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USACE / NAVFAC / AFCESA / NASA UFGS-11220 (August 2004)
------------------------------
Preparing Activity:
USACEMasterFormatTM 2004 - 02 51 13
Superseding
UFGS-11220A (January 2003)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated 23 June 2005
Latest change indicated by CHG tags
Section Table of Contents
SECTION 11220
PRECIPITATION/COAGULATION/FLOCCULATION WATER TREATMENT
08/04
PART 1 GENERAL
1.1 REFERENCES
1.2 MEASUREMENT AND PAYMENT
1.3 SYSTEM DESCRIPTION
1.3.1 Equalization Unit
1.3.2 Oxidation/Reduction Unit
1.3.3 Precipitation Unit
1.3.4 Coagulation Unit
1.3.5 Flocculation Unit
1.3.6 Clarification Unit
1.3.7 Post-pH Adjustment Unit
1.3.8 Effluent Holding Unit
1.4 PERFORMANCE REQUIREMENTS
1.5 RESULTS OF PREVIOUSLY CONDUCTED TREATABILITY STUDIES
1.6 UTILITIES
1.7 SUBMITTALS
1.8 QUALIFICATIONS
1.9 REGULATORY REQUIREMENTS
1.10 DELIVERY AND STORAGE
1.11 PROJECT/SITE CONDITIONS
1.11.1 Environmental Requirements
1.11.2 Existing Conditions
1.11.3 Field Measurement
1.11.4 Spare Parts
PART 2 PRODUCTS
2.1 STANDARD PRODUCTS
2.2 TANKS
2.2.1 General Requirements
2.2.2 Tank Construction Materials
2.2.2.1 Carbon Steel
2.2.2.2 Polyethylene
2.2.2.3 Stainless Steel
2.2.2.4 Structural Steel
2.2.2.5 Fiberglass
2.2.3 Corrosion Allowance
2.2.4 Shop Fabrication
2.2.5 Bolts
2.2.6 Gaskets
2.2.7 Accessories
2.2.7.1 Manholes and Pipe Connections
2.2.7.2 Baffles, Weirs, and Overflow Pipes
2.2.7.3 Vents
2.2.7.4 Ladders and Safety Devices
2.2.7.5 Scaffold and Cable Support
2.2.7.6 Miscellaneous Tank Accessories
2.3 CHEMICAL FEED SYSTEMS
2.4 MIXERS
2.4.1 Equalization Unit Mixer
2.4.2 Precipitation Unit Mixer
2.4.3 Coagulation Unit Mixer
2.4.4 Flocculation Unit Mixer
2.4.5 Effluent Holding Unit Mixer
2.5 CLARIFIERS
2.5.1 Clarifier Vessel
2.5.2 Influent Distribution and Effluent Collection Systems
2.5.3 Separator Module
2.5.4 Skimmer and Sludge Collection/Thickening Devices
2.5.5 Miscellaneous
2.6 PIPING/VALVES
2.7 PUMPS
2.7.1 Water Pumps
2.7.2 Chemical Metering Pumps
2.7.3 Sludge Pumps
2.8 ELECTRICAL WORK
2.8.1 General
2.8.2 Electric Motors
2.9 INSTRUMENTATION AND CONTROL
2.9.1 pH Monitoring/Control
2.9.2 ORP Monitoring/Control
2.9.3 Flow Monitoring/Control
2.9.4 Level Monitoring/Control
2.9.5 Control System
2.9.6 Control Panel Enclosures
2.10 STRUCTURAL SKIDS
2.11 PAINT/COATINGS
2.12 INSULATION/HEATING/VENTILATION
2.13 NAMEPLATES
2.14 SPECIAL TOOLS
PART 3 EXECUTION
3.1 EXAMINATION
3.2 PREPARATION
3.3 INSTALLATION
3.3.1 Foundations
3.3.2 Excavating, Filling, and Grading
3.3.3 Cathodic Protection
3.3.4 Welding
3.3.5 Erection
3.3.6 Field Painting
3.3.7 Inspections and Testing
3.3.8 Radiographic Inspection and Testing
3.4 FIELD QUALITY CONTROL
3.4.1 Inspection
3.4.2 Tests
3.4.3 Manufacturer's Service
3.5 STARTUP AND OPERATION
3.5.1 Hydrostatic Tests
3.5.2 Pre-startup Checkout
3.5.3 Pre-startup Testing
3.5.4 Startup Performance Testing
3.5.5 Field Training
3.5.6 Operation and Maintenance Manual Updates
3.5.7 System Operation by Contractor
SECTION 11220
PRECIPITATION/COAGULATION/FLOCCULATION WATER TREATMENT
NOTE: This guide specification covers the requirements for
precipitation/coagulation
/flocculation (P/C/F) systems with flow rates ranging from 4 to 940 liters (1
to 250 gallons) per minute.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of
technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a
Criteria Change Request
(CCR).
