will be captured prior to entry into the motor stator
housing. Such seal leakage shall not contaminate the motor lower bearing. The leakage
chamber shall be equipped with a float type switch that will signal if the chamber should
reach 50% capacity.
E. Pump Shaft
The pump and motor shaft shall be a single piece unit. The pump shaft is an extension of the
motor shaft. Shafts using mechanical couplings shall not be acceptable. The shaft shall be
stainless steel — ASTM A479 543100-T. Shaft sleeves will not be acceptable.
F. Impeller
The impeller shall be of gray cast iron, ASTM A-48 Class 3513, dynamically balanced, semi -
open, multi -vane, back swept, screw-shaped, non -clog design. The impeller leading edges shall
be mechanically self -cleaned automatically upon each rotation as they pass across a spiral groove
located on the volute suction. The screw-shaped leading edges of the impeller shall be hardened
to Rc 45 and shall be capable of handling solids, fibrous materials, heavy sludge and other matter
normally found in wastewater. The screw shape of the impeller inlet shall provide an inducing
effect for the handling of up to 5% sludge and rag -laden wastewater. The impeller to volute
clearance shall be readily adjustable by the means of a single trim screw. The Impeller shall be
locked to the shaft, held by an impeller bolt and treated with a corrosion inhibitor.
G. Protection
Each pump motor stator shall incorporate three thermal switches, one per stator phase winding
and be connected in series, to monitor the temperature of the motor. Should the thermal switches
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open, the motor shall stop and activate an alarm. A float switch shall be installed in the seal
leakage chamber and will activate if leakage into the chamber reaches 50% chamber capacity,
signaling the need to schedule an inspection.
The thermal switches and float switch shall be connected to a Mini CAS control and status
monitoring unit. The Mini CAS unit shall be designed to be mounted in the pump control panel.
H. Wet Well Piping
All piping within wet well shall be 316 stainless steel with rated minimum working pressure of
200 psi. All piping shall be securely supported and/or braced by pipe hangers and/or pipe
supports as identified in the plans.
I. Ductile Iron Pipe
Ductile iron pipe, fittings and joints shall conform to the requirements specified in the Plans.
J. Check Valves
1. The contractor shall furnish and install Series No. 500 Swing -Flex check valves as
manufactured by Val -Matic Valve and Mfg. Corp., or approved equal.
2. Check Valve body shall be ductile iron ASTM A536 Grade 65-45-12 and have a Buna-N
disc.
3. Nuts, Bolts, and Studs shall be Type 316 Stainless Steel.
4. The valve disc shall be of one piece construction, precision molded with an integral o -ring
type sealing surface and contain alloy steel and nylon reinforcement in the flexible hinge
area. l
5. The valve body shall have full flow equal to nominal pipe diameter at all points through the
valve. The seating surface shall be on a 45° angle to minimize disc travel. The top access
point shall be full size, allowing removal of the disc without removing the valve from the
pipeline. The access cover shall be domed in shape, to allow the disc to be fully operational
in lines containing high solids content.
6. Backflow capabilities shall be available by means of a screw type backflow actuator. The
actuator shall be factory installed.
7. The interior and exterior of the valve shall be coated with an ANSI/NSF 61 approved fusion
bonded epoxy coating.
8. The valve shall be cycle tested 1,000,000 times with no signs of wear or distortion to the
valve disc or seat and shall remain drop tight at both high and low pressures. The test results
shall be independently certified.
9. Materials shall be certified to the following A.S.T.M. specifications:
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Body & cover
Disc
Interior Coating
Exterior Coating
K. Plug Valves
1. Requirements
Ductile iron
Buna-N (NBR)
Fusion Bonded Epoxy
Fusion Bonded Epoxy
August 2011
ASTM A536 Grade
65-45-12
ASTM D 2000-136
ANSI/NSF 61 approved
ANSI/NSF 61 approved
The contractor shall furnish and install plug valves as manufactured by De Zurik Corporation
or approved equal. Plug valves shall be manufactured in accordance with AWWA C-504 and
shall be of the 1/4 turn, eccentric non -lubricated type, serviceable under full line pressure, and
capable of sealing in both directions at the rated pressure. Plug valves shall have a minimum
port area of 80% of the nominal pipe size.
2. Materials
The valve body shall be of ductile iron, 30,000 psi tensile strength, with added nickel and
chromium, ASTM A536, Grade 65-45-12. The valve plug shall be ductile iron conforming to
ASTM A126, Class B, with neoprene resilient facing. The valve seating design shall be
resilient and of the continuous interface type having consistent opening/closing torques, and
shall be non jamming in the closed position. Closure shall be accomplished by means of an
offset plug design with a resilient seating face that achieves full 360 degree seating contact.
Valves shall be of the bolted bonnet design. The resilient faced plug shall be replaceable
without removing the valve body from the line. The valve body seating area shall be
corrosive resistant by a welded -in overlay of high nickel content. Sprayed or plated seating
surfaces will not be acceptable. Valves shall have permanently lubricated Type 316 stainless
steel bearings on the upper and lower plug stem journal. Bearings shall be replaceable.
Packing shall be Buna N (Vee Type). Valves shall be designed such that they can be
repacked without removing the bonnet. All exposed nuts, bolts, springs, and washers shall be
zinc plated, except exposed hardware for submerged valves and valves in the wet well that
shall be of stainless steel.
3. Actuators
Plug valves shall be equipped with worm gear actuators. All gearing shall be enclosed
suitable for running in oil with seals provided on all shafts to prevent entry of dirt and water
into the actuator. All shaft bearings shall be furnished with permanently lubricated bronze or
stainless steel bearing bushings. Actuator shall clearly indicate valve position and an
adjustable stop shall be provided. Construction of actuator housing shall be semi -steel.
Hardware on actuators shall be of the same materials as the valves.
4. Plug valves in buried service shall be provided with a polyethylene coating.
5. Plug valves for buried service shall be furnished with a square 2" operating nut. The valve
box shall be Tyler Pipe 6850 series or approved equal.
6. Installation
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Plug valves shall be installed such that the direction of flow through the valve is in
accordance with the manufacturer's recommendations.
L. Guide Rails
1. General
a. Contractor shall furnish all labor, materials, equipment and incidentals required to
provide a complete pumping system as specified herein.
b. The rail system shall include three (3) submersible pump base elbows, sealing flanges
with rail guides, upper guide brackets, lifting chain or cables, float mounting brackets,
guide rails (Type 316 stainless steel) and discharge piping.
c. Nuts, bolts and studs shall be Type 316 stainless steel.
2. Discharge Elbow
A sealing flange adapter and discharge base elbow, designed to mount directly to the sump
floor shall be supplied for each of the three (3) pumps. It shall have a standard 125 pound
flange faced and drilled on the outlet side with a matching inlet connection. The design shall
be such that the pump to discharge connection is made without the need for any nuts or bolts.
The adapter and elbow shall also anchor and align the guide rails.
3. Sealing Flange with Cable Guide
A sealing flange/rail guide bracket shall be mounted on each pump discharge. It shall have a
machined mating flange which matches the base elbow discharge connection. Sealing of this
discharge connection shall be accomplished by a simple linear downward motion of the pump
culminating with the entire weight of the pumping unit supported entirely by the base elbow.
4. Upper Guide Bracket
The upper guide bracket shall align and support the three guide rails at the top of the sump. It
shall bolt directly to the hatch frame and incorporate an expandable rubber grommet for
secure rail installation.
5. Lifting Chain/Cable
Each pumping unit shall be provided with a stainless steel lifting chain or cable, and be of
sufficient length to extend from the pump to the top of the wet -well. The access frame shall
provide a hook to attach the chain or cable when not in use. The lifting chain or cable shall
be sized according to the pump weight. The working load shall be 50% greater than the
pump unit weight.
6. Float Mounting Bracket
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August 2011
A float mounting bracket shall be provided with strain reliefs that support and hold the level
control cords. Continuous cords are to run from pump(s) and level controls to a control panel
or junction box. No splices shall be made in the wiring. The bracket shall be fabricated from
steel, coated for corrosion resistance, and attached to the access frame with 300 series
stainless steel fasteners. A dielectric spacer should be installed when bolting to an aluminum
access frame.
M. Access Hatches
1. The contractor shall furnish and install access hatches as manufactured by Bilco, Inc., ITT
Flygt, or approved equal, as shown on the plans.
2. Door leaf shall be 1/4" aluminum diamond pattern plate to withstand a live load of 300 lb./sq.
ft. with a maximum deflection of 1/1501h of the span.
3. Drop handle shall be cast aluminum and flush with door leaf.
4. Channel frame shall be 1/4" aluminum with an anchor flange around the perimeter and shall
have a minimum cross-sectional area of 7-1/2 sq. in. to allow for proper water drainage.
Door shall be equipped with Type 316 stainless steel hinge having 3/8" minimum diameter
stainless steel pins and pivot so that the cover does not protrude into the channel frame.
Compression spring operators enclosed in telescopic tubes shall be provided for smooth, easy
and controlled door operation throughout the entire arc of opening and closing. Operation
shall not be affected by temperature. The door shall automatically lock in the vertical
position by means of a heavy steel hold -open arm with release handle. A Type 316 stainless
steel snap lock with a gasketed cover plug and removable turn handle shall be provided. A 1-
1/2" drainage coupling shall be located in the front right corner of the channel frame.
Hardware and all fasteners shall be Type 316 stainless steel.
6. Factory finish shall be mill -finish aluminum with a bituminous coating applied to the exterior
of the frame.
7. Installation shall be in accordance with the manufacturer's instructions.
N. Warranty
All equipment purchased under this contract shall be warranted for a minimum of one (1) year.
The warranty shall be the responsibility of the Developer. The warranty is to begin on the date of
substantial completion. The project shall be considered substantially complete after acceptance
by the City, which will include 30 -days of successful operation by the Contractor as a proof of
suitability.
The Contractor shall also furnish a "trouble shooter" within twenty -for (24) hours from
notification to repair any malfunction with any unit purchased under this contract for the duration
of that unit's warranty.
PART 3 - EXECUTION
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3.01 GENERAL:
August 2011 f
I
i
A. All work shall be performed by skilled craftsmen qualified to perform the required work in a
manner comparable with the best standards of practice.
B. The Contractor shall provide a supervisor at the work site during all construction operations. The
supervisor shall have the authority to sign change orders, coordinate work and make decisions
pertaining to the fulfillment of the contract.
C. The Contractor and all workmen employed by him shall conduct all operations in a clean and
sanitary manner and in conformance with all aspects of the contract documents.
3.02 START-UP:
The Contractor shall provide services of the manufacturer's representative as needed to ensure
proper installation of equipment and to provide start-up supervision and O&M instruction.
3.03 TESTING:
A. All pumps shall be site tested after installation to demonstrate satisfactory operation without ,
excessive noise, vibration, cavitation or over -heating. Site tests shall be conducted by the
manufacturer or his Authorized Representative.
Tests shall include checking for correct rotation, maximum motor amperage draws within
nameplate specifications, balanced voltages on each power leg with the pump operating to within
manufacturers' tolerances, and demonstrated compatibility of the pump/motor with the controls I
supplied.
Test results shall be in printed from and signed by the manufacturer or his representative and
supplied to the Owner.
B. A non -witnessed certified Hydraulic Institute performance test shall be performed. This shall
include the following:
The pump with motor shall be tested at the design point as well as at least 7 other points to
develop a curve. Data shall be collected to plot the head -capacity curve as well as a KW input and
amperage curve.
In making these tests, no minus tolerance or margin shall be allowed with respect to capacity,
total head, or efficiency at the specified design condition. Pump shall be held within a tolerance
of +10% of rated capacity or at rated capacity with a tolerance of +5% of rated head. The pump
shall be tested at shut-off but shall not be plotted and only used as a reference point when plotting
the performance curve.
Complete records shall be kept of all information relevant to the test as well as the manufacturer's
serial number, type and size of pump as well as any impeller modifications made to meet the
design conditions.
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A written test report shall be prepared, signed and dated by the test engineer incorporating 3
curves (head -capacity, KW input, and amperage) along with the pump serial number, test
number, date, speed, volts, phase, and impeller diameter. This report shall then be submitted to
the Owner for approval.
END OF SECTION
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SECTION 13200 — ODOR CONTROL EQUIPMENT
PART I - GENERAL
1.01 SUMMARY
A. Furnish, install, and place into operation one odor control system for the lift station. The odor control
system shall consist of one drum scrubber unit containing dry scrubbing material. The drum scrubber
shall be powered unit (blower mounted on top of drum). All piping, fittings, and appurtenances
necessary to place the odor control system into operation shall be provided along with the drum
scrubber unit and dry scrubbing material.
1.02 REFERENCE STANDARDS
A. Reference Standards: Comply as a minimum with applicable provisions and recommendations of the
following publications are referred to in the text by basic designation only.
1. American National Standards Institute (ANSI)
2. American Society for Testing and Materials (ASTM)
3. Institute of Electrical and Electronic Engineers (IEEE)
4. National Electric Code (NEC)
5. National Electrical Manufacturers Association (NEMA)
1.03 SUBMITTALS
A. Submittals required after award of contract and prior to installation:
1. Shop drawings and product data, including construction features and materials of construction.
B. Submittals required prior to final walk through:
Operation and Maintenance Data Package — submit three (3) sets. The O&M manual shall be
provided in both paper and electronic (Microsoft Word or Adobe PDF) format.
1.04 OPERATING INSTRUCTIONS
A. A factory representative of all major component manufacturers, who has complete knowledge of
proper operation and maintenance, shall be provided for one day to instruct representatives of the
Owner on proper operation and maintenance. If there are difficulties in operation of the equipment
during instruction sessions, additional sessions shall be provided at no cost to the Owner.
B. Prior to scheduling instructions, submit outline of instructions to Engineer for approval.
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C. Operating and maintenance manual shall be explained during these instructions.
1.05 SHIPPING INSTRUCTIONS
A. All parts shall be properly protected so that no damage or deterioration will occur during a prolonged
delay from the time of shipment until installation is completed and the units and equipment are ready
for operation.
B. All equipment and parts must be properly protected against any damage during a prolonged period at
the site.
C. The finished surfaces of all exposed flanges shall be protected by wooden blank flanges, strongly built
and securely bolted thereto.
D. Finished iron or steel surfaces not painted shall be properly protected to prevent rust and corrosion.
1.06 QUALITY ASSURANCE
A. All materials used shall be new with properties best suited to the work required.
B. System Coordination: CONTRACTOR is responsible for all details necessary to properly install,
adjust, and place in operation a working system.
C. Manufacturer shall be a single source provider of equipment, media, and testing services and shall be
certified to ISO -9001 standards.
D. Manufacturer shall have local, factory -trained representatives.
E. Manufacturer shall have a minimum of 10 years experience in the design, fabrication, and testing of
odor control systems.
1.07 WARRANTY
A. The equipment shall be warranted to be free from defects in workmanship, design and materials (not
including the chemical media) for a period of one (1) year. If any part of the equipment should fail
during the warranty period, it shall be replaced and the unit restored to service at no expense to the
Owner. The warranty shall be the responsibility of the Developer.
The warranty is to begin on the date of substantial completion. The project shall be considered
substantially complete after acceptance by the City, which will include 30 -days of successful operation
by the Contractor as a proof of suitability.
PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
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A. Purafil, Inc., or Owner approved equal.
2.02 MATERIALS AND/OR EQUIPMENT
A. General:
1. Provide one DS -500 drum scrubber (powered) as manufactured by Purafil, Inc., or Owner
approved equal, designed to operate at 99.5% or better gas removal efficiencies.
2. The scrubber shall consist of dry scrubbing material contained in a 200 gallon, low-density
polyethylene drum, the scrubber shall have a blower mounted on top of a FRP lid.
3. Configuration shall be arranged so that the contaminated air flows into the bottom inlet plenum of
the first drum and be drawn upward through the media bed. Treated air from the drum shall
discharge out the top of the drum through a centrifugal air ventilator.
4. All components of the drum scrubber shall be factory skid mounted.
B. Drums:
1. Drum material shall be linear, low density, polyethylene at least 1/4 inch in thickness.
2. Drum shall have a capacity of at least 200 gallons.
3. Latches shall be stainless steel and rubber.
4. Fasteners shall be stainless steel.
5. Drum shall have two 1 -inch diameter media sampling ports.
6. Drum shall have 3/4 -inch drain pipe with a ball valve.
7. Media shall be supported in drum by FRP air diffusers and shall be surrounded by marble chips.
8. Polymedia filters shall be used to separate the marble chips from the media, and to separate the
media from the blower.
9. Inlet to drum shall be equipped with a flexible coupling.
10. A grounding rod shall be provided, if required.
C. Blower Section
1. Blower shall be sized to deliver the recommended airflow of 320 to 608 cfm at 3.0 IWG with
damper half open to 100 cfm at 4.5 IWG with the damper fully open.
2. Blower shall consist of a direct drive motor -fan assembly.
3. Motor shall be 0.5 hp, 3450 rpm, 115/230 volt/ 1 phase/ 60 Hz TEFC motor.
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4. Motor shall be prewired with a 6 -foot grounded power cord.
D. Chemical Media.
1. The DS -500 shall contain 13 ft3 of OdorcarbTM Ultra and 4 ft3 of OdormixTM SP, each.
The OdorcarbTM Ultra Media shall consist of manufactured, generally spherical porous pellets.
The pellets shall be formed from a combination of powered activated carbon, alumina, and other
binders suitably impregnated with chemicals to enhance the capacity for removal of odorous
gases. The pellets shall also chemically react to produce solid reaction products within the media.
Impregnants shall be applied during pellet formation such that the impregnant is uniformly
distributed throughout the pellet volume.
3. OdorcarbTM Ultra Media shall have the following physical properties:
a. Moisture content: 35% maximum
b. Average crush strength: 35% minimum — 70% maximum
c. Average abrasion: 4.5 maximum
d. Bulk density: 45 lbs/ft3
e. Nominal pellet diameter: 1/16" —1/8"
4. OdorcarbTM Ultra Medial shall be UL Classified Class 2.
5. OdorcarbTM Ultra Media shall be capable of absorbing and removing odorous gases throughout
the entire pellet.
The OdormixTM SP Media shall consist of an equal mix (by volume) of Purafil ESD's, or Engineer
approved equal, OdoroxidantTM Media and OdorkolTM Media. OdoroxidantTM Media shall be
manufactured of generally spherical, porous pellets formed from a combination of powdered
activated alumina and other binders, suitably impregnated with sodium permanganate to provide
optimum adsorption, absorption, and oxidation of a wide variety of gaseous contaminants. The
sodium permanganate shall be applied during pellet formation, such as the impregnant is
uniformly distributed throughout the pellet volume and is totally available for reaction. Odorkoff
Media shall be a premium grade, activated carbon with a high surface area available for
adsorption.
7. OdormixTM Media shall have the following physical properties:
a. OdoroxidantTM Media
■ Moisture content: 35% maximum
■ Average crush strength: 35% minimum — 70% maximum
■ Average abrasion: 4.5% maximum
■ Bulk density: 50 lbs/ft3
■ Nominal pellet diameter: 1/16"-1/8"
■ Sodium permanganate content: 12% minimum
b. OdorkolTM Media
■ Moisture content: 2.0% maximum
Page 4 of 5
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
■ CTC: 60% minimum
■ Base material: activated carbon
■ Bulk density: 30 lbs/ft3+/- 5%
■ OdormixTm Media shall be UL Classified Class I
PART 3 - EXECUTION
3.01. INSTALLATION
A. All odor control equipment shall be installed in accordance with the instructions of the manufacturer
and as shown on the drawings.
B. Installation and adjustment shall be checked and approved by a manufacturer's factory representative.
After acceptance, the representative shall address a letter to the Engineer outlining all installation and
start up procedures. The letter shall include a statement that the odor control equipment is installed
per the manufacturer's recommendations. The letter shall be included in a separate, and distinctly
marked, section of the Operations and Maintenance Manual. The O&M manual shall be provided in
both paper and electronic (Microsoft Word or Adobe PDF) format.
C. The manufacturer or his qualified representative shall conduct training session for the Owner's
personnel in the operation -and maintenance of the odor control equipment.
D. The manufacturer, after start up, shall analyze media samples to predict the remaining service life of
system media. Such service will be provided as needed at the manufacturer's expense.
END OF SECTION
Page 5 of 5
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 13300 — TRANSIT TIME FLOW METER
PART 1- GENERAL
1.01 SUMMARY:
A. Furnish all labor, materials, equipment and incidentals required to completely install and put into
operation, transit time flow meters as specified herein and shown on the drawings.
1.02 QUALITY ASSURANCE:
A. The Contractor shall cause all equipment specified under this section to be furnished by the meter
manufacturer who shall be responsible for the adequacy and compatibility of all components including
transducer. The term `adequacy and compatibility' shall mean not only the adequacy and compatibility
of the equipment within the lift station, but also the adequacy and compatibility of the new equipment
in regards to working with the existing Dallas Water Utilities (DWU) SCADA systems.
B. Any component of each complete unit not provided by the meter manufacturer shall be designed,
fabricated, tested, and installed by factory -authorized representatives experienced in the design and
manufacture of the meter equipment. This requirement, however, shall not be construed as relieving
the Contractor of the overall responsibility for this portion of the work.
1.03 ENVIRONMENTAL CONDITIONS:
The equipment to be provided under this section shall be suitable for installation and operation inside
the pump control and instrumentation building. Outside ambient temperatures range between 10° F
and 115° F, and reported water temperatures vary between 50° F and 90° F. Relative humidity is
expected to range between 5 and 100 percent.
1.04 SUBMITTALS:
A. Submittals required after award of contract and prior to installation:
1. Technical bulletins and brochures.
2. Electrical diagram.
B. Submittals required prior to final walk through:
1. Operation and Maintenance Manual — submit three (3) sets. The O&M manual shall be provided
in both paper and electronic (Microsoft Word or Adobe PDF) format.
1.05 SHIPPING INSTRUCTIONS:
A. All parts shall be properly protected so that no damage or deterioration will occur during a prolonged
delay from the time of shipment until installation is completed and the units and equipment are ready
for operation.
Page 1 of 3
Cypress Waters Phase I
Lift Station —Dallas, Texas
August 2011
B. All equipment and parts must be properly protected against any damage during a prolonged period at
the site.
C. The finished surfaces of all exposed flanges shall be protected by wooden blank flanges, strongly built
and securely bolted thereto.
D. Finished iron or steel surfaces not painted shall be properly protected to prevent rust and corrosion.
E. Storage and Protection: All plastic and similar brittle items shall be covered at all times to prevent
from being directly exposed to the sun, or exposed to extremes in temperature, preventing any
deformation.
1.06 WARRANTY:
A. The equipment shall be warranted to be free from defects in workmanship, design and materials. If
any part of the equipment should fail during the warranty period, it shall be replaced and the unit(s)
restored to service at no expense to the Owner. All equipment purchased under this contract shall be
warranted for a minimum of one (1) year. The warranty shall be the responsibility of the Developer.
The warranty is to begin on the date of substantial completion. The project shall be considered
substantially complete after acceptance by the City, which will include 30 -days of successful operation
by the Contractor as a proof of suitability.
PART 2 - PRODUCTS
2.01 TRANSIT TIME FLOW METER:
A. Meter shall be a Thermo Scientific DCT6088 Transit Time Flow Meter.
B. Meter shall be calibrated for a flow range of 500 gpm to 1,500 gpm.
C. The meter shall function accurately over a range of 0 to 20 feet per second.
D. The accuracy shall be ± 0.5% of actual velocity indicated in the tabulation.
E. The flow meter shall be complete with transmitter enclosed in a NEMA 4X enclosure. Output shall be
4-20 mA, 12 bit, 5 kV opto-isolated, loop or self -powered with RS232 serial interface. Power supply
shall be 90-132 VAC, 50/60 Hz. The transmitter shall have a relay contact output for sampling unit.
E Transducers shall be of the dual head design suitable for submersible/underground service. Sufficient
transducer cable length shall be provided for the application. Transducer cables shall be enclosed in
1 " PVC pipe and installed approximately two feet below proposed grade to connect from meter vault
to transmitter within instrumentation panel.
G. Programming software shall be included with the flow meter, and shall be Microsoft Windows
compatible, and shall work with the existing DWU SCADA systems.
Page 2 of 3
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
PART 3 - EXECUTION
3.01 INSTALLATION:
A. All transit time flow meters shall be installed in accordance with the instructions of the manufacturer
and as shown for general location on the drawings.
B. Installation and adjustment shall be checked and approved by a manufacturer's factory representative.
After acceptance, the representative shall address a letter to the Engineer outlining all installation and
start up procedures. The letter shall include a statement that the flow meters are installed per the
manufacturer's recommendations. The letter shall be included in a separate, and distinctly marked,
section of the Operations and Maintenance Manual. The O&M manual shall be provided in both
paper and electronic (Microsoft Word or Adobe PDF) format.
END OF SECTION
Page 3 of 3
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16010 — ELECTRICAL GENERAL PROVISIONS
PART 1- GENERAL
1.1 GENERAL CONDITIONS
A. The General Conditions and Requirements, Special Provisions, are hereby made a part of this
Section.
B. The Electrical Drawings and Specifications under this Section shall be made a part of the
Contract Documents. The Drawings and Specifications of other sections of this contract, as
well as supplements issued thereto, information to bidders and pertinent documents issued by
the Owner's Representative are a part of these Drawings and Specifications and shall be
complied with in every respect. All the above documents will be on file at the office of the
Owner's representative and shall be examined by all the bidders. Failure to examine all
documents shall not relieve the responsibility or be used as a basis for additional
compensation.
C. Contractor shall furnish all work, labor, tools, superintendence, material, equipment and
operations necessary to provide for a complete and workable electrical system as defined by
the Contract Documents.
D. It is the intent of the Contract Documents that upon completion of the electrical work, the
entire system shall be in a finished, workable condition and integrated into the Dallas Water
Utilities SCADA and control system.
E. All work that may be called for in the Specifications but not shown on the Drawings, or, all
work that may be shown on the Drawings but not called for in the Specifications, shall be
performed by the Contractor as if described in both. Should work be required which is not set
forth in either document, but which work is nevertheless required for fulfilling of the intent
thereof, then the Contractor shall perform all work as fully as if it were specifically set forth in
the Contract Documents.
F. The definition of terms used throughout the Contract Documents shall be as specified by the
following agencies:
1. Underwriters Laboratories
2. National Electrical Manufacturers Association
3. American National Standards Institute
4. Insulated Power Cable Engineers Association
5. National Electrical Code
6. National Fire Protection Association
G. The use of the terms "as (or where) indicated", "as (or where) shown", "as (or where)
specified", or "as (or where) scheduled" shall be taken to mean that the reference is made to the
Contract Documents, either on the Drawings or in the Specifications, or both documents.
H. The use of the words "furnish", "provide", or "install" shall be taken to mean that the item or
facility is to be both furnished and installed under Division 16, unless stated to the contrary
that the item or facility is to be either furnished under another Division or under another
Contract, furnished under this Division and installed under another Division or under another
Contract, or furnished and installed under another Division or under another Contract.
Electrical General Provisions 16010-1
Cypress Waters Phase I
Lift Station — Dallas, Texas
1.2 PERMITS AND CODES
August 2011
A. Secure all permits, licenses, and inspection as required by all authorities having jurisdiction.
Give all notices and comply with all laws, ordinances, rules, regulations and contract
requirements bearing on the work.
B. The minimum requirements of the electrical system installation shall conform to the latest
edition of the National Electrical Code, as amended by Chapter 56 of the Dallas City Code, as
well as state and local codes.
C. Codes and ordinances having jurisdiction and specified codes shall serve as minimum
requirements, but, if the Contract Documents indicate requirements which are in excess of
those minimum requirements, then the requirements of the Contract Documents shall be
followed. Should there be any conflicts between the Contract Documents and codes, or any
ordinances, report these with bid.
PART2-PRODUCTS
2.1 STANDARDS
A. All materials and equipment shall conform to the requirements of the Contract Documents.
They shall be new, free from defects, and they shall conform to the following standards where
these organizations have set standards:
1. Underwriters Laboratories (UL)
2. National Electrical Manufacturer's Association (NEMA)
3. American National Standards Association (ANSI)
4. Insulated Cable Engineers Association (ICEA)
B. All material and equipment of the same class shall be supplied by the same manufacturer,
unless specified to the contrary.
C. All products shall bear UL labels where standards have been set for listing. All other products
shall be UL labeled. Motor control centers, switchboards, and switchgear shall have UL labels
by the manufacturer. Custom panels, modified motor starters, control panels, and instrument
panels and the like shall be manufactured by a fabricator approved as a UL508A shop and shall
bear a UL 508A (UL Industrial Control Panel) label.
D. When the Contractor provides a product for this project he shall be bound by the terms and
conditions of the Contract Documents and he shall agree to warrant and to be liable for the
merchantability and fitness of his product to the applications to which his product is applied
under the Contract Documents.
2.2 SHOP DRAWINGS AND SUBMITTALS
A. Shop drawings and submittals shall comply with Section 0 13 40.
PART 3 - EXECUTION
3.1 CUTTING AND PATCHING
Electrical General Provisions 16010-2
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
A. Cutting and patching required under this section shall be done in a neat workmanlike manner.
Cutting lines shall be uniform and smooth.
B. Use concrete saws for large cuts in concrete and use core drills for small round cuts in
concrete.
C. Where openings are cut through masonry walls, provide lintel or other structural support to
protect the remaining masonry. Adequate support shall be provided during the cutting
operation to prevent damage to masonry.
D. Where large openings are cut through metal surfaces, attach metal angle around the opening.
E. Patch concrete openings that are to be filled with nonshrinking cementing compound. Finish
concrete patching shall be troweled smooth and shall be uniform with surrounding surfaces.
3.2 WATERPROOFING
Provide waterproof flashing for each penetration of exterior walls and roofs.
3.3 CONSTRUCTION REQUIREMENTS
A. Except where specifically noted or shown, the locations and elevations of equipment are
approximate and are subject to small revisions as may prove necessary or desirable at the time
the work is installed. Locations changed substantially from that shown on the drawings shall
be confirmed with the Engineer in advance of construction.
B. Where equipment is being furnished under another Division, request from Engineer an
accepted drawing that will show exact dimensions of required locations or connections. Install
the required facilities to the exact requirements of the accepted drawings.
C. All work shall be done in the best and most workmanlike manner by qualified, careful
electricians who are skilled in their trade. The standards of work required throughout shall be
of the first class only.
D. Unless shown in detail, the Drawings are diagrammatic and do not necessarily give exact
details as to elevations and routing of raceways, nor do they show all offsets and fittings;
nevertheless, install the raceway system to conform to the structural and mechanical conditions
of the construction.
E. Holes for raceway penetration into sheet metal cabinets and boxes shall be accurately made
with an approved tool. Cutting openings with a torch or other device that produces a jagged,
rough cut will not be acceptable.
F. Cabling inside equipment shall be carefully routed, trained and laced. Cables so placed that
they obstruct equipment devices will not be acceptable.
G. Equipment shall be set level and plumb. Supporting devices installed shall be set and so
braced that equipment is held in a rigid, tight -fitting manner.
3.4 EQUIPMENT PROTECTION
Electrical General Provisions 16010-3
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
A. Provide suitable protection for all equipment, work and property against damage during
construction.
B. Assume full responsibility for material and equipment stored at the site.
C. Conduit openings shall be closed with caps or plugs during installation and made watertight.
All outlet boxes and cabinets shall be kept free of concrete, plaster, dirt and debris.
D. Equipment shall be covered and tightly sealed against entrance of dust, dirt and moisture.
3.5 COOPERATION WITH WORK UNDER OTHER DIVISIONS
A. Cooperate with all other trades so as to facilitate the general progress of their work. Allow all
other trades every reasonable opportunity for the installation of their work and the storage of
their materials.
B. The work under this section shall follow the general building construction closely. Set all pipe
sleeves, inserts, etc., and see that openings for chases, pipes, etc.., are provided before concrete
is placed or masonry installed.
C. Work with other trades in determining exact locations of outlets, conduits, fixtures, and pieces
of equipment to avoid interference with lines as required to maintain proper installation of
other work.
D. Make such progress in work that will not delay the work of other trades. Schedule the work so
that completion dates as established by the Engineer are met. Furnish sufficient labor or work
overtime to accomplish these requirements if directed to do so.
3.6 INSTALLATION OF WORK UNDER ANOTHER DIVISION
A. Verify the electrical capacities of electrical equipment furnished under other sections, or
furnished by the Owner, and request wiring information from the Engineer if wiring
requirements are different from that specified under this Section. Do not make rough -ins until
equipment verification has been received.
B. Install transformer/panels, controllers, terminal boxes, pilot devices, and miscellaneous items
of electrical equipment that are not integrally mounted with the equipment furnished under
other divisions. All such equipment shall be securely mounted and adequately supported in a
neat and workmanlike manner.
Electrical General Provisions 16010-4
Cypress Waters Phase I
Lift Station — Dallas, Texas
3.7 CHANGE ORDERS
August 2011
A. In the event change orders are prepared, they shall each be itemized as to quantities in addition
to labor, materials, and overhead.
B. Pricing of change orders shall be done in compliance with the latest edition of "Means
Electrical Cost Data" and pricing shall not exceed values tabulated therein.
3.8 CLEAN-UP
A. Remove all temporary labels, dirt, paint, grease and stains from all exposed equipment. Upon
completion of work, clean equipment and the entire installation so as to present a first class job
suitable for occupancy. No loose parts or scraps of equipment shall be left on the premises.
B. Equipment paint scars shall be repaired with paint kits supplied by the equipment manufacturer
or with an approved paint.
C. Clean interiors of each item of electrical equipment. At completion of work all equipment
interiors shall be free from dust, dirt and debris.
3.9 TESTS
A. Test all systems furnished under Division 16 and repair or replace all defective work. Make all
necessary adjustments to the systems and instruct the Owner's personnel in the proper
operation of the system.
B. Make all circuit breaker and protective relay adjustments and settings.
C. Make the following minimum tests and checks prior to energizing the electrical equipment:
1. Check all wire and cable terminations for tightness.
2. Test all wiring as specified in 16120.
3. Test grounding system as specified in Section 16450.
4. Set all transformer taps as required to obtain the proper secondary voltage.
5. Carefully check all interlocking, control and instrument wiring for each system to ascertain
that the system will function properly as indicated by schematics, wiring diagrams or as
specified herein.
6. Mechanical inspection of all low voltage circuit breakers, disconnect switches, motor
starters, control equipment, etc. for proper operation.
7. Provide all instruments and equipment required for the above tests.
3.10 RECORD DRAWINGS
A. At the start and during the progress of the job, keep one separate set of blue -line prints for
making construction notes and mark-ups.
B. Show conduit routing and wiring runs as constructed and identify each.
C. Record all deviations from the Contract Documents.
D. Submit set of marked -up drawings for review. The final payment will not be made until the
review is complete.