Use of electronic communication is encouraged.
Brackets are used in the text to indicate designer choices or locations where
text must be supplied by the designer.
PART 1 GENERAL
NOTE: This Section is intended for specification of PCF unit processes and
is specifically applicable for remediation of ground water and landfill leachate
containing dissolved heavy metals. This guide specification should not be used
until thorough, site specific treatability studies (jar testing) have been performed,
clearly demonstrating that P/C/F is an appropriate treatment technique that
can meet the performance criteria set forth in this Section.
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
| AMERICAN PETROLEUM INSTITUTE (API) |
| |
| API Std 650 | | (1998; A 2001) Welded Steel Tanks for Oil Storage |
| AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE) |
| |
| ASCE 7 | | (2002) Minimum Design Loads for Buildings and
Other Structures |
| AMERICAN WATER WORKS ASSOCIATION(AWWA) |
| |
| AWWA D100 | | (1996) Welded Steel Tanks for Water Storage |
| |
| AWWA D103 | | (1997) Factory-Coated Bolted Steel Tanks for
Water Storage |
| |
| AWWA EWW | | (1998) Standard Methods for the Examination
of Water and Wastewater |
| AMERICAN WELDING SOCIETY (AWS) |
| |
| AWS A2.4 | | (1998) Standard Symbols for Welding, Brazing
and Nondestructive Examination |
| ASME INTERNATIONAL (ASME) |
| |
| ASME B40.100 | | (2000) Pressure Gauges and Gauge Attachments |
| ASTM INTERNATIONAL (ASTM) |
| |
| ASTM A 283/A 283M | | (2003) Low and Intermediate Tensile Strength
Carbon Steel Plates |
| |
| ASTM A 36/A 36M | | (2004) Carbon Structural Steel |
| |
| ASTM C 582 | | (2002) Contact-Molded Reinforced Thermosetting
Plastic (RTP) Laminates for Corrosion-Resistant
Equipment |
| |
| ASTM D 2035 | | (1980; R 2003) Standard Practice for Coagulation-Flocculation
Jar Test of Water |
| |
| ASTM D 3299 | | (2000) Filament-Wound Glass-Fiber-Reinforced
Thermoset Resin Corrosion-Resistant Tanks |
| ISA - THE INSTRUMENTATION, SYSTEMS AND AUTOMATION SOCIETY (ISA) |
| |
| ISA S5.1 | | (1984; R 1992) Instrumentation Symbols and Identification |
| NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) |
| |
| NEMA MG 1 | | (2003; R 2004) Motors and Generators |
| NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) |
| |
| NFPA 70 | | (2005) National Electrical Code |
| NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST) |
| |
| NIST SP 250 | | (1998) Calibration Services Users Guide |
1.2 MEASUREMENT AND PAYMENT
Measurement and payment requirements shall be as identified in the Payment Schedule of the Bid Form.
1.3 SYSTEM DESCRIPTION
NOTE: The system described in this paragraph includes the P/C/F equipment required
for a water treatment plant to remove dissolved metals. The system can be a
stand-alone system, or it can be a pretreatment system for other systems such
as air stripping, advanced oxidation, activated carbon, etc. Ancillary P/C/F
equipment which may be required for pre-treatment or post-treatment of the water
is also described and includes an equalization unit, an oxidation/reduction
unit, a clarification unit, a post-pH adjustment unit, and an effluent holding
unit. The precipitation, coagulation, and flocculation units may be supplied
by the Contractor as individual pieces of equipment or as a single, integral
unit. Typically, if a single unit is supplied, it will incorporate the coagulation,
flocculation, and precipitation equipment within a clarification unit. Alternately,
a unit may be supplied which performs two of the processes, e.g., precipitation
and coagulation within one unit.
This paragraph should be edited to identify only the necessary equipment to
suit conditions at the project site. The design team should review treatment
objectives, water characterization data, and results of previously conducted
treatability testing and other predesign information to determine the equipment
required.
The Precipitation/Coagulation/Flocculation (P/C/F) system shall be a fully integrated water treatment plant which
shall remove dissolved heavy metals and solids from [groundwater] [and] [landfill leachate] [_____]. The system
shall include equipment for [flow equalization,] wastewater conveyance, precipitation, coagulation, flocculation,
clarification, [post-pH adjustment,] and treated effluent storage required to meet the specified performance
requirements. The P/C/F system shall be complete with required instruments, controls, and local control panels.
A main control center shall be provided to facilitate the overall control of the treatment plant. All parts
shall be factory or shop preassembled to the maximum extent possible, compatible with transportation limitations
and equipment protection considerations. Field assembly shall be minimized to the assembly of match-marked components.
1.3.1 Equalization Unit
Equalization unit shall include [one tank] [[_____] tanks] with accessories, mixers, piping, valves, [pumps,]
motors, and instrumentation and controls to provide a constant flow and contaminant concentration to the subsequent
treatment equipment. All components of the unit shall be furnished as shown on the drawings.
1.3.2 Oxidation/Reduction Unit
NOTE: Delete this paragraph if the contaminants in the water to be treated
do not include metals which require reduction prior to precipitation (e.g.,
chromium 6+), or metals which require oxidation prior to precipitation (e.g.,
iron or manganese).
[Reduction unit shall include a mix tank, a mixer, a chemical feed system for acid addition, a chemical feed
system for the reducing agent addition, piping, valves, pumps, motors, pH controls, oxidation-reduction potential
(ORP) controls, and other instrumentation and controls as indicated on the drawings.] [Oxidation unit shall
include a mix tank, a mixer, a chemical feed system for oxidant addition, piping, valves, pumps, motors, oxidation-reduction
potential (ORP) controls, and other instrumentation and controls as indicated on the drawings.]
1.3.3 Precipitation Unit
Precipitation unit shall include a mix tank, a mixer, a chemical feed system for the precipitant addition, piping,
valves, pumps, motors, pH controls, and other instrumentation and controls as indicated on the drawings.
1.3.4 Coagulation Unit
Coagulation unit shall include a mix tank, a mixer, a chemical feed system for the coagulant addition, piping,
valves, pumps, motors, and instrumentation and controls as indicated on the drawings.
1.3.5 Flocculation Unit
Flocculation unit shall include a tank with accessories (e.g., nozzles, supports, lifting lugs, etc.), a mixer,
a chemical feed system for the coagulant aid addition, piping, valves, pumps, motors, and instrumentation and
controls as indicated on the drawings.
1.3.6 Clarification Unit
Clarification unit shall include an inclined plate or tube type settler with all necessary accessories (e.g.,
inlet distribution system, separator module, skimmer, etc.), [a thickener,] a sludge removal system, piping,
valve, pumps, motors, and instrumentation and controls as indicated on the drawings.
1.3.7 Post-pH Adjustment Unit
Post-pH adjustment unit shall include piping, chemical feed systems for both acid and base addition, and in-line
pH instrumentation and controls as indicated on the drawings.