Electrical General Provisions 16010-5
Cypress Waters Phase I
Lift Station — Dallas, Texas
END OF SECTION
August 2011
Electrical General Provisions 16010-6
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16110 — RACEWAYS
PART 1- GENERAL
1.1 SCOPE
A. This section shall include raceways, enclosures, supporting devices ancillary fittings and
appurtenances. Furnish and install the complete raceway systems as shown on the Drawings and
as specified herein.
B. Raceway is a broad -scope term that shall be defined by the National Electrical Code under
Article 100 as amended by the latest edition of the City of Dallas Chapter 56 of the City Charter.
1.2 APPLICATIONS
A. Except as otherwise shown on the Drawings, or otherwise specified, all underground and in -slab
conduit raceways shall be shall be made with schedule 40 PVC. Bends to grade shall be made
with plastic coated rigid galvanized steel conduit.
B. Except as otherwise shown on the Drawings, or otherwise specified, all outdoor exposed power,
control, and instrumentation, signal, and communication conduit shall be rigid steel conduit,
except where areas are denoted as corrosive or NEMA 4X. In those area furnish plastic coated
rigid steel conduit, fittings, and boxes.
1.3 SUBMITTALS AND SHOP DRAWINGS
A. Process catalog submittals for the following:
1. Plastic Jacketed Rigid Steel Conduit
2. Rigid Non -Metallic Conduit
3. Liquid -tight Flexible Conduit
4. Liquid -tight Fittings
5. Conduit Bushings
6. Conduit Bodies
7. Conduit Sealing Fittings
8. Expansion -Deflection Fittings
9. Expansion Fittings
10. Cast Metal Boxes
11. NEMA 4X J -Boxes
12. Tape Products
13. Wiring Devices
14. Supporting Devices
15. Labels
16. Grounding Devices
17. Foam Sealant
18. Conduit End Bell Fittings
PART 2 - PRODUCTS
2.1 RACEWAYS
RACEWAYS 16110-1
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
A. Rigid metallic aluminum conduit shall be manufactured of 6063 alloy, T-1 temper, with no more
than 0.02% copper content. All conduit couplings shall be threaded aluminum. All such conduit
shall be listed with UL and comply with UL -6 and ANSI C80.5. Aluminum conduit shall be
Easco, Indalex or equal.
B. Rigid metallic steel conduit shall be hot -dip galvanized inside and outside and over threads. All
such conduit shall comply with U.L. Standard UL -6, Federal Specification WWC-581-D, ANSI
C90.1, and NEMA RN1-1980. Furnish Wheatland, Allied or equal.
C. Plastic coated rigid steel conduit shall consist of rigid steel body that complies with above
specifications for rigid metallic steel conduit, plus conduit shall have 40 mil thick heat -fused
PVC over outside and 2 mil coat of fully catalyzed phenolic inside. The inside coat shall have the
chemical resistance of the outer coating and shall not dissolve in lacquer thinner. All couplings
shall be equipped with PVC sleeves that extend one pipe diameter or 2", whichever is less,
beyond the end of the coupling. All plastic coated conduit shall conform to NEMA Standard
#RNI-1974 (Type A) and such conduit shall be Robroy "Plastibond Red", or equal.
D. Non-metallic rigid conduit shall be Schedule 40 PVC. Such conduit shall be UL listed for 90
degrees C and shall conform to NEMA TC -2 and UL -651 standards. Furnish Carlon, Cantex, or
equal. Furnish manufacturer's approved solvent for joining couplings.
E. Liquid -tight flexible conduit shall consist of hot -dipped galvanized, flexible interlocking steel
core with thermoplastic cover, integral copper ground wire (through 1-1/4" trade size) and shall
be Anaconda Sealtite or equal.
2.2 CONDUIT FITTINGS
A. NEMA 4 locknuts for rigid metallic conduit shall consist of galvanized steel body with neoprene
sealing ring. Furnish Crouse -Hinds, T&B, or equal.
B. NEMA 1 locknuts for rigid metallic conduits shall be galvanized steel for use with galvanized
steel conduit and hardened aluminum for use with aluminum conduit.
C. Conduit field -applied hubs for sheet metal enclosures shall be aluminum body with recessed
neoprene sealing ring, threaded NPT insert, and shall be, T&B 370 AL series, or equal products
by OZ/Gedney.
D. Conduit hubs for non-metallic enclosures shall be fiberglass polyester reinforced with galvanized
steel core, complete with locknut and grounding bushing. All such hubs shall be Crouse -Hinds
Type NHU, or equal.
E. Rigid metallic conduit chase nipples, split couplings, slip fittings, unions, reducers, and
enlargers, shall be hot -dip or mechanically galvanized malleable iron.
F. Rigid metallic conduit short els and long els shall be hot -dip galvanized malleable iron with NPT
threaded hubs and male ends. Throats shall be smooth and free from burrs. All such fittings
shall be OZ/Gedney Type "9" Series, Appleton, or equal.
G. Rigid metallic conduit split couplings shall have threaded body with split tightening shelves with
neoprene sandwich. Furnish malleable iron mechanically galvanized body. Such fittings shall be
OZ type "SSP", or equal.
RACEWAYS 16110-2
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
H. Rigid metallic conduit grounding bushings shall be aluminum body with threaded hub, bakelite
insulated throat, and tin-plated copper ground lug. Furnish OZ/Gedney type ABLG, or equal.
I. Liquid -tight flexible conduit fittings shall be hot -dip galvanized steel body with internal locking
ring and ground cone plus external ground wire fitting. Furnish straight or angle connectors as
required. All such connectors shall be OZ/Gedney 4Q series, or equal.
J. Rigid metallic conduit expansion/deflection fittings shall consist of galvanized malleable iron
hubs with heat -fused epoxy coating, flexible neoprene joining sleeve banded to hubs with
stainless steel bands, and with internal bonding jumper and guide cones. Furnish Crouse -Hinds
type "XDHF" or equal.
K. Rigid metallic conduit expansion fittings shall consist of metallic barrel joined to hubs at each
end. One hub shall be threaded to barrel and other hub shall have slip fit to allow up to four (4")
inches of conduit lateral movement. Provide external bonding jumper for each expansion joint.
Furnish Crouse -Hinds type "XJ", OZ Type "AX", or equal.
L. Conduit waterstops for sealing inside of conduit runs shall consist of aluminum pressure discs
with sandwiched neoprene seal and with 316 stainless steel hardware. Furnish OZ/Gedney type
"CS" series products, as indicated.
2.3 CONDUIT BODIES AND BOXES
A. Conduit bodies such as "C", "LB", "T" and the like pulling fittings shall be zinc coated with
malleable iron or aluminum (material shall match conduit). Covers for damp and/or wet location
use shall be gasketed cast metal with "wedge -nut" clamps. Covers for dry locations shall be cast
aluminum and hardware shall be 316 stainless steel. All covers shall be equipped with clamp
type clevises. Furnish Crouse -Hinds Form 7, or Appleton Form "FM7" products.
B. Conduit bodies for use in corrosive areas shall be as specified above but shall have 40 mil plastic
coated PVC jacket and 2 mil interior coating as specified for plastic coated rigid steel conduit.
Furnish Robroy Plasti-bond Red fittings or equal.
C. Conduit bodies such as "GUA", "GUAT", "GUAL", and the like pulling/splicing fittings shall be
cast aluminum with threaded cast aluminum covers. All such conduit bodies shall be Killark
"GE" series, or equal products by Crouse -Hinds or Appleton.
D. Cast metal outlet boxes, pullboxes, and junction boxes whose volume is smaller than 100 cubic
inches, and cast metal device boxes, shall be sand-cast, copper -free aluminum or zinc coated
sand-cast malleable iron. All boxes shall have threaded hubs. Furnish Crouse -Hinds "FD" style
condulets, Appleton "FD" style Unilets, or equal.
E. Covers for cast metal boxes shall be gasketed cast metal covers with 316 stainless steel screws
and shall be suitable for use in wet or damp locations.
2.4 PULL AND JUNCTION BOXES
A. Pullboxes and junction boxes whose volume is less than 100 cubic inches shall be furnished as
specified hereinbefore except where sheet metal types are shown, in which case, furnish such
sheet metal enclosures in NEMA 4X 316 stainless steel construction with gasketed covers of
same material.
RACEWAYS 16110-3
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
B. Pullboxes and junction boxes whose volume is 100 cubic inches and greater shall be NEMA 4X
316 grade stainless steel type with gasketed stainless steel covers. Provide print pocket and
interior back panel for mounting of terminal strips where terminal strips are called for on the
drawings. Sheet metal boxes shall be as manufactured by Hoffman or equal.
C. Covers for sheetmetal pullboxes and junction boxes over 100 cubic inches (and for smaller sized
where shown) shall have hinged doors. All hardware shall be 316 stainless steel.
D. Cast metal junction boxes shall be cast aluminum type with gasketed, cast metal covers and with
stainless steel cover screws.
2.5 LABELS
A. Buried conduit marking tape for marking path of secondary buried conduits shall be four (4")
inch nominal width strip of polyethylene with highly visible, repetitive marking "BURIED
CONDUIT" or similar language, repeated along its length.
B. Voltage warning labels for cabinets shall be waterproof vinyl strips with adhesive back and shall
have "DANGER (VOLTAGE) - DISCONNECT ALL SOURCES OF POWER BEFORE
ENTERING". Letters shall be highly visible red color on white background.
2.6 SUPPORTING DEVICES
A. Mounting hardware, nuts, bolts, lockwashers, and washers, shall be Grade 304 stainless steel.
B. Unless otherwise indicated, channel framing and supporting devices shall be manufactured of
ASTM 6063, T06 grade aluminum; 1-5/8" wide x 3-1/4" deep (double opening type). Clamp
nuts for use with channels shall be grade 316 stainless steel.
C. Where indicated, furnish grade 316 stainless steel slotted channel members 1-5/8" wide x 1-5/8"
deep or 1 5/8" x 3 1/4" deep, double-faced type. All hardware and conduit clamps shall be grade
316 stainless steel.
D. Conduit clamp supports for terminating conduits onto cable trays shall be mechanically
galvanized malleable iron with adjustable angle clamp. Fittings shall be provided with 316
stainless steel hardware. Furnish OZ/Gedney type CTC products.
E. All such channel members and fittments shall be B -Line, Unistrut or equal.
F. Conduit straps, and associated nuts, lockwashers and bolts for use with channels shall be 316
stainless steel with 316 stainless steel hardware. Furnish B -Line products or equal.
G. After -set concrete inserts (drilled expansion shields "D.E.S.") shall consist of two types. For
anchors to accommodate 5/16" diameter bolts and smaller, provide HILTI "HDI" series 304
stainless steel anchors. For anchors to accommodate 3/8" diameter and larger bolts, provide
HILTI "HVA" series with 316 stainless steel threaded inserts.
H. Hanger rod shall be 3/8" minimum diameter Type 316 stainless steel all -thread.
I. One hole conduit clamps shall be two piece nest -back or clamp -back type constructed of cast
malleable iron or cast copper -free aluminum. The material shall match the conduit. Furnish
Crouse -Hinds series 500 clamp and series CB spacer, T&B series 1270/1280 clamp + series 1350
RACEWAYS 16110-4
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
spacer (add suffix "al" for aluminum items for T&B parts), OZ\Gedney 14G clamp + series 141 G
spacer + 141NG nestback (if required), or equal. Finish for malleable iron items shall be hot dip
galvanized
J. Conduit beam clamps shall be hot -dip galvanized malleable iron and shall be as follows:
TYPE MANUFACTURER
Right Angle OZ/Gedney Type "UBCG", or equal.
Parallel OZ/Gedney Type "UPCG", or equal.
Edge OZ/Gedney Type "UECG", or equal.
K. Hanger rod beam clamps shall be clamp type with hardened steel, bolt, Steel City "500" Series,
Crouse -Hinds series "500", or equal. Furnish swivel stud for each rod make- up.
L. Conduit "J" hangers shall consist of steel straddle with detachable bolt. Finish shall be electro-
galvanized. Furnish Kindorf type "C-149", Unistrut "J-1200" Series, or equal.
M. Conduit "U" bolts shall be hot -dip galvanized steel with 316 stainless steel hex -head bolts.
N. Equipment stands for supporting devices such as control stations, device boxes and the like, shall
consist of a welded structural steel c -channel and plate steel floor plate as detailed on the
drawings. Equipment stands shall be hot -dipped galvanized after fabrication.
2.7 MISCELLANEOUS MATERIAL
A. Double bushings for insulating wiring through sheet metal panels shall consist of mating male
and female threaded phenolic bushings. Phenolic insulation shall be high -impact thermosetting
plastic rated 150 degrees C. Furnish OZ Type "ABB", or equal.
B. Conduit pull -cords for use in empty raceways shall be glass -fiber reinforced tape with foot -
marked identification along its length. Furnish Thomas, Greenlee, or equal products.
C. Conduit thread coating compound shall be conductive, non -galling, and corrosion -inhibiting.
Furnish Crouse- Hinds Type "STL", Appleton Type "ST", or equal.
D. Plastic compound for field -coating of ferrous material products shall be PVC in liquid form that
sets -up semi- hard upon curing. Furnish Rob Roy "Rob Kote", Sedco "Patch Coat", or equal.
E. Zinc spray for coating galvanized steel threads shall be Research Laboratory type "LPS", Mobil
"Zinc -Spray" or equal conductive zinc -rich spray enamel product.
F. Foam sealant for waterproofing uses shall be "AV280 Hydrofoam" by Avanti Internarional of
Webster, Texas or equal.
PART 3 - EXECUTION
3.1 RACEWAYS
RACEWAYS 16110-5
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
A. Install the conduit system to provide the facility with the utmost degree of reliability and
maintenance free operation. The conduit system shall have the appearance of having been
installed by competent workmen. Kinked conduit, conduit inadequately supported or carelessly
installed, do not give such reliability and maintenance free operation and will not be accepted.
B. Raceways shall be installed for all wiring runs, except as otherwise indicated.
C. Conduit sizes, where not indicated, shall be N.E.C. code -sized to accommodate the number and
diameter of wires to be pulled into the conduit. Unless otherwise indicated, 3/4" trade -size shall
be minimum size conduit.
D. Unless otherwise noted, conduit runs shall be installed exposed. Such runs shall be made
parallel to the lines of the structure. Conduit shall be installed such that it does not create a
tripping hazard or an obstruction for headroom.
E. All runs of rigid conduit shall be threaded, and all male threads shall be coated with non -galling
thread compound prior to assembly.
F. Plastic coated metallic conduit lengths shall be joined with threaded metallic coupling that shall
be each equipped with a 40 mil thickness sleeve that shall extend over the threads of the joined
conduit. Each joint shall be watertight.
G. Field -cut threads in runs of plastic coated metallic conduit shall be cut with a special die that has
rear reamed out oversize so as to slip over plastic coating. Do not attempt to cut threads on
plastic coated conduit with regular dies, whereby plastic coating is skinned back to allow the
incorrect die to be used. Coat all field -cut threads with cold -galvanizing spray, use two coats to
provide 1 -mil minimum coating thickness.
H. Conduit runs made in concrete pours or surface -mounted runs that are attached to the structure
shall be equipped with an expansion/deflection fitting where they cross an expansion joint, or at
every 100 feet.
I
I. Unless otherwise shown, conduit penetrations through floors located below enclosures, shall be
made each with couplings set flush with the outside faces of the concrete pour. Each pair of
couplings shall be joined with a threaded spool piece. Use coated aluminum or galvanized steel
couplings.
J. Rigid metallic conduit runs shall have their couplings and connections made with screwed
fittings and shall be made up wrench -tight. Check all threaded conduit joints prior to wire pull.
Coat all male threads with Crouse -Hinds "STL" or equal, conductive lubricant prior to joining.
K. All conduit runs shall be watertight over their lengths of run, except where drain fittings are
indicated. In which cases, install specified drain fittings.
L. Plastic jacketed flexible steel conduit shall be used to connect wiring to motors, limit switches,
bearing thermostats, and other devices that may have to be removed for servicing. Unless
otherwise indicated, maximum lengths of flex shall be three (3') feet.
M. Where plastic jacketed flex is installed, make up terminal ends with liquid -tight flex connectors.
In wet locations, install sealing gaskets on each threaded male connector. Each flex connector
shall be made-up tightly so that the minimum pull-out resistance is at least 150 lbs. Install
RACEWAYS 16110-6
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
external spirally -wrapped ground wire around each run of liquid -tight flex and bond each end to
specified grounding -type fittings.
N. Empty conduits shall have pull -ropes installed. Identify each terminus as to location of other end
and trade size of conduit. Use blank plastic waterproof write -on label and write information on
each label with waterproof ink. Pull a mandrel through each conduit to check and clear blockage
before installing pull -rope. Owner's representative shall witness test. Provide documentation that
all conduits are clear and ready for future use. Cap exposed ends of empty conduit with threaded
plugs.
O. Conduit runs into boxes, cabinets and enclosures shall be set in a neat manner. Vertical runs
shall be set plumb. Conduits set cocked or out of plumb will not be acceptable.
P. Conduit entrances into equipment shall be carefully planned. Cutting away of enclosure
structure, torching out sill or braces, and removal of enclosure structural members, will not be
acceptable.
Q. Use approved hole cutting tools for entrances into sheet metal enclosure. Use of cutting torch or
incorrect tools will not be acceptable. Holes shall be cleanly cut and they shall be free from
burrs, jagged edges, and torn metal.
R. All raceways shall be swabbed clean after installation. There shall be no debris left inside. All
interior surfaces shall be smooth and free from burrs and defects that would injure wire
insulation.