1.3.8 Effluent Holding Unit
[One effluent holding tank] [[_____] effluent holding tanks] shall be supplied to store treated water for testing
prior to discharging. Tanks shall include all piping, valves, sample taps, pumps, and instrumentation and controls
as indicated on the drawings.
1.4 PERFORMANCE REQUIREMENTS
NOTE: The designer, in consultation with the appropriate technical team personnel,
should use the treatability testing results and other predesign information
to set influent parameters, such as maximum and minimum ground water and landfill
leachate flow rates, maximum and minimum temperatures, pH, viscosity, density,
and maximum and minimum influent metals and solids concentrations. The required
effluent quality is typically established by federal, state, or local agency
permit or regulation.
The designer should consider that fugitive emissions from landfill leachates
or contaminated groundwater may have volatile components. Federal, state, or
local air regulations should be consulted to establish allowable air emissions
for the P/C/F system.
Performance requirements for the Contractor will indicate that the supplied
equipment must be operated to meet the required effluent quality. Performance
requirements for the Contractor stated in this paragraph should only apply to
the performance of the complete system and not individual pieces of equipment.
Performance criteria and minimum equipment standards for specific equipment
should be listed under PART 2 PRODUCTS, where applicable.
Flow rates specified for the P/C/F system should be consistent with the pumping
rates required by Sections 11211A PUMPS: WATER, CENTRIFUGAL, 11212A PUMPS: WATER,
VERTICAL TURBINE, or 11310A PUMPS: SEWAGE AND SLUDGE.
A P/C/F system shall be provided which is capable of processing [ground water] [landfill leachate] [_____] at
the conditions provided below:
a. Flow Rate
Maximum [_____] litersgallons per minute
Minimum [_____] litersgallons per minute
b. Temperatures
Maximum [_____] degree CF
Minimum [_____] degree CF
c. Influent/Effluent pH
Influent Effluent
Maximum [_____] [_____]
Minimum [_____] [_____]d. Liquid Viscosity [_____] centipoiselb-sec/(sq. ft.)
e. Liquid density [_____] degree CF
f. Maximum Air Emissions
Particulates [_____] ug/kg
Volatile Organic Compounds [_____] ug/kg
[_____] [_____] ug/kg
[_____] [_____] ug/kg
g. Space Availability
Maximum Area [[_____] mfeet by [_____] mfeet]
[[_____] square metersfeet]Maximum Height [_____] mfeet
The P/C/F system shall be capable of meeting the maximum effluent metals and solids concentrations achieved in
the previously conducted treatability testing (report appended to this specification), as listed below at the
indicated maximum concentrations. Influent and effluent solids are as determined in accordance with Part 2000
Physical and Aggregate Properties, and metals as determined in accordance with Part 3000 METALS of AWWA EWW:
Maximum Influent Maximum Effluent
Concentration Concentration
mg/L mg/L
[Total Cadmium [_____] [_____]]
[Hexavalent Chromium [_____] [_____]]
[Total Chromium [_____] [_____]]
[Total Copper [_____] [_____]]
[Total Iron [_____] [_____]]
[Total Lead [_____] [_____]]
[Total Mercury [_____] [_____]]
[Total Nickel [_____] [_____]]
[Total Silver [_____] [_____]]
[Total Zinc [_____] [_____]]
[TSS [_____] [_____]]
[TDS [_____] [_____]]
[[_____] [_____] [_____]]
P/C/F system instrumentation and controls shall have the necessary accuracy and sensitivity to measure and control
the operating ranges of the specified equipment. Sampling and analysis shall be performed in accordance with
Section
01450A
01450A
01450A CHEMICAL DATA QUALITY CONTROL.
1.5 RESULTS OF PREVIOUSLY CONDUCTED TREATABILITY STUDIES
NOTE: Treatability testing reports should be appended to this specification
to enable the Contractor to make a full evaluation of the testing methodologies
used, the results of the testing, and to evaluate the completeness of necessary
data gathering. The Contractor will use these treatability testing reports
along with the required effluent quality to select the specific P/C/F equipment
(including ancillary equipment) required to meet the specified performance requirements.
Even though methodologies and results of the previously conducted treatability studies in Appendix [_____] have
demonstrated that P/C/F is capable of meeting the post treatment criteria identified in this section, the Contractor
shall perform an independent evaluation of these studies and results in accordance with ASTM D 2035. Based on
the Contractor's own interpretation of all treatability study results, the Contractor shall provide a full scale
treatment plant which meets the performance requirements identified in this section.
1.6 UTILITIES
NOTE: The locations and details (such as utility point of contact, sizes, capacities,
and flows) of the utility hookups should be provided on the drawings for the
Contractor to use.
The Contractor shall provide the utilities associated with the installation and operation of the treatment plant
including, but not limited to: telephone, electricity, water, [gas], sanitary and solid waste facilities. The
[telephone] [electricity] [_____], [steam] [water] [gas] [sanitary] [_____], and [solid waste facilities] [_____]
are available at the site. Refer to the drawings for hookup locations.
1.7 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01330 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.][information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] The following shall be
submitted in accordance with Section
01330
01330
01330 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Tanks[; G][; G, [_____]]
Detailed drawings of each tank showing the dimensions, nozzle orientations and elevations,
interconnecting piping, equipment layout, hydraulic profile, and any other detail required to
demonstrate that the tank has been coordinated and will properly function as a part of the overall
P/C/F system. Drawings shall show proposed layout, foundation requirements, anchorage of equipment
and accessories, installation/connection details, and equipment relationship to other parts
of the work including clearances for installation, maintenance and operation.
Mixers[; G][; G, [_____]]
Detailed drawings of each mixer including dimensions, mounting details, wiring, schematics,
and any other details required to demonstrate that the system has been coordinated and will
properly function as a unit.
Clarifiers[; G][; G, [_____]]
Detailed drawings showing the dimensions, nozzle orientation and elevations, interconnecting
piping, equipment layout, hydraulic profile, and other details required to demonstrate that
the unit has been coordinated and will properly function as part of the overall P/C/F system.
Drawings shall show proposed layout, foundation requirements, anchorage of equipment and accessories,
installation/connection details, and equipment relationship to other parts of the work including
clearances for installation, maintenance and operation.
Instrumentation and Control[; G][; G, [_____]]
Electrical one-line diagrams illustrating all electrical components (motor controls, disconnects,
starters, selector switches, pushbuttons, pilot lights, conduit, wire, etc.), electrical load
analyses, cable and conduit schedules (including conduit designation, materials of construction,
descriptions for each conduit of the end points of each conduit segment in a run, wire count
by number, type and size, wire length, etc.), and complete control ladder logic diagrams. All
control ladder logic diagrams shall be fully coordinated between components and ladder rungs
to illustrate component tag names for all relays, timers, selector switches, pushbuttons, pilot
lights, etc. All wires and terminals shall be number tagged. Terminal designations shall distinguish
between terminals contained within differing enclosures such as control panels, equipment enclosures,
motor control centers, etc. All auxiliary relay contacts shall be illustrated and designated.
All ladder rungs shall be numbered with cross referencing between all associated rungs. A narrative
description shall be fully coordinated with the ladder logic diagrams so as to fully describe
all control operations, sequences, interlocks, alarms, and shutdowns for the P/C/F system including,
but not limited to, flow control systems, level control systems, pH/ORP control systems, chemical
addition control systems, pump/valve controls, alarm and shutdown schemes, PLC input/output
points, and all component interlocking. Locations of all control panels, equipment enclosures,
motor control centers, etc. shall be designated on an equipment layout drawing.
Structural Skids[; G][; G, [_____]]
. Shop details for each structural skid including members (with their connections) not shown
on the drawings. Welds shall be indicated by standard welding symbols in accordance