3.2 CONDUIT BODIES AND BOXES
A. Conduit bodies such as "LB", "T", "GUAT", etc., shall be installed in exposed runs of conduit
wherever indicated and where required to overcome obstructions and to provide pulling access to
wiring. Covers for such fittings shall be accessible and unobstructed by the adjacent
construction. GUA series pulling bodies rather than LB fittings and the like, shall be used for
splicing purposes as well as pulling access.
B. Covers for all conduit bodies shall be installed with gasketed cast metal type where located in
damp or wet locations.
C. All conduit boxes installed whose inside volume is less than 100 cubic inches shall be cast metal
type with gasketed cast metal cover, unless otherwise indicated.
D. All conduit boxes whose inside volume exceeds 100 cubic inches shall be sheet metal type
except where gasketed cast metal type, stainless steel or fiberglass reinforced polyester are
indicated.
3.3 RACEWAY SUPPORT
A. All raceway systems shall be adequately and safely supported. Loose, sloppy and inadequately
supported raceways will not be acceptable. Supports shall be installed at intervals not greater
than those set forth by the NEC, unless shorter intervals are otherwise indicated, or unless
conditions require shorter intervals of supports.
RACEWAYS 16110-7
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
B. Multiple runs of surface mounted conduit on concrete or masonry surfaces shall be supported off
the surface by means of aluminum channels. Attach each slotted channel support to concrete
surface by means of two (2) 1/4" diameter stainless steel bolts into drilled expansion shields.
C. Single runs of surface mounted conduit on concrete or masonry surfaces shall be supported with
hot -dipped malleable iron conduit clamps and nest -back spacers. Furnish plastic coated malleable
iron conduit clamps and nest backs where corrosive areas are called out.
D. Conduit runs that are installed along metallic structures shall be supported by means of hot -
dipped galvanized beam clamps as specified herein.
3.4 LABELING
A. In addition to labeling requirements as specified throughout this and other Sections, install
wiring and raceway labeling as follows:
1. Apply write -on identification to empty conduits to identify each conduit as to terminus of
other end and also to identify trade size of conduit.
2. Where active conduits terminate into bottoms of motor control centers, install label on each
conduit terminus and show number and size of wiring and function of circuitry and trade size
of conduit.
11"011 K911M1[6K*)k
RACEWAYS 16110-8
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16120 — WIRE AND CABLE
PART 1- GENERAL
1.1 SCOPE
This section shall include wire and cable, terminating devices, splice kits, labeling, and
appurtenances.
1.2 SUBMITTALS AND SHOP DRAWINGS
Process catalog submittals for the following:
1. Power and control cable
2. Conductor Connectors
3. Tape Products
4. Labels
PART2-PRODUCTS
2.1 WIRE AND CABLE
A. Conductors for submersible pump power and control cables shall be supplied by the submersible
pump supplier and installed in accordance with the suppliers instructions.
B. All conductors shall be soft -drawn annealed copper, Class B stranding that meets ASTM B-8.
Copper conductors shall be uncoated, except as otherwise specified.
C. Single conductor cable for power, control, and branch circuits shall have cross-linked
polyethylene insulation, rated for 600 volts. Cable shall be NEC type XHHW. All such cable
shall be rated for wet or dry use. Cable insulation shall be color coded with factory pigmented
colors below size #6 awg. Color coding shall be as specified under Part 3 of this section. Cable
shall be as manufacturered by Southwire or equal.
D. Instrument cable for analog circuits, shall be # 16 awg, twisted shielded pairs or triads with PVC
insulation and overall jacket. Cable assembly shall be rated for 600 volts, wet or dry locations.
Furnish Okonite "Okoseal-N Type P -OS" or approved equal.
E. Single conductor cable for 24 volt do control shall be minimum size #16. Furnish MTW type
insulation for panel wiring and THWN insulation for field wiring in conduits.
F. Grounding and associated upcomers and grounding conductors shall be tin-plated stranded
copper.
2.2 CONNECTORS
A. Mechanical connectors for 600V class wiring shall be tin-plated copper alloy bolted pressure
type with bronze tin-plated hardware. Furnish connectors as follows:
Wire and Cable 16120-1
Cypress Waters Phase I
Lift Station — Dallas, Texas
TYPE
MANUFACTURER & TYPE
Single conductor
Blackburn LH
to flat -plate connector
Multiple conductor
Blackburn L2H, L3H, L4H
to flat -plate connector
Split -bolt connector
Blackburn HPS
Two -bolt parallel
Blackburn 2BPW
connector with spacer
Cross Connector
Blackburn XT
Splice Connector
Blackburn S
Flush ground connector OZ Type "VG"
August 2011
B. Insulated spring wire connectors, "wire -nuts", for small building wire taps and splices shall be
plated spring steel with thermoplastic jacket and pre -filled sealant. Connector shall be rated for
600 volts, 75 degrees C continuous. Furnish King Technology, or equal.
C. Connectors for control conductor connections to screw terminals shall be crimp -type with vinyl
insulated barrel and tin-plated copper ring -tongue style connector. Furnish T&B "Sta-Kon", 3M
"Scotchlok", or equal.
D. Terminal strips for miscellaneous field terminations of control and instrumentation circuits shall
consist of 12 point box lug terminals with marking surface. Terminal assembly shall accept #18
to #12 awg and shall be rated 600 volts. Furnish Allen-Bradley #1492-HJ812 terminal blocks.
2.3 INSULATING PRODUCTS
A. Tape products shall be furnished as hereinafter specified and shall be Plymouth/Bishop, 3M, or
equal.
B. General purpose electrical tape shall be 7 mil thick stretchable vinyl plastic, pressure adhesive
type, Plymouth/Bishop Premium 11 I Black, 3M Scotch 33+, or equal.
C. Insulating void -filling tape and high voltage bedding tape shall be stretchable ethylene propylene
rubber with high -tack and fast fusing surfaces. Tape shall be rated for 90 degrees C continuous,
130 degrees C overload, and shall be moisture -proof. Void filling tape shall be Plymouth/Bishop
W963 Plysafe, 3M Scotch 23, or equal.
D. High temperature protective tape shall be rated 1800C continuous indoor/outdoor, stretchable,
self -bonding silicone rubber. High temperature tape shall be Plymouth/Bishop 20 Plysil, 3M
Scotch 70, or equal.
E. Insulation putty filler -tape shall be Plymouth/Bishop 125 Filler Tape, 3M Scotchfill, or equal.
Wire and Cable 16120-2
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
F. Are and fireproofing tape shall be Plymouth/Bishop 20 Plysil, 3M Scotch #70 or equal.
2.4 LABELS
A. Colored banding tape shall be stretchable vinyl with permanent solid color. Colors shall be as
hereinafter specified. Tape shall be Plymouth/Bishop Premium 37, 3M Scotch #35, or equal.
B. Numbered wire marking labels shall be PVC sleeve -type markers, T&B, Brady or equal.
C. Cable identification ties shall be weather resistant polyester with blank write -on space, T&B,
Brady or equal.
2.5 MISCELLANEOUS MATERIAL
A. Cable grips shall be grip -type wire mesh with machined metal support. Furnish Kellems,
Appleton, or equal products.
B. Wire pulling compound shall be non -injurious to insulation and to conduit and shall be
lubricating, non -crumbling, and non-combustible. Furnish Gedney "Wire -Quick", Ideal
"Yellow" or equal.
PART 3 - EXECUTION
3.1 POWER AND CONTROL CABLE
A. Power and control conductors shall be sized as shown and where no size is indicated, the
conductor size shall be #12 awg for power circuits #14 awg for 120 vac control circuits, and #16
awg for instrumentation circuits.
B. Equipment grounding conductors shall be installed with type XHIIW or THHN insulated
stranded copper conductors and the insulation color shall be green in sizes up to and including
#10 awg.
C. Color coding shall be as follows. Non -factory color coded cables shall be marked
with specified color tape. Use the following colors:
120/208/240V 480V
CONDUCTOR SYSTEMS SYSTEMS
Phase A or L1 Black Brown
Phase B or L2 Red Orange
Phase C Blue Yellow
Neutral White N/A
Ground Green Green
Wire and Cable 16120-3
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
D. Branch circuits may be spliced for receptacle, lighting and small appliance load inside
appropriate junction boxes. Feeders shall be installed without splice.
G. Except as otherwise specified, taps and splices with #10 AWG and smaller, shall be made with
insulated spring wire connectors. Such connectors in damp or wet locations shall be
waterproofed by filling interstices around wires with silicone rubber and further insulating with
an envelope of stretched piece of EPR tape around each wire. Then, apply one-half lapped layer
of electrical tape over all.
H. Taps, splices, and connections in #8 AWG and larger wires shall be made with copper alloy
bolted pressure connectors. Each such connector shall be insulated by means of applying
insulation putty over sharp edges so as to present a smooth bonding surface. Next, apply at least
four (4) layers, half -lapped each layer of EPR tape. Then, make final wrapping of at least three
(3) layers, half -lapped each layer of electrical tape.
I. Control wiring connections to stud type and screw type terminals shall be made with ring -tongue
type crimp connectors. Label each terminal jacket with wire marking label at each connection.
Each wire connection shall be made up tightly so that resistance of connection is as low as
equivalent length of associated conductor resistance.
K. Numbered marking labels shall be installed to identify circuit numbers from panelboards. Install
labels on each wire in each panelboard, junction, pullbox and device connection.
L. Label each wiring run with write -on waterproof labels inside motor control center. Install write -
on label ties around wire group at conduit entrance and write -on label the wire size, conduit size
and service.
M. Install PVC sleeve type numbered marking on each control wire termination at each terminal
strip and at each device. Do this in motor control center, terminal cabinets, safety switches,
remote controllers, pilot operators, and instrumentation equipment. Number selected shall
correspond to number on terminal strip.
N. All wiring inside equipment enclosures shall be neatly trained and laced with nylon tie -wraps.
Nylon tie straps shall be trimmed of excess materials and tie straps will present a neat and
orderly appearance.
3.2 INSTRUMENTATION WIRING
A. All 4-20mA analog pairs shall have shields grounded at the instrumentation panel and insulated
on the field end unless otherwise required by instrument supplier. Single point grounding shall be
maintained.
3.3 GROUND WIRING
A. Each item of equipment shall be adequately and thoroughly grounded. Comply with Article 250
of N.E.C., as amended by the latest edition of Chapter 56 of the City of Dallas City Code, except
where higher standards of grounding have been specified. In addition to requirements as
specified under Section 16450, install grounding for general wiring systems as follows.
Wire and Cable 16120-4
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
B. Equipment grounding conductors (EGC) shall be installed in each run of power and control
conduits. The.se wires shall be green colored in sizes #6 AWG and smaller and green banded in
larger sizes. Ground wires shall be type THHN or XHHW insulated copper wires.
C. EGC runs into equipment shall be grounded to equipment bus where available, or to equipment
ground lugs.
D. Where grounding type bushings are installed, bond EGC thereto, and furthermore, ground each
bushing lug to equipment ground bus or ground lug, or ground rod.
3.4 LABELING
A. In addition to labeling requirements as specified throughout this Section, install wiring and
raceway labeling as follows:
1. Apply numbered wire marking labels to control wiring terminations for each termination in
each item of equipment. Use PVC sleeve type labels.
2. Apply numbered wire marking labels to power and control wiring terminations in motor
control centers, panelboards, and at outlets, to identify circuit numbers. Use PVC sleeve
type labels.
3. Apply numbered wire marking labels to each signal wire termination in each instrument
junction box, and in each item of equipment served by instrumentation circuits. Use PVC
sleeve type labels.
4. Apply write -on identification labels to wiring sets in each motor control center, and in each
pullbox and junction box. Show wire size, conduit size, and line and load information. Use
waterproof plastic write -on labels with nylon tie -wraps.
3.5 TESTING
A. Each run of 600V class power and control wiring shall be tested prior to connection of line and
load. Make tests with 1000V de hand -crank or motor driven ohmmeter. Each run of wiring shall
be tested phase -to -phase and/or phase -to -neutral, and phase -to -ground. Test results for each test
shall be equal to or greater than 25,000,000 ohms with 1000V do applied. All tests shall be made
in the presence of the Owners representative or Engineer.
B. Test all runs of signal wiring with 250V do megger. Insulation values shall meet or exceed
1,000,000 ohms per 100 feet (cable to shield).
C. Should any cable or circuit fail to meet the above tests, replace wire and retest.
END OF SECTION
Wire and Cable 16120-5
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16199 — MISCELLANEOUS
PART 1- GENERAL
1.1 SCOPE
A. This section shall include wiring devices, enclosed circuit breakers, and equipment stands
B. Furnish and install all such devices and completely connect and wire each device.
1.2 SUBMITTALS AND SHOP DRAWINGS
A. Process catalog submittals, and equipment data for the following:
1. Wiring Devices
2. Wiring Device Covers
3. Wiring Device Boxes
4. Equipment Stands
5. Dry Type Transformer Catalog Data
6. Enclosed Circuit breakers
7. Terminal strips
8. Wireways
B. Submit shop drawings for equipment.
PART 2 - PRODUCTS
2.1 WIRING DEVICES
A. All wiring devices shall be specification grade and shall meet NEMA WD -1 requirements. Color
shall be brown, unless otherwise indicated.
B. Cover plates for wiring devices shall be Appleton FSK series unless otherwise noted on the
drawings. Boxes shall be Appleton type FD, cast metal, raised -lid type. Furnish integral
mounting feet where called for on the drawings. Furnish multi -gang units for two or more
switches.
C. Furnish the following miscellaneous wiring devices:
1. Single -pole, single -throw, 20A toggle switch shall be Arrow -Hart #1221, or equal.
2. Single -pole, double -throw (three-way) 20A toggle switch shall be Arrow -Hart #1223, or
equal.
3. Double -pole, single -throw, 20A toggle switch shall be Arrow -Hart #1222, or equal.
D. Receptacles shall each consist of the following:
1. 2 -gang FDB cast metal box with raised lids and integrally cast mounting feet.
2. Arrow -Hart 20A/120V corrosion resistant duplex receptacle #5362CR-GRY.
Miscellaneous 16199-1
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
3. Arrow -Hart #GF2091M1 GFCI device with Bryant "While in Use" weatherrproof flip lid
cover.
2.2 TERMINAL STRIPS
A. Terminal strips for installation in junction boxes and the like shall be 600 volt, rated for 25 amps
with tin- plated copper box lugs.
B. Terminal strips for installation in junction boxes and the like shall be 600 volt, rated for greater
than 25 amps with tin- plated copper box lugs.
C. Furnish Allen-Bradley type 1492-HJ812 or equal in quantities as required for 25 amp
requirements.
D. Furnish Allen-Bradley type 1492-PDM3111 or equal in quantities as required for greater than 25
amp requirements.
2.3 EQUIPMENT STANDS
A. Equipment stands for mounting control stations shall be constructed of strut members or H.D. l
galvanized conduit together as called for on the drawings.
B. Each equipment stands shall be installed with anchor bolts or 3/8" anchors. Furnish grout as
indicated on the drawings.
2.4 ENCLOSED CIRCUIT BREAKER
A. Enclosed circuit breaker shall be heavy duty, rated 600 volts ac and shall have circuit breaker
suitable for 22,000 amp AIC in sizes as indicated on the drawings.
B. Enclosed circuit breaker enclosures shall be NEMA 4X type 316 stainless steel. Safety switches
for use as service entrance shall be UL listed for service entrance and shall have solid neutral.
C. Enclosed circuit breaker enclosure shall be as manufactured by Eaton, General Electric, or
approved equal.
D. Enclosed circuit breakers used for Service Entrance use shall be UL listed and labeled
accordingly.
2.5 Dry Type Transformers
SEE PUMP STARTER PANEL
PART 3 - EXECUTION
3.1 WIRING DEVICES
A. Install wiring devices where shown and support each box to panel or stanchion with stainless j
steel hardware into typical drilled expansion shields.
Miscellaneous 16199-2
Cypress Waters Phase I
Lift Station —Dallas, Texas
August 2011
B. Set each wiring device with axis plumb and install with yoke screws so as to adequately support
each device.
3.2 TERMINAL STRIPS
A. Install terminal strips as hereinbefore specified. Mount to enclosures or backpans with stainless
steel hardware.
B. Label each terminal directory with numbers corresponding to wire numbers landed.
END OF SECTION
Miscellaneous 16199-3
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16210 — ELECTRICAL UTILITY SERVICE
PART 1— GENERAL
1.1 SCOPE
A. The new lift station shall be served by ONCOR ELECTRIC DELIVERY. The service voltage is
to be 480Y/277 volts, 3 phase, solidly grounded.
B. The Contractor shall furnish and install new underground conduit duct from a ONCOR
ELECTRIC DELIVERY pad mounted switch to the new pad mounted switchgear. The meter
transocket shall be furnished by ONCOR ELECTRIC DELIVERY and installed by the
Contractor as shown on the electrical plans. The Contractor in co-ordination with ONCOR
ELECTRIC DELIVERY shall schedule the sequencing of work including inspection by ONCOR
ELECTRIC DELIVERY.
C. The Contractor shall furnish and install new conduit and service entrance wiring from the
ONCOR ELECTRIC DELIVERY transformer to a rack mounted transocket and then service
entrance rated enclosed circuit breaker as shown on the electrical drawings. The work shall
include furnishing and installing necessary elbows, conduits, sleeves, grounding, extra cable
lengths, terminations and other miscellaneous hardware for the complete electrical utility service
installation from the transcocket to the panel. Scheduling, sequencing work (including
transformer pole installation by ONCOR ELECTRIC DELIVERY), and inspection by ONCOR
ELECTRIC DELIVERY and the Owner shall be done by the Contractor in co-ordination with
ONCOR ELECTRIC DELIVERY.
D. ONCOR ELECTRIC DELIVERY will furnish and install any new underground distribution
equipment. ONCOR ELECTRIC DELIVERY will connect the electrical service in co-ordination
with the Contractor at their pole for the Lift Station. This work shall be as specified herein and
per ONCOR ELECTRIC DELIVERY specifications and shall be verified by the Contractor to
meet the requirements of ONCOR ELECTRIC DELIVERY "Electric Service Guidelines,
SECTION 300, September 2004, TSN449260". Scheduling, sequencing of work and inspection
required by ONCOR Electric Delivery and the Owner shall be done by the Contractor in co-
ordination with ONCOR ELECTRIC DELIVERY. The installation shall meet the latest
requirements of the NESC and NEC (NFPA 70). Contact ONCOR ELECTRIC DELIVERY,
James McCasland, Phone: 817-858-2509, Email: james.mccasland@oncor.com
E. The Contractor shall coordinate a schedule with ONCOR ELECTRIC DELIVERY to provide
temporary power to meet project schedule requirements. All forms such as ONCOR Electric
Delivery Form 1080 "Client Installed Facilities Civil Construction Information For Electric
Distribution" shall be submitted to ONCOR Electric Delivery as required to meet scheduling
requirements.
PART2-PRODUCTS
2.1 RACEWAYS
Raceways shall be as specified under Section 16110, or as required by ONCOR ELECTRIC
DELIVERY.
Electrical Utility Service 16210-1
Cypress Waters Phase I
Lift Station — Dallas, Texas
2.2 WIRE AND CABLE
Service wire and cable (480 volt) shall be as specified under Section 16120.
2.3 UNDERGROUND
Underground shall be as specified under Section 16410 and as specified herein.
PART 3 - EXECUTION
3.1 GENERAL
A. Underground conduit shall be installed per Section 16410.
August 2011
B. Coordinate with electric utility (ONCOR ELECTRIC DELIVERY) inspector for inspection of
transocket installation and underground work prior to trenching and backfilling and as otherwise ;
required by utility. 1
C. Pull a mandrel through each conduit to check and clear blockage. Install service conductors with
cable as specified under Section 16120. Install service conductors with cable as specified under 1
RACEWAY SECTION. Install a mule tape (pull tape - a flat ribbon, consecutively numbered in
feet, which is usually made of polyester or aramid yarn and may be coated with plastic for
waterproofing) in the empty conduit for use by ONCOR Electric Delivery.
D. The new service shall operate in parallel with the existing service until the new lift station is in
service. Remove the existing service after the new service and lift station is in service.
END OF SECTION
Electrical Utility Service 16210-2
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16220 — STANDBY GENERATOR SET
PART 1. GENERAL
1.1 SCOPE
A. Furnish to the site a standby generator as specified herein. Work shall include all necessary
materials, equipment, labor, and services.
B. Auxiliary and accessory devices necessary for system operation or performance, such as
relays or terminals to interface with other Sections of these Specifications, shall be included.
C. Generator shall be 480Y/277 volt three phase four wire. The alternator shall include an
isolated neutral connection to be connected to by an insulated neutral conductor to a neutral at
the automatic transfer switch, which is connected to a grounding connection at the motor
control center.
D. All equipment shall be new and of current production, factory tested, and startup by a
supplier authorized by the equipment manufacturer. Technicians specifically trained and
certified by the manufacturer to support the product shall provide the support for the on-site
testing of the generator set equipment.
1.2 DESCRIPTION OF SYSTEM
Provide a Standby diesel fueled power system (genset) to supply electrical power in event of
failure of normal supply. The genset shall consist of a liquid cooled engine, an AC alternator,
system controls to be connected to a separate motor control center automatic transfer switch with
all necessary accessories for a complete operating system, including but not limited to the items
as specified hereinafter.
1.3 REQUIREMENTS OF REGULATORY AGENCIES
A. An electric generating system, consisting of a prime mover, generator, governor, coupling
and all controls, must have been tested, as a complete unit, on a representative engineering
prototype model of the equipment to be sold.
B. The generator set must conform to applicable National Electrical Code and applicable
inspection authorities. The generator set and supplied accessories shall meet the requirements
of the following standards:
1. IEEE446 — Recommended Practice for Emergency and Standby Power Systems for
Commercial and Industrial Applications
2. Mil Std 461D-1993. Military Standard, Electromagnetic Interference Characteristics.
3. Mil Std 462D - 1993. Military Standard, Measurement of Electromagnetic Interference
Characteristics.
Standby Generator Set 16220-1
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
4. NFPA70 — National Electrical Code. Equipment shall be suitable for use in systems in
compliance to Article 700, 701, and 702.
5. NFPAl 10 —Emergency and Standby Power Systems. The generator set shall meet all
requirements for Level 1 systems. Level 1 prototype tests required by this standard shall
have been performed on a complete and functional unit. Component level type tests will
not substitute for this requirement.
6. NEMA MGI -1998 Part 32. Alternator shall comply with the requirements of this
standard.
7. UL142 — Sub -base Tanks
8. UL1236 —Battery Chargers
9. UL2200. The generator set shall be listed to UL2200 or submit to an independent third
party certification process to verify compliance as installed.
C. The control system for the generator set shall comply with the following standards.
1. CSA C22.2, No. 14 — M91 Industrial Control Equipment.
2. EN50082-2, Electromagnetic Compatibility — Generic Immunity Requirements, Part 2:
Industrial.
3. EN55011, Limits and Methods of Measurement of Radio Interference Characteristics of
Industrial, Scientific and Medical Equipment. i
4. IEC8528 part 4. Control Systems for Generator Sets
5. IEC Std 801.2, 801.3, and 801.5 for susceptibility, conducted, and radiated
electromagnetic emissions.
i
6. UL508A. The entire control system of the generator set shall be UL508A listed and
labeled. "
D. The generator set must be available with the Underwriters Laboratories listing as a stationary
engine generator assembly.
1.4 SUBMITTALS AND SHOP DRAWINGS
A. Process catalog data submittals for the following: (I
1. Engine
2. Generator (Alternator)
3. Control panel
4. Battery charger
5. Jacket water heater
6. Enclosure
7. Muffler
8. Subbase Fuel Tank
Standby Generator Set 16220-2 I
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
9. Load bank
10. Main Circuit Breaker
11. Load Bank Circuit Breaker
12. Ground Fault Relay
13. Lighting
14. Genset Sizing Report showing that the starting conditions listed in 2.02. B. are met by the
voltage drop values of the generator set.
15. Accessories
B. Process dimensioned shop drawings for the generator set skid showing sub -base fuel tank,
enclosure, control panel, circuit breaker, silencer (muffler) and location of accessories.
C. Process dimensioned shop drawings for the generator set skid showing sub -base fuel tank,
enclosure, control panel, circuit breaker, silencer (muffler) and location of accessories.
D. Provide seven complete sets of Engineering Submittals for approval, prior to production
release, showing all components, in addition to the engine and generator. Submittals shall
include compliance with these specifications.
PART 2. PRODUCTS
2.1 MANUFACTURERS QUALIFICATIONS
A. This system shall be supplied by Loftin Equipment Company or an approved equal from
Caterpillar, Cummins Southern Plains, Stewart & Stevenson or an approved equal who has
been regularly engaged in the production of engine -alternator sets and associated controls for
a minimum of ten years, thereby identifying one source of supply and responsibility. The
supplier must be the parts and service supplier and warranty administrator of all equipment
on the unit including the engine. To be classified as a manufacturer, the builder of the
generator set must manufacture, at a minimum, engines or alternators.
B. The manufacturer shall have printed literature and brochures describing the standard series
specified. It shall not be a one of a kind fabricated machine.
2.3 PROTOTYPE TESTING
A. To assure that the equipment has been designed and built to the highest reliability and quality
standards, the manufacturer and/or local representative shall be responsible for three separate
tests: design prototype tests, final production tests, and site tests.
1. Design Prototype Tests: Components of the emergency system such as the
Standby Generator Set 16220-3
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
engine/generator set and accessories shall not be subjected to prototype tests since the
tests are potentially damaging. Rather, similar design prototypes and pre -production
models shall be subject to the following tests.
a. Maximum power (kW).
b. Maximum motor starting (kVA) at 35% instantaneous voltage dip.
c. Alternator temperature rise by embedded thermocouple and/or by resistance method
per NEMA MGI -32.40
d. Governor speed regulation under steady-state and transient conditions.
e. Voltage regulation and generator transient response.
f. Harmonic analysis, voltage waveform deviation, and telephone influence factor.
g. Three-phase short circuit tests.
h. Alternator cooling air flow.
i. Torsional analysis to verify that the generator set is free of harmful torsional stresses.
j. Endurance testing.
2.4 ENGINE -GENERATOR SET
A. The generator set shall be a Kohler model 100REOZJE with a 4S11 alternator as provided by
Loftin Equipment Company (469) 261-9548. It shall provide 100 kW, 125 kVA when
operating at 277/480 volts, 0.8 power factor. The generator set shall be capable of this rating
while operating in an ambient condition of 122°F (50°C) with a sound attenuated enclosure.
B. The generator set shall be capable of starting the equipment in starting two 20 horsepower
motors with 5 KVA base load with no more than 17.5% voltage dip at the generator
terminals.
C. Vibration isolators shall be provided between the engine -generator and heavy-duty steel base
D. The 276 cubic -inch -displacement engine shall deliver a minimum of 158 hp at a governed
speed of 1800 rpm. The engine shall be equipped with the following:
1. An electronic isochronous governor capable of +0.25% steady-state frequency regulation.
2. 24 Volt positive engagement solenoid shift -starting motor.
3. 65 -Ampere minimum automatic battery charging alternator with solid-state voltage
regulation.
4. Positive displacement, full pressure lubrication oil pump, cartridge oil filters, dipstick,
and oil drain.
5. Dry -type replaceable air cleaner elements for normal applications.
6. Engine -driven or electric fuel transfer pump capable of lifting fuel 10 feet, fuel filters,
and electric solenoid fuel shut-off valve.
E. The turbocharged and after cooled engine shall be fueled with No. 2 diesel
Standby Generator Set 16220-4
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
F. The engine shall have a minimum of 4 cylinders, and be liquid -cooled by a unit -mounted
radiator, blower fan, water pump, and thermostats. This system shall properly cool the
engine with up to 0.5 inches H2O static pressure on the fan in an ambient temperature up to
122F/50C.
H. The engine shall be EPA Tier III certified.
2.5 ALTERNATOR
A. The alternator shall be a Fast ResponseTM II permanent magnet brushless design.
B. The alternator shall be salient -pole, brushless, 12 -lead reconnectable, self -ventilated of drip -
proof construction with amortisseur rotor windings and skewed stator for smooth voltage
waveform. The insulation shall meet the NEMA standard (MG 1-33.40) for Class H and be
insulated with epoxy varnish to be fungus resistant per MIL 1-24092. Temperature rise of the
rotor and stator shall be limited to 130°C. The excitation system shall be of brushless
construction controlled by a solid- state voltage regulator capable of maintaining voltage
within 10.25% at any constant load from 0% to 100% of rating. The regulator must be
isolated to prevent tracking when connected to SCR loads, and provide individual
adjustments for voltage range, stability and volts -per -hertz operations; and be protected from
the environment by conformal coating.
C. The generator set shall meet the transient performance requirements of ISO 8528-5 level G-2.
D. The alternator excitation shall be of a permanent magnet exciter design.
E. The generator shall be inherently capable of sustaining at least 300% of rated current for at
least 10 seconds under a 3-phase symmetrical short circuit without the addition of separate
current support devices.
F. The alternator having a single maintenance -free bearing, shall be directly connected to the
flywheel housing with a semi -flexible coupling between the rotor and the flywheel
2.6 DOUBLE WALL SECONDARY CONTAINMENT SUB BASE FUEL TANK
A. A subbase fuel tank used in conjunction with a diesel powered generator set of 100 kW
rating will contain a minimum of 80 gallons of fuel to support the generator set for a period
of 8 hours at 100% of rated load.
B. The sub base fuel system is listed under UL 142, sub section entitled Special Purpose Tanks
EFVT category, and will bear their mark of UL Approval according to their particular
classification.
C. The above ground steel secondary containment rectangular tank for use as a sub base for
diesel generators is manufactured and intended to be installed in accordance with the
Flammable and Combustible Liquids Code NFPA 30, the Standard for Installation and Use
of Stationary Combustible Engine and Gas TurbinesNFPA 37, and Emergency and
Standby Power Systems NFPA 110.
D. Construction:
Standby Generator Set 16220-5
Cypress Waters Phase I
Lift Station — Dallas, Texas
1. Primary Tank
August 2011
It will be rectangular in shape and constructed in clam shell fashion to ensure maximum
structural integrity and allow the use of a full throat fillet weld.
2. Steel Channel Support System
Reinforced steel box channel for generator support, with a load rating of 5,000 Ibs. per
gen set mounting hole location. Full height gussets at either end of channel and at gen set
mounting holes shall be utilized.
3. Exterior Finish
The exterior coating shall be tested to withstand continuous salt spray testing at 100
percent exposure for 244 hours to a 5 percent salt solution at 92-97° F. The coating has
been subjected to full exposure humidity testing to 100 percent humidity at 100° F for 24
hours. Tests are to be conducted in accordance with The American Standard Testing
Methods Society.
4. Venting:
Normal venting shall be sized in accordance with the American Petroleum Institute
Standard No 2000, Venting Atmospheric and Low Pressure Storage Tanks not less than
1-1/4" (3 cm.) nominal inside diameter. A 1-1/4" atmospheric mushroom cap shall be
furnished and the installing contractor shall pipe above the highest fill point as a
minimum
5. Emergency Venting
The emergency vent opening shall be sized to accommodate the total capacity of both
normal and emergency venting and shall be not less than that derived from NFPA 30,
table 2-8, and based on the wetted surface area of the tank. The wetted area of the tank
shall be calculated on the basis of 100 percent of the primary tank. A zinc plated
emergency pressure relief vent cap shall be furnished for the primary tank. The vent is
spring -pressure operated: opening pressure is 0.5/psig and full opening pressure is 2.5
prig. Limits are stamp marked on top of each vent. The emergency relief vent is sized to
accommodate the total venting capacity of both normal and emergency vents
Fuel Fill: l
There shall be a 2" NPT opening within the primary tank with an 8" raised fill pipe and
lockable manual fill cap.
6. Fuel Level:
A direct reading, UL listed, magnetic fuel level gauge with a hermetically -sealed vacuum
tested dial shall be provided to eliminate fogging.
7. Low Fuel Level Switch
Consists of a 50 watt float switch for remote or local annunciation of a (50% standard)
low fuel level condition.
Standby Generator Set 16220-6
Cypress Waters Phase I
Lift Station — Dallas, Texas
2.7 WEATHER ENCLOSURE
August 2011
A. Provide a sound attenuated walk-in type weatherproof enclosure with a resulting sound
level not to exceed 85 dbA @ 3 feet when measured 5 feet above grade and both units
operating at full load. Enclosure shall be constructed of formed galvanized sheet metal
panels. The enclosure shall be sized to adequately house the generator set and all
accessories. Maintain nominal aisle space of 24 inches on each side and 36 inches at the
rear. Enclosure shall be designed for a minimum wind load rating of 100 mph.
B. The enclosure shall be constructed from G60 galvanized high strength, low alloy steel.
C. The enclosure shall be primed with BASF urethane and finish coated with BASF Superl
System paint. Enclosures will be finished in the manufacturer's standard color.
D. The enclosure must allow the generator set to operate at full load in an ambient of 46°C with
no additional derating of the electrical output.
E. The enclosures must meet all of the requirements of UL -2200.
F. Enclosures must be equipped with sufficient side and end doors to allow access for operation,
inspection, and service of the unit and all options. Minimum requirements are two doors per
side. When the generator set controller faces the rear of the generator set, an additional rear
facing door is required. Access to the controller and main line circuit breaker must meet the
requirements of the National Electric Code.
G. Doors must be hinged with stainless steel hinges and hardware and be removable.
H. Doors must be equipped with lockable latches. Locks must be keyed alike and to the City of
Dallas Standards.
I. Enclosures must be mounted to the generator set skid.
J. The enclosure roof must be pitched to prevent accumulation of water
K. A duct between the radiator and air outlet must be provided to prevent re -circulation of hot
air.
L. The complete exhaust system shall be internal to the enclosure. Enclosures with roof
mounted or externally exposed silencers are not acceptable.
M. The silencer shall be an insulated critical silencer with a tailpipe and rain cap
N. Interior lights shall be DC. Lights shall have 1 -hour timer, and shall be wired to engine
cranking batteries.
2.8 ACCESSORIES
A. The generator set(s) must be manufactured to the applicable specifications on file
with Underwriters Laboratories and the UL 2200 mark must be affixed.
Standby Generator Set 16220-7
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
B. Provide an engine jacket water heater and thermostatic control sized per the manufacturers
recommendations.
C. A 100% rated line circuit breaker of 150 amperes, 150 amps sensor, 600 volt rated, molded case
type, generator mounted.
D. Furnish a ground fault relay to alarm ground fault with contacts for remote indication.
E. Engine coolant heater. Thermostatically controlled and sized to maintain manufacturers
recommended engine coolant temperature to meet the start-up requirements of NFPA-99 and
NFPA-110, Level 1.
F. Battery rack, and battery cables, capable of holding the manufacturer's recommended
batteries, shall be supplied.
G. 12 -volt lead -antimony battery(ies) capable of delivering the manufacturer's recommended
minimum cold -cranking Amps required at 0°F, per SAE Standard J-537, shall be supplied.
H. 10 -Ampere automatic float and equalize battery charger with +/- I% constant voltage
regulation from no load to full load over +/-10% AC input line variation, current limited
during engine cranking and short circuit conditions, temperature compensated for ambient
temperatures from -40°C to +60°C, 5% accurate voltmeter and ammeter, fused, reverse
polarity and transient protected.
I. The engine exhaust silencer shall be coated to be temperature and rust resistance, rated for
critical application.
J. Gas -proof, seamless, stainless steel, flexible exhaust bellows with threaded NPT connection.
K. Two flexible fuel lines rated 257T and 100 psi ending in pipe thread.
L. Air cleaner restriction indicator to indicate the need for maintenance of the air cleaners.
M. The 20 relay dry contact kit provides normally open and normally closed contacts in a form C
configuration to activate warning devices and other customer provided accessories allowing
remote monitoring of the generator set. Typically, lamps, audible alarms, or other devices
signal faults or status conditions.
N. Run Relay to provide a three -pole, double -throw relay with 10 amps at 250 VAC contacts for
indicating that the generator is running.
O. Common Failure relay to remotely signal auxiliary faults, emergency stop, high engine
temperature, low oil pressure, overcrank, and overspeed via one single -pole, double -throw
relay with 10 amps at 120 VAC contacts.
P. Ground fault relay and indicator for shutdown of generator set and with dry contacts for
alarm to RTU.
Q. Unit shall be supplied with radiator mounted resistive load bank, rated 50 % of load in a
NEMA 3R enclosure. Controls shall be pre -wired so that load bank will accept signal from
ATS that will disengage the load bank if exercising and normal power is lost. Controls shall
also be pre -wired so that any time ATS sets genset to exercise it engages the load bank for an
Standby Generator Set 16220-8
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
exercise cycle utilizing the load bank. This shall be automatic and require no manual
switching at time of exercising. Load bank shall be tied into genset via its own main line
circuit breaker. The load bank controls shall be inside the generator set enclosure.
PART 3. EXECUTION
3.1 FACTORY TESTING
A. Before shipment of the equipment, the engine -generator set shall be tested under rated load
for performance and proper functioning of control and interfacing circuits. Tests shall
include:
1. Verify all safety shutdowns are functioning properly.
2. Single step load pick-up per NFPA 110-1996, Paragraph 5-13.2.6.
3. Transient and voltage dip responses and steady state voltage and speed (frequency)
checks
4. Test completed unit under full load for 4 hours before shipment.
5. Safety shutdown device testing.
6. Voltage regulation.
7. Rated Power @ 0.8 PF
8. Maximum Power.
9. Contractor shall contact owner for arrangements to either witness this test, or to have the
factory send a certified test record prior to shipment.
3.2 OWNERS MANUALS
B. Six (6) sets of owner's manuals specific to the product supplied must accompany delivery of
the equipment. General operating instruction, preventive maintenance, wiring diagrams,
schematics and parts exploded views specific to this model must be included. These must be
supplied in a printed form and one electronic version in Microsoft Word (Latest Version) or
Searchable PDF (Latest Version) format.
3.3 SITE TRAINING
A. Allow in bid for a factory -authorized service representative to train Owner's maintenance
personnel to adjust, operate, and maintain packaged engine generators.
B. Allow in bid for a factory -authorized service representative to train Owner's maintenance
personnel on procedures and schedules for starting and stopping, troubleshooting, servicing,
and maintaining equipment.
3.4 INSTALLATION
A. Contractor shall install the complete electrical generating system including all fuel
Standby Generator Set 16220-9
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
connections in accordance with the manufacturer's recommendations as reviewed by the
Engineer.
3.5 SERVICE
A. Supplier of the electric plant and associated items shall have permanent service facilities in
this trade area. These facilities shall comprise a permanent force of factory trained service
personnel on 24 hour call, experienced in servicing this type of equipment, providing
warranty and routine maintenance service to afford the owner maximum protection.
Delegation of this service responsibility for any of the equipment listed herein will not be
considered fulfillment of these specifications. Service contracts shall also be available.
3.6 WARRANTY
A. One year basic extended warranty for the generator set shall be included to guarantee against
defective material and workmanship in accordance with the manufacturer's published
warranty from date of start-up. Optional warranties shall be available upon request.
B. The generator set manufacturer and its distributor shall maintain a 24-hour parts and service
organization. This organization shall be regularly engaged in a maintenance contract
program to perform preventive maintenance and service on equipment similar to that
specified. A service agreement shall be available and shall include system operation under
simulated operating conditions, adjustment to the generator set and switchgear controls as
required, and certification in the owner's maintenance log of repairs made and proper
functioning of all systems.
3.7 CHECKOUT AND START UP
A. The manufacturer's local representative shall perform an installation check, start-up, and
building load test. The engineer, regular operators, and the maintenance staff shall be
notified of the time and date of the site test. The tests shall include:
B. Fuel, lubricating oil, and antifreeze shall be checked for conformity to the manufacturer's
recommendations, under the environmental conditions present and expected.
I
C. Accessories that normally function while the set is standing by shall be checked prior to
cranking the engine. These shall include: block heaters, battery charger, generator strip y
heaters, remote annunciator, etc.
D. Start-up under test mode to check for exhaust leaks, path of exhaust gases outside the
building, cooling air flow, movement during starting and stopping, vibration during running,
normal and emergency line -to -line voltage and frequency, and phase rotation.
E. Automatic start-up by means of simulated power outage to test remote- automatic starting,
transfer of the load, and automatic shutdown. Prior to this test, all transfer switch timers shall
be adjusted for proper system coordination. Engine coolant temperature, oil pressure, and
battery charge level along with generator voltage, amperes, and frequency shall be monitored
Standby Generator Set 16220-10
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
throughout the test. An external load bank shall be connected to the system if sufficient
facility load is unavailable to load the generator to the nameplate kW rating.
3.8 SUBMITTALS
A. Provide seven (7) complete sets of Engineering Submittal for approval, prior to production
release, showing all components, in addition to the engine and generator. Submittals shall
include compliance with these specifications. These must be supplied in a printed form and
one electronic version in Microsoft Word (Latest Version) or Searchable PDF (Latest
Version) format.
3.9 SUBSTITUTIONS
A. The emergency power system has been designed to the specified manufacturer's electrical
and physical characteristics. The equipment sizing, spacing, amounts, electrical wiring,
ventilation equipment, fuel and exhaust components have all been sized and designed around
Loftin Equipment Company/Kohler equipment. Should any substitutions be made, the
contractor shall bear responsibility for the installation, coordination and operation of the
system as well as any engineering and redesign costs that may result from such substitutions.
Alternate equipment suppliers shall furnish equipment submittals 14 days prior to bid date for
approval to bid. As part of the submittals, the substitute manufacturer shall supply as a
minimum engine, alternator and control panel wiring diagrams and schematics. A separate
list of all printed circuit boards with part numbers and current pricing must also be included
END OF SECTION
Standby Generator Set 16220-11
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16230 —AUTOMATIC TRANSFER SWITCH
PART 1. GENERAL
1.01 SCOPE
A. Furnish and install open transition automatic transfer switch, ATS, without bypass and as
shown on the drawings and specified herein. Work shall include all necessary materials,
equipment, labor, and services
B. Auxiliary and accessory devices necessary for system operation or performance, such as
relays or terminals to interface with other Sections of these Specifications, shall be included.
C. The switch must be a self-contained device with all features described herein. The equipment
shall be front accessible only in an outdoor, NEMA 4X Panel suitable for installation adjacent
to wet well pump control panel on a rack or support provided by the contractor as shown on
the project drawings.
D. The ATS shall be 480 volt 3 phase with ground, 60 Hz., 22 kAIC rated, 3 pole with isolate
neutral pad for connecting the service neutral through the transfer switch to the isolated
neutral of the generator set. Grounding in the ATS shall be for bonding of the equipment to
the electrical facilities for the lift station. Grounding of the system shall be as shown on the
drawings.
E. Auxiliary and accessory devices necessary for system operation or performance, such as
relays or terminals to interface with other Sections of these Specifications, shall be included.
1.02 SUBMITTAL AND SHOP DRAWINGS
A. Process catalog data submittals for the automatic transfer switch.
B. Process shop drawings for the automatic transfer switch including dimensional layout The
automatic transfer switches covered by these specifications shall be designed, tested, and
assembled in strict accordance with all applicable standards of ANSI, U.L., IEEE and NEMA.
C. Process rating information on specified switch and bus ratings of the assembly. In addition
process catalog or manufacturer document submittals on the following added equipment not a
standard part of the product as they apply:
1. Pilot lights
2. Pilot operators
3. Control relays
4. Timers
5. Protective relays
6. Overloads
7. Nameplate legends
Automatic Transfer Switch 16230- 1
Cypress Waters Phase I
Lift Station — Dallas, Texas
8. One -line diagrams
9. Equipment schedule
10. Contactors
11. Circuit breakers
12. Fuses
13. Control Wire
14. Bill-of-material/component list
15. Electronic Controllers
16. Programming requirements.
August 2011
D. The submittal shall include prototype test certification and specification sheets showing all
standard and optional accessories to be supplied, schematic wiring diagrams, dimension
drawings, and interconnection diagrams identifying by terminal number, each required
interconnection between the generator set and the transfer switch if it is included elsewhere in
these specifications.
1.03 QUALITY ASSURANCE
A. The ATS shall conform to the requirements of:
1. UL 1008 --Standard for Automatic Transfer Switches
2. NFPA 70 --National Electrical Code, including use in emergency and standby systems in
accordance with Articles 517, 700
3. NFPA 110 --Standard for Emergency and Standby Power Systems
4. IEEE Standard 446 --Recommended Practice for Emergency and Standby Power Systems
(Orange Book)
5. IEEE Standard 241 --Recommended Practice for Electric Power Systems in Commercial
Buildings (Gray Book)
6. NEMA Standard IC 10 (formerly ICS 2-447) Automatic Transfer Switches.
7. EN61000-4-5 Surge Immunity Class 4 (voltage sensing and programmable inputs only)
8. EN61000-4-4 Fast Transient Immunity Severity Level 4
9. IEC Specifications for EMI/EMC Immunity as follows:
a. CISPR 1 Radiated Emissions
b. IEC 1000-4-2, Electrostatic Discharge
c. IEC 1000-4-3, Radiated Electromagnetic Fields
d. IEC 1000-4-4, Electrical Fast Transient (Bursts)
Automatic Transfer Switch 16230-2
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
e. IEC 1000-4-5, Surge Voltage
f. IEC 1000-4-6, Conducted RF Disturbances
g. IEC 1000-4-8, Magnetic Fields
h. IEC 1000-4-11, Voltage Variations and Interruptions
10. The starter and enclosure shall include a UL 508A (UL Industrial Control Panel) Label
representing that the equipment was assembled by and meets the requirements of a
UL508A shop.
1.04 ACCEPTABLE MANUFACTURERS
Automatic Transfer Switch shall be Kohler model KCP-AMTF-02255, Substitutions shall be
submitted in writing prior to original bid date with supporting documentation demonstrating that
the alternate manufacturer conforms to all aspects of the specifications herein.
1.05 RELATED SPECIFICATION SECTION
Section 16220, STANDBY GENERATOR SET
PART 2. PRODUCTS
2.01 AUTOMATIC TRANSFER SWITCH
A. Automatic transfer switch shall be rated for 480 vAC, 260 amp. 3 pole with isolated neutral
and with microprocessor controls.
B. The enclosure shall be NEMA 4X, gasketed construction.
C. The automatic transfer with bypass switch (ATS) shall consist of a double throw power
transfer switch mechanism and a microprocessor controller to provide automatic operation.
The automatic transfer and bypass -isolation switch and controllers shall be the products of the
same manufacturer.
D. The withstand and closing ratings with a current -limiting fuse shall be 200,000 Amps
E. The withstand and closing ratings with any overcurrent protective device shall be 35,000
Amps
F. The switch shall be 600 -volt class.
G. Automatic transfer switches not intended for continuous duty or repetitive load transfer
switching are not acceptable.
H. The automatic transfer switch shall be rated in amperes for total system transfer including
control of motors, electric -discharge lamps, electric heating, and tungsten -filament lamp load.
Switches rated 400 amperes and below shall be suitable for 100% tungsten -filament lamp
load. Switches rated above 400 amperes shall be suitable for 30% tungsten -filament load.
I. The automatic transfer switch shall be rated to withstand the rms symmetrical short circuit
Automatic Transfer Switch 16230-3
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
current available at the automatic transfer switch terminals.
2.02 MECHANICAL REQUIREMENTS
A. All main contacts shall be of silver composition. The main contacts shall be protected by
arcing contacts in sizes 400 amperes and above. The main contacts shall be of the blow -on
configuration and of segmented construction in ratings 600 amperes and above.
B. All contacts, coils, springs, and control elements shall be conveniently removable from the
front of the transfer switch without major disassembly or disconnection of power conductors.
C. The contact transfer time shall not exceed one-sixth of a second.
D. All moveable parts of the operating mechanism shall remain in positive mechanical contact
with the main contacts during the transfer operation without the use of separate mechanical
interlocks.
E. All contacts, coils, springs, and control elements shall be conveniently removable from the
front of the transfer switch without major disassembly or disconnection of power conductors.
F. The neutral conductor shall be isolated from ground connected as shown on the plans, a
neutral conductor terminal plate with fully rated AL -CU pressure connectors shall be
provided. Neutral conductor shall be grounded at the service.
2.03 TRANSFER SWITCH CONTROL SYSTEM
A. The control module shall direct the operation of the transfer switch. The module's sensing
and logic shall be a built-in microprocessor -based system for maximum reliability, minimum
maintenance, and inherent digital communications capability. The control settings shall be
stored in nonvolatile EEPROM. The module shall contain an integral battery -backed
programmable clock and calendar. The control module shall have a keyed disconnect plug to
enable the control module to be disconnected from the transfer mechanism for routine
maintenance.
B. The control module shall be mounted separately from the transfer mechanism unit for safety
and ease of maintenance. Interfacing relays shall be industrial control grade plug-in type with
dust cover.
C. The control module shall include a user interface keypad with tactile feedback pushbuttons
and light -emitting diode status indication. These features shall be user accessible when the
enclosure door is closed:
a. Keypad pushbuttons:
i)
Start/end system test
ii)
Set/end exercise
iii)
End time delay
iv)
Lamp test/service reset
Automatic Transfer Switch 16230-4
Cypress Waters Phase I
Lift Station —Dallas, Texas
b. Light -emitting diode status indicators:
i) Contactor Position: Normal, Off, Emergency
C. Outputs:
i)
ii)
2.04 OPERATION
August 2011
Source Available: Normal, Emergency
Service required: immediate, maintenance
Not in automatic mode
Four stage time delay remaining
Exercise: load, no load, set/disabled
Test: load, no load
Load control active: peak shave, load shed, pre/post-transfer signal
In-phase monitor/Off delay active
Generator engine start gold flashed contact rated 2 amps @ 30
VDC/250VAC.
Pre -transfer load control, one normally open contact rated 10 amps @ 30
VDC/250 VAC
One Programmable output, factory -set to load bank control rated 2 amps
@ 30 VDC/250 VAC.
A. All phases of normal and all phases of emergency shall be monitored for over and under
voltage and single phase of normal and emergency for over- and under -frequency. In
addition, the controller shall use anti -single phasing protection that detects regenerative
voltage (using the phase angle of the source) to determine a failed source condition.
B. Voltage and frequency sensing:
1. Undervoltage pick-up set at 90% of nominal voltage, adjustable 85% - 100% of nominal
voltage.
2. Undervoltage dropout set at 90% of pickup voltage, adjustable 75% - 98% of pickup
voltage.
3. Overvoltage dropout set at 110% of nominal voltage, adjustable 105% - 135% of nominal
voltage.
4. Overvoltage pick-up set at 95% of dropout voltage, adjustable 85% - 100% of nominal
voltage.
5. Voltage dropout time set at 0.5 seconds adjustable 0.1 — 9.9 seconds.
6. Voltage accuracy: 2%.
Automatic Transfer Switch 16230-5
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
7. Under frequency pick-up set at 90% of nominal frequency, adjustable 85% - 95% of
nominal frequency.
a. Under frequency dropout set at 99% of pick-up frequency, adjustable 95% - 99% of
pick-up frequency.
b. Over frequency dropout set at 101% of pick-up frequency, adjustable 101% - 105%
of nominal frequency.
c. Over frequency pick-up set at 110% of nominal frequency, adjustable 105% - 120%
of nominal frequency.
d. Frequency accuracy: l%
8. Time Delays:
a. Time delay for engine start to delay initiation of transfer for momentary source
outages: Range 0-6 seconds. Factory set at 3 seconds.
b. Time delay for transfer to standby: Range 0-60 minutes. Factory set at 1 second.
c. Time delay for off to standby and off to preferred: Range 0-60 minutes. Factory set
at 1 second.
d. Time delay for transfer back to normal: Range 0-60 minutes. Factory set at 15
minutes.
e. Time delay for engine cool down: Range 0-60 minutes. Factory set at 0 minutes.
f. Failure to acquire standby source: Range 0-60 minutes. Factory set at 1 minute.
g. Pre -transfer to normal signal: Range 0-60 minutes. Factory set at 3 second.
h. Pre -transfer to standby signal: Range 0-60 minutes. Factory set at 3 second.
i. Post -transfer to normal signal: Range 0-60 minutes. Factory set at 0 minute.
j. Post -transfer to standby signal: Range 0-60 minutes. Factory set at 0 minute.
9. User terminals shall be available to connect a normally open contact that, when closed,
signals the control module to start and transfer load to the engine -generator. Opening
these contacts shall initiate a retransfer and engine cool down sequence. The load shall
be transferred to an available utility source immediately if the generator source should
fail.
10. The following features shall be built into the control module logic. These features shall
be enabled at the factory or in the field.
a. Phase rotation sensing programmable ABC or CBA.
b. An LED on the user interface panel shall indicate contactor in off position.
c. Plant Exerciser: Programmable seven-day or fourteen -day exerciser with user
selectable load or no-load operation. An LED, on the user interface, shall indicate the
type of exercise (load or no load). The time remaining on the exercise shall be
indicated. The exercise time may be reset at any time with a single keystroke. The
engine shall be allowed to run when the exercise period is terminated. The exerciser
Automatic Transfer Switch 16230-6
Cypress Waters Phase I
Lift Station —Dallas, Texas
August 2011
may be disabled for maintenance purposes. An amber LED shall flash on the user
interface if the exerciser has been disabled.
The exerciser shall have the capability of being programmed, using up to twenty-one
(21) event for a calendar mode.
The controller shall have provisions for disconnecting a load bank (during exercise)
if there is a loss of normal power.
d. The control module must be upgradeable to provide a programmable input/output
(UO) module with two inputs and six outputs rated 2 amps @ 30 VDC/250 VAC
2.05 MONITORING PROGRAMMING AND COMMUNICATIONS CAPABILITY
A. Modbus® link:
Industry standard Modbus® RTU communication shall be available with network and
setup connections.
2. A Modbus® master will be able to monitor controller data.
3. A Modbus® master will be able to alter parameters.
4. The Modbus® master must be capable of starting and stopping the generator.
5. The manufacturer shall provide a Modbus® communications protocol manual to facilitate
communications with a Modbus® master by a third party developer.
6. The Modbus® network shall communicate to the controller using a twisted pair of wire.
7. Event monitoring shall be available over an Ethernet based Internet connection.
2.06 PROTOTYPE TESTING
A. To assure that the equipment has been designed and built to the highest reliability and quality
standards, the manufacturer and/or local representative shall be responsible for three separate
tests: design prototype tests, final production tests, and site tests.
B. Design Prototype Tests: Components of the emergency system such as the engine/generator
set, transfer switch, and accessories shall not be subjected to prototype tests since the tests are
potentially damaging. Rather, similar design prototypes and preproduction models, which
will not be sold, shall have been used for the following tests.
PART 3. EXECUTION
3.01 PRODUCTION TESTS
Final Production Tests: Each transfer switch shall be tested under load with all guards in place.
Tests shall include:
1. The complete automatic transfer switch shall be tested to ensure proper operation of the
Automatic Transfer Switch 16230-7
Cypress Waters Phase I
Lift Station —Dallas, Texas August 2011
individual components and correct overall sequence of operation and to ensure that the
operating transfer time, voltage, frequency, and time delay settings are in compliance
with the specification requirements.
2. The complete automatic transfer switch shall be subjected to a dielectric strength test per
NEMA Standard ICS 1-109.05.
3. The control panel shall meet or exceed the voltage surge withstand capability in
accordance with ANSI C37.90a-2978 and the impulse withstand voltage test in
accordance with NEMA Standard ICS 1-109.
3.02 SITE TESTS
Site Tests: The manufacturer's local representative shall perform an installation check, start-up,
and building load test. The engineer, regular operators, and the maintenance staff shall be
notified of the time and date of the site test.
3.03 WARRANTY & MAINTENANCE
A. A one year extended warranty for the automatic transfer switch shall be included to
guaranteed against defective material and workmanship in accordance with the
manufacturer's published warranty from date of start-up. Optional warranties shall be
available upon request.
B. The automatic transfer switch manufacturer and its distributor shall maintain a 24-hour parts
and service organization. This organization shall be regularly engaged in a maintenance
contract program to perform preventive maintenance and service on equipment similar to that
specified. A service agreement shall be available and shall include system operation under
simulated operating conditions, adjustment to the generator, transfer switch, and switchgear
controls as required, and certification in the owner's maintenance log of repairs made and
proper functioning of all systems.
3.04 OPERATION AND MAINTENANCE MANUALS
A. The equipment and maintenance manuals shall be provided prior to final payment.
B. Operations and maintenance manuals shall include the following information:
1. Instruction books and leaflets
2. Recommended renewal parts lists
3. Drawings and information
4. Preventive and routine maintenance requirements
5. Copies of field testing results
These must be supplied in a printed form and one electronic version in Microsoft Word (Latest
Automatic Transfer Switch 16230-8
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
Version) or Searchable PDF (Latest Version) format.
3.05 INSTALLATION
A. Automatic Transfer Switch shall be provided with adequate lifting means for ease of
installation of wall or rack mounted enclosure.
B. Equipment shall be protected for shipping of equipment or loose items.
C. Provide access and working space as indicated or as required.
D. The Contractors shall install equipment per manufacturer's recommendations and the
Contract Drawing.
fi�ILi�i��7:�► Illb`��u1D ►�.y
A. Tighten assembled bolted connections with appropriate tools to manufacturer's torque
recommendations prior to first energization.
i
B. The Manufacturer's representative shall field adjust all timing and voltage setting of the
transfer switch as necessary for proper operation of the unit.
3.07 TRAINING
A. A manufacturer's qualified representative familiar with the maintenance and servicing of the
equipment shall conduct a two (2) hour training session at the Owner's facility.
B. The training session shall consist of instruction on operation and maintenance of the transfer
switch.
END OF SECTION
Automatic Transfer Switch 16230-9
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16310 — WET WELL CONTROL PANEL
PART 1- GENERAL
1.01 SCOPE
A. Furnish and install 1 -phase connected 120/240 volt wet well control panel as shown on the
drawings and specified herein for the Dallas Water Utilities Lift Station. The Lift Station
electrical work shall include the necessary power components to provide control for pump starter
panel. Work shall include furnishing all necessary materials, equipment, labor, and services.
B. Auxiliary and accessory devices necessary for system operation or performance, such as relays or
terminals to interface with other Sections of these Specifications, shall be included.
C. Voltage available for wet well control will be 120/240 volt, single-phase, solidly grounded. Wet
Well Control panel shall be rated for an available fault current of 22,000 amps symmetrical at
240 vac.
D. The same vendor as the pump starter panel to be supplied by the wet well submersible pump
supplier shall furnish wet well control panel. The wet well control panel shall be constructed as
shown on the electrical drawings to be installed on an outdoor rack with main and automatic
transfer switch.
1.02 SUBMITTAL AND SHOP DRAWINGS
A. Process catalog data submittals for the following:
1. Pilot lights
2. Pilot operators
3. Control relays
7. Fuses
8. Control Wire
9. Surge protection devices
10. Intrinsic Safety Barriers
11. Consolidated Electric Level Floats
12. Level Transmitter
13. Alarm Beacon
14. Fused Main Disconnects
15. Terminal Strips
16. Intrinsic Safety Relays for float switches
17. Electronic Motor Control (MPE)
18. Flygt ground wire monitor
19. Flygt AutoMeg "Submeg" insulation tester
20. Flygt Leak and Temperature Module
B. Process shop drawings for the wet well control panel.
C. Submit manufacturer and manufacturer's time current curve for each overcurrent device and
overloads used in the motor control starters. Furnish time current curves with shop drawings.
Wet Well Control Panel 16310- 1
Cypress Waters Phase I
Lift Station — Dallas, Texas
1.03 STANDARDS
August 2011
The wet well control and starter panel and enclosure shall include a UL 508A (UL Industrial
Control Panel) Label representing that the equipment was assembled by and meets the
requirements of a UL508A shop.
PART2-PRODUCTS
2.01 GENERAL
Wet well control panel shall be built to UL 508 standards and shall be rated for 22,000 amps rms
symmetrical interrupting capacity at its rated voltage. Reference the electrical drawings for pump
and wet well control schematics.
2.02 ENCLOSURES
A. Enclosures shall be rated NEMA 4X and shall be constructed of 316 stainless steel. Wet well
control panel construction shall be dead front with door in door construction. The pilot lights and
selector switches shall be mounted on the inner door. The motor circuit protectors shall be in a
separate pump starter panel with a pad -lockable main circuit.
B. Enclosure shall be sized for the indicated components, but shall not be less than 36" wide by 18"
deep by 48" tall. Enclosure shall be designed to be supported on a rack as shown on the
drawings.
C. Enclosure shall be Hoffman or equal products provided with sun shield. Enclosure shall be
designed such that equipment will not overheat where installed or mounted at the site location.
Air to air exchangers shall be added if needed to reduce heat load.
2.03 COMPONENTS
A. Wet well control panel shall include intrinsic safety barriers for float switches, intrinsically safe
level transmitter circuits, phase failure relay, hatch intrusion limit switches, and any required
interface relays. Wet well control panel shall also be furnished with intrinsically safe leak
detection and over -temperature modules supplied with pump.
B. Wet well control panel control voltage shall be 120/240 vAC. Level sensing shall be floats with
24 volt or less pilot voltage. Furnish B/W series 53 intrinsically safe relays driving floats. Each
control panel shall have low level cutoff and high level alarm. Pumps will be stage started after a
power failure with all pumps operating at high level alarm. Control panel shall also contain
specified leak detection and over -temperature modules supplied with pump. Furnish run contacts
for each pump, leak detection alarm, low-level cutoff, and high level alarm contacts for inputs for
connection to the Autodialer. Furnish analog input for remote level indication for connection to
the Autodialer.
Wet Well Control Panel 16310-2
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
C. Wet Well Direct Acting Float Switches shall be Consolidated Electric Co. Model 9GEF type
316SS, 5 —1/2" diameter, #20 gauge (.035" wall) with Teflon coating. The float switches shall
be permanently crimped/sealed to cable/switch assembly. Float switch shall include 13/16"
outside diameter synthetic rubber hinge tube for flexing support of the tilt type float switch.
Cable shall be Type SOW, Nitrile PVC hacket, 4#18 AWG fine-stranted conductors for heavy
flexing, underwater service. Switch shall be rated 4 amp, 250 VAC, single/pole double -throw,
suitable for 10 million operations. Three floats and cable assembly and 25# weight for holding
down floats and cables along with attachments shall be provided as shown in electrical drawings.
D. A UPS System shall be furnished and built into the control panel for supplying power to the
Autodialer and the electronic motor control SC2000 (MPE). The UPS shall be be APC Back -
UPS ES, 500 VA/300W, Input 120 volt, Output 120 volt.
E. Pump Starters and control power transformer shall be installed in a separate pump starter panel
controlled by the wet well control panel. The starters shall be across the line starters as shown
on the drawings. Non-resettable six figure elapsed time AC Hour meters shall be provided for
each pump.
F. The wet well control panel shall be wired with stranded MTW or SIS stranded copper conductors
rated at 75 degrees C. conductor terminations shall be as manufactured by the device
manufacturer.
G. A self-contained pump controller shall be included for control and monitoring of the lift station
operation. The controller shall accept a 4-20 mA DC input for wet well level and up to 18
discrete inputs configurable by the operator. The controller shall provide 24vdc power for
discrete inputs and 20vdc power for the analog input. The controller shall allow monitoring of
wet well level, pump status, level alarm status, and power status via LED display on the front
panel. The controller shall provide programmable pump alternation sequences, including bypass
of disabled pumps. The controller shall also accept level control from float switches to provide
redundancy in case of transducer failure. The controller shall provide Modbus RTU
communication capability with Master/Slave operation for future SCADA system to allow
monitoring and control of pump station conditions. The controller shall allow complete operator
programming via pushbuttons on the front panel.
H. The pump controller shall be SC2000, manufactured by Motor Protection Electronics (MPE),
Inc. Communication to the auto dialer shall be via relay output contacts. All pump controller
internal Modbus RTU addresses required for monitoring points shown and input/output signals
to the controller shall be identified and submitted to the Engineer and provided with the panel.
A process signal converter/isolator shall be furnished to provide transient voltage isolation and
sufficient power to use an intrinsic safety barrier in conjunction with the submersible pressure
transducer as shown on the drawings. The process signal converter/isolator shall be Love
Controls 4380 Isoverter.
J. Crouse -Hinds Intrinsically Safe Barriers shall be provided for isolation of control signals for the
submersible transducer and floats.
Wet Well Control Panel 16310-3
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
K. An NHCO approved limit switch shall be installed on the panel door for intrusion detection.
2.04 WET WELL INSTRUMENTS
A. Transducer. A submersible pressure transducer shall be provided for wet well level monitoring.
The transducer shall provide a 4-2- ma DC signal proportional to the wet well level. The
transducer shall be accurate to 0.25% of full scale and be FM approved for intrinsically safe
operation. The transducer -wetted parts shall be 316 stainless steel win Inconnel sensor. The
transducer shall be provided with a protective cage to prevent blockage of the sensing face.
B. The transducer shall be Blue Ribbon Birdcage, manufactured by Blue Ribbon Industrial
Components Corp. Transducer cable length shall be determined for installation in the wet well
and up to the field junction box with associated breather bat.
C. Level sensing shall be floats with 24 volt or less pilot voltage. Furnish B/W series 53
intrinsically safe relays driving floats. Each control panel shall have low level cutoff and high
level alarm. Pumps shall be stage started after a power failure by the pump controller. Floats
shall be attached to a 316 stainless steel cable with a plastic coated 25# weight at the bottom of
the wet well as shown on the electrical drawings. Furnish B/W, Contegra, or equal floats.
D. Furnish a 24 volt power supply for testing and startup. Permanent loop power shall be from the
wet well control panel.
E. Wet well control panel shall also contain Flygt leak detection and over temperature modules,
Flygt Automeg "Submeg" insulation tester and Flygt ground wire tester as shown on the panel.
All signals and alarms shall be connected to Auto -dialer.
F. Auto -dialer shall be Sensaphone Model 2000. Autodialer shall be provided programming with
appropriate phone numbers and messages as required by Dallas Water Utilities.
PART 3 - EXECUTION
3.01 INSTALLATION
A. All equipment shall be carefully inspected after assembly and all wiring shall be checked to
ensure correctness of connections and operation.
B. Prior to energization of motor control centers, keep enclosures protected with plastic sheets and
maintain specified space heaters energized to prevent internal condensation, use 150W lamp in
bottom of each section.
C. Each conduit entry into bottom of cabinets shall be equipped with grounding bushing. Bond each
raceway equipment grounding conductor to its bushing ground lug, and thence to equipment
ground bus where bonding jumper shall be connected with specified flat bus connector. Where
empty conduits terminate, install blank disc in grounding bushing. Bring specified foot -marked
Wet Well Control Panel 16310-4
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
pull tape through the blank penny and label with plastic write -on label and show the size of
conduit and the terminus of the other end. For each active conduit, install plastic write -on label
and identify cable number, size, conduit size, and identify load served.
D. Install all power and control wiring and make all connections. Install wiring between motor
controller and starter units. Phase band each power cable at each connection. Neatly train and
lace all gutter wiring with nylon tie wraps. Do not obstruct relays and other pan -mounted
devices with load cables. Install wire markers to identify each control wire at each termination.
E. Install all devices, fuses, breakers, and make installation ready. Set all adjustable and
programmable devices such as breaker magnetic trips.
G. Functionally test control panel with pumps and Auto -dialer connections. Coordinate testing with
wet well supplier.
H. Functionally test auto -dialer with DWU operations to assure proper operation and configuration.
3.02 SPARE PARTS
A. One timing relay for every three or less of each range and type installed complete with mounting
socket.
B. One control relay for every three or less of each range and type installed complete with mounting
socket.
C. Six pilot light bulbs and 10% spare lenses.
D. Three (3) fuses for each type included.
E. One SC2000 (MPE) motor controller for Dallas Water Utilites backup.
END OF SECTION
Wet Well Control Panel 16310-5
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16330 — PUMP STARTER PANEL
PART 1- GENERAL
1.01 SCOPE
A. Furnish and install 3 phase connected 480Y/277 volt pump starter panel as shown on the
drawings and specified herein. Work shall include all necessary materials, equipment, labor, and
services.
B. Auxiliary and accessory devices necessary for system operation or performance, such as relays or
terminals to interface with other Sections of these Specifications, shall be included.
C. Voltage available for pump starter panel will be 480Y277 volt, three phase, solidly grounded.
Pump starter panel shall be rated for an available fault current of 22,000 amps symmetrical at
480 vac.
D. Pump starter panel shall be sized for the pumps as specified by the pump supplier. Reference
Civil Specification Section 13100.
E. Pump starter panel shall be supplied by the same vendor as the submersible pump supplier and
the wet well control panel vendor for the Cypress Waters Phase I Dallas Water Utilities Lift
Station.
F. The pump wet well shall be classified as a National Electric Code (NEC) Class I Division 2
Group D environment as amended by the Chapter 56 of the City of Dallas City Code. The pump
panel will be in a non -hazardous area. The pump and starter panel installation shall conform to
the latest edition of the NEC for the specified area classifications.
1.02 SUBMITTAL AND SHOP DRAWINGS
A. Process catalog data submittals for the following:
1. Overloads
2. Contactors
3. Circuit breakers and Mechanical Interlock
4. Starters
5. Fuses
6. Control Wire
7. Surge protection devices
8. TVSS
9. Alarm Beacon
10. Fused Main Disconnects
11. Terminal Strips
B. Process shop drawings for the pump starter panel. Submit with pumps.
C. Submit manufacturer and manufacturer's time current curve for each overcurrent device and
overloads used in the motor control starters. Furnish time current curves with shop drawings.
Pump Starter Panel 16330- 1
Cypress Waters Phase I
Lift Station — Dallas, Texas
1.03 STANDARDS
August 2011
The pump starter panel and enclosure shall include a UL 508A (UL Industrial Control Panel)
Label representing that the equipment was assembled by and meets the requirements of a
UL508A shop.
PART 2 - PRODUCTS
2.01 GENERAL
Pump starter panel shall be furnished by the pump supplier. Pump starter panels shall be built to
UL 508 standards and shall be rated for 22,000 amps rms symmetrical interrupting capacity at its
rated voltage. Reference the electrical drawings for pump control schematics.
2.02 ENCLOSURES
A. Enclosures shall be rated NEMA 4X and shall be constructed of 316 stainless steel. Pump starter
panel shall have a main disconnect with flange mounted external handle that is padlockable.
Door mounted handles are not acceptable. Pump starter panel construction shall be dead front
with door in door construction. The pilot lights and selector switches shall be mounted on the
inner door. The handles for the motor circuit protectors shall be operable from the inner door.
B. Enclosure shall be sized for the indicated components, but shall not be less than 48" wide by 18"
deep by 48" tall. Total enclosure height including open mounting support assembly shall not
exceed 60". Enclosure shall be designed to be rack mounted.
C. Enclosure shall be Hoffman or equal products furnished with sun shield. Enclosure shall be
designed such that equipment will not overheat where installed or mounted at the site location.
Air to air exchangers shall be added if needed to reduce heat load.
2.03 COMPONENTS
A. Starters shall be across the line as shown on the drawing sheets, with circuit breakers and NEMA
rated contactors and overloads. A phase balance/undervoltage relay shall be provided for the
starters, TimeMark model 2501 or Flygt standard. Non-resettable elapsed time meters shall be
provided for each pump in the wet well control panel.
B. Circuit breakers shall be NEMA/ANSI rated for branch circuits to wet well control panel and
miscellaneous equipment.
C. TVSS shall be 160 kA peak amps/phase and shall be Square -D XW or equal. The TVSS shall be
mounted separately ahead of the automatic transfer switch and connected at the service entrance
main disconnect. TVSS shall be mounted in NEMA 4X separate stainless steel panel as shown
on drawing E05.
D. An NHCO approved limit switch shall be installed on the panel door for intrusion detection.
Pump Starter Panel 16330-2
Cypress Waters Phase I
Lift Station —Dallas, Texas
2.04 DRY TYPE TRANSFORMER
August 2011
A. Furnish and install transformers as shown on the Drawing E05 and as specified hereinafter.
B. Dry type transformers shall be totally enclosed non- ventilated, 115°C rise. Core and coil shall be
totally encapsulated in sand and resin or equivalent.
C. Each transformer shall be equipped with two 2.5% full- capacity below normal and two 2.5% full
capacity above normal taps.
D. Furnish transformers in KVA and voltage ratings as shown on the Drawings. Transformer
enclosure shall be suitable for outdoor use. Enclosure shall be rated 3R and shall be constructed
of 316 stainless steel.
E. Sound level of each transformer shall not exceed 60 dB at three feet.
F. Furnish General Electric, Cutler -Hammer, Square D or equal products.
G. Installation
1. Install transformers where shown. Adequately support transformers to rack near starter panel.
Top bolt shall be 1/2" and shall extend through channel support and shall have bolt head and
2" square by 1/8" thick hot -dipped galvanized washer on the outside. Use stainless steel bolt
and hardware.
2. Bond neutral of transformer to its enclosure and to grounding electrode conductors per NEC
article 250 as amended by Chapter 56 of the City of Dallas City Code. Install grounding
electrode conductors from transformer secondary neutral to ground mat.
PART 3 - EXECUTION
3.01 INSTALLATION
A. All equipment shall be carefully inspected after assembly and all wiring shall be checked to
ensure correctness of connections and operation.
B. Prior to energization of motor starter, keep enclosures protected with plastic sheets and maintain
specified space heaters energized to prevent internal condensation, use 150W lamp in bottom of
each section.
C. Each conduit entry into bottom of cabinets shall be equipped with grounding bushing. Bond each
raceway equipment grounding conductor to its bushing ground lug, and thence to equipment
ground bus where bonding jumper shall be connected with specified flat bus connector. Where
empty conduits terminate, install blank disc in grounding bushing. Bring specified foot -marked
pull tape through the blank penny and label with plastic write -on label and show the size of
conduit and the terminus of the other end. For each active conduit, install plastic write -on label
and identify cable number, size, conduit size, and identify load served.
Pump Starter Panel 16330-3
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
D. Install all power and control wiring and make all connections. Install wiring between motor
controller and starter units. Phase band each power cable at each connection. Neatly train and
lace all gutter wiring with nylon tie wraps. Do not obstruct relays and other pan -mounted
devices with load cables. Install wire markers to identify each control wire at each termination.
E. Install all devices, fuses, breakers, and make installation ready. Set all adjustable and
programmable devices such as breaker magnetic trips.
F. Functionally test starter panel with pumps and Auto -dialer connections. Coordinate testing with
control panel supplier.
3.02 SPARE PARTS
A. One timing relay for every three or less of each range and type installed complete with mounting
socket.
B. One control relay for every three or less of each range and type installed complete with mounting
socket.
C. One phase sequence/phase failure relay.
D. Six pilot light bulbs and 10% spare lenses.
E. Three (3) fuses for each type included.
F. One extra overload relay used.
END OF SECTION
Pump Starter Panel 16330-4
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16410 — ELECTRICAL UNDERGROUND
PART 1- GENERAL
1.1 SCOPE OF WORK
A. Furnish and install a system of underground raceways and wiring as shown on the drawings.
1.2 APPLICATIONS
A. Except as otherwise shown on the Drawings, or otherwise specified, all underground and in -slab
conduit raceways shall be of the following type:
1. Except as otherwise specified, all power and control underground conduit runs shall be made
with schedule 40 PVC. Bends to grade shall be made with plastic coated rigid galvanized
steel conduit.
2. All instrumentation underground conduit runs shall be made with plastic coated rigid
galvanized steel conduit.
1.3 SUBMITTALS
Process submittals for the following:
1. Non Metallic conduit
2. Metallic conduit
3. Grounding Bushings
4. Buried conduit marker tape
5. Conduit supporting saddles
1.4 RELATED WORK SPECIFIED UNDER OTHER SECTIONS
A. Refer to Section 16110 for raceways.
B. Refer to Section 16120 for wiring.
C. Refer to Section 16450 for grounding.
D. Refer to City of Dallas Detail 1005 for concrete.
PART2-PRODUCTS
2.1 RACEWAYS
A. Conduits shall be watertight over the entire length of the underground run. All fiberglass
conduits shall be manufactured by Champion and be suitable for direct burial with tight lock
joint.
B. Raceways shall be as specified in Section 16110.
Electrical Underground 16410-1
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
2.2 MISCELLANEOUS
A. Gravel for underbedding of conduits shall be washed type pea gravel.
B. Plastic saddles for spacing and supporting conduits shall be interlocking types as manufactured
by Cantex.
C. Plastic marker label tape for buried conduits shall be yellow background with black letters with
repetitive marking "ELECTRIC LINE" on yellow background, continuous along its length.
Furnish T&B #NA -0608, or equal tape.
PART 3 - EXECUTION
3.1 EXCAVATION AND BACKFILLING
A. Do all excavating and backfilling necessary for the installation of the work. This shall include
shoring and pumping in ditches to keep them dry until the work has been installed.
B. All excavations shall be made, to proper depth, with allowances made for floors, forms, beams,
piping, finished grades, etc. Ground under conduits shall be undisturbed earth or if disturbed,
mechanically compacted to a standard proctor density ratio of 95% before conduits are installed.
C. All backfilling shall be made with selected soil, free of rocks and debris, and shall be
pneumatically tamped in six (6") inch layers to a standard proctor density ratio of 95%.
D. Field check and verify the locations of all underground utilities prior to any excavating. In the
event existing utilities are damaged, they shall be repaired to their original condition.
fc��7:��1�r�/:�•fy
A. All underground conduits shall be PVC schedule 40 unless otherwise noted. All bends to grade
shall be made with plastic coated rigid steel conduits and shall extend to 6" above grade.
Conduits shall be watertight over the entire length of the underground run.
B. Install all power, control, and signal wiring. Label each single conductor wire at each connection
with PVC sleeve type wire labels. Label each signal cable at each end with plastic waterproof
write -on type label to identify terminal connection and function and device served.
C. Where empty conduits terminate into equipment install blank "disc" under grounding bushing
and bring specified foot -marked pull tape through disc. Label each end of each pull tape with
waterproof plastic label to identify terminus of other end and also show conduit size.
3.3 WIRING
All underground wiring runs shall be installed from line to load without splice.
END OF SECTION
Electrical Underground 16410-2
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16450 — GROUNDING
PART 1- GENERAL
1.1 SCOPE
A. Furnish and install complete grounding systems in accordance with Article 250 of the National
Electrical Code, as amended by the latest version of Chapter 56 of the City of Dallas City Code
as shown on the Drawings and as specified herein.
B. Provide ground mat grounding electrode system as shown on the drawings and as specified
herein.
1.2 SUBMITTALS
Submit manufacturers' catalog sheets with catalog numbers marked for the items furnished,
which shall include:
1. Ground well casings
2. Ground rods
3. Terminal lugs and clamps
4. Exothermal welding materials
5. Ground cable
6. Ground connection hardware
PART 2 — PRODUCTS
2.1 GROUNDING ELECTRODES
A. All ground mat grounding electrodes and grounding electrode conductors shall consist of tin
plated stranded copper.
B. All ground rods shall be copper clad steel products, 3/4" diameter x 10 foot long, unless
otherwise indicated. Ground rods shall be Blackburn #6258, or equal. Provide heavy duty
ground rod clamps equal to Blackburn #GG58 where vertical connections are installed and
#GUV where U -bolt connectors are installed to serve horizontal connections.
2.2 GROUNDING DEVICES
A. Connectors shall be furnished as specified under Section 16120.
B. Conduit grounding bushings shall be furnished as specified under Section 16110.
C. Equipment grounding conductors shall be furnished as specified under Section 16120.
D. Flush cast metal grounding plates shall consist of bronze body with flat plate on top and bolted
clamp connector on bottom. Furnish OZ type "VG", or equal flush connectors. Each such
Grounding 16450-1
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
connector shall be furnished with silicon bronze connector bolts for installation of top -mounted
grounding connectors.
E. Exothermal welding kits shall be "Cadweld" products as manufactured by Erico. Molds,
cartridges, powder, and accessories shall be as recommended by the manufacturer.
2.3 GROUND TEST WELLS
A. Ground test wells shall be furnished for each ground rod.
B. Ground test wells shall each consist of ground rod with connector attached to a #2 upcomer from
the ground mat and contained within an access well with labeled top.
C. Ground test well enclosures shall be Oldcastle Precast product #VB-3RT series, or equal.
Enclosures shall be 10 1/4" diameter and shall include cast iron cover with integrally cut
"GROUND TEST WELL" in top of cover.
PART 3 - EXECUTION
3.1 GROUND MATS AND GROUND WELLS
A. Install ground mat around the perimeter and under the new foundations as shown. Use #2/0
AWG tin-plated copper stranded conductor for the ground mat. Install upcomer with indicated
wire sizes of tin plated copper conductors. Exothermally weld all connections.
B. Unless other larger sizes are indicated on the drawings, install #2 upcomers from ground mat to
Pump Panel, and other equipment indicated on the drawings.
C. Install ground rods in test wells where indicated on the drawings.
3.2 WIRING SYSTEMS GROUNDING
A. All equipment enclosures, motor and transformer frames, metallic conduit systems and exposed
structural steel systems shall be grounded.
B. Equipment grounding conductors shall be run with all wiring. Sizes of equipment grounding
conductors shall be based on Article 250 of the N.E.C. except where larger sizes may be shown.
Bond each equipment grounding conductor to the equipment grounds at each end of each run.
C. Liquid tight flexible metal conduit in sizes V and larger shall be equipped with external bonding
jumpers. Use liquid tight connectors integrally equipped with suitable grounding lugs.
D. Where conduits enter into equipment free of the metal enclosure, install grounding bushing on
each conduit and bond bushing lug to equipment ground bus.
E. Where conduits enter equipment enclosures, equip each penetration inside with grounding
bushing. Install bonding jumper from each grounding bushing to ground bus.
Grounding 16450-2
Cypress Waters Phase I
Lift Station — Dallas, Texas
August 2011
F. Equipment enclosures that do not come furnished with a ground bus, install ground lug in each
enclosure that shall be bonded to the metal cabinet or backpan of the enclosure.
G. Separately derived systems shall be each grounded as shown and shall comply with Article 250
of the NEC as amended by the latest version of Chapter 56 of the City of Dallas City Code
except where higher standards are shown.
H. Ground the instrumentation panel to the ground mat with a #6 ground wire.
3.3 TESTING
A. All exothermic weld connections shall successfully resist moderate hammer blows. Any
connection which fails such test or if upon inspection, weld indicates a porous or deformed
connection, the weld shall be remade.
B. All exothermic welds shall encompass 100 percent of the ends of the materials being welded.
Welds which do not meet this requirement shall be remade.
C. Test the ground resistance of the system. All test equipment shall be furnished by Contractor and
be approved by Engineer. Test equipment shall be as manufactured by Biddle or approved equal.
Dry season resistance of the system shall not exceed five ohms. If such resistance cannot be
obtained with the system as shown, provide additional grounding as directed by Engineer.
END OF SECTION
Grounding 16450-3
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
SECTION 16910 — INSTRUMENTATION
PART 1— GENERAL
1.1 SCOPE
A. This section covers the general requirements for the instrumentation and SCADA work.
B. Auxiliary and accessory devices necessary for system operation or performance, such as relays din
connectors, or terminals to interface with other Sections of these Specifications, shall be included.
1.2 QUALITY ASSURANCE
A. Installer: Qualified with at least 5 years of successful installation experience on projects with work
similar to that required for this project.
B. NEC Compliance: Comply with the National Electrical Code, NFPA 70, as applicable to wiring and
other electrical construction of the unit.
C. UL Compliance: Provide components with UL listing and labeling for applicable UL categories.
D. Provide complete unit and installation to conform with NFPA-90A.
1.3 SUBMITTALS
A. Submit catalog literature, specification material and installation and operation manual for each
instrument and device specified herein.
B. Submit outline and dimensional drawings and wiring diagrams to Engineer for review.
PART2-PRODUCTS
2.1 SURGE SUPPRESSORS
A. Surge suppressors for protecting 120vac circuits shall meet UL 1449, UL 1283, NEMA LS -1 1992,
and ANSUIEEE C62.41 and C62.45. Load current rating shall be 20 amps at 120vac.
B. Surge suppressors shall be series connected and shall have a surge current capacity of 45,000 amps.
High frequency noise filtration shall be as follows:
Mode 1kHz lOkHZ IOOkHZ lMHz
L -N 6db 16db 42db 25db
L -G 6db 6db 16db 55db
C. Surge suppressor shall be Current Technology model MSU45-120-lG-20A-3.
2.3 ENCLOSURES
Instrumentation 16910-1
Cypress Waters Phase I
Lift Station — Dallas, Texas August 2011
A. Enclosure rating outdoors shall be NEMA 4X and shall be constructed of 316 stainless steel.
2.4 MISCELLANEOUS
A. Terminal strips for connection of field wiring shall be DIN rail mounted channel mounted terminals
suitable for connecting #22 to #12 wire sizes. Terminals shall be solderless box lug type with
pressure plate and removable terminal marking strips. Box lugs shall be tin-plated copper. Terminals
shall be Allen-Bradley 1492 -HMI series with required DIN rail mounting channel and end clamps.
Fused terminals for 24 volt do instrumentation circuits shall be rated 10-57 volts dc, shall have blown
fuse LED indicator and shall be Allen-Bradley 1492-H5 series. Fused terminals for 120 volt ac
circuits shall be rated 300 volts ac, shall have neon blown fuse indicator and shall be Allen-Bradley
1492-114 series. Terminal strips shall have factory terminal markers.
B. Control relays shall be 3 pole double throw with pin base and matching socket. Furnish Potter &
Brumfield model RR3P with 120 volt coil.
C. Furnish control panel devices as indicated in the drawings. 120vac pushbuttons, selector switches, and
pilot lights shall be NEMA 4X, Allen-Bradley type 800H or equal. Pilot lights shall be transformer
type and shall have push -to -test option.
PART 3 - EXECUTION
3.1 INSTALLATION GENERAL
A. Permanently mount the instruments, and all required appurtenances in accordance with manufacturer's
requirements. All work shall be done in accordance with industry standards, the NEC, ISA
recommendations and in a workmanship like manner.
B. Calibrate, and test all instruments.
C. Certify that all instrument installations and calibrations are done in accordance with ISA and the
manufacturer's recommendations.
D. Provide completed ISA calibration sheets for all new instruments provided.
E. All surge suppression devices shall be grounded with minimum #8 ground wire.
3.2 OPERATIONS AND MAINTENANCE MANUALS
A. Six (6) weeks prior to the completion of the project, compile an Operations and Maintenance Manual
on the instrumentation equipment. These manuals shall include detailed instructions, periodic
calibration requirements and maintenance, as well as recommended spare parts lists. Operations and
Maintenance Manuals shall be supplied in a printed form and one electronic version in Microsoft
Word (Latest Version) or Searchable PDF (Latest Version) format.
B. Submit for review per appropriate sections in other parts of the specifications.
Instrumentation 16910-2
Cypress Waters Phase I
Lift Station — Dallas, Texas
END OF SECTION
August 2011
Instrumentation 16910-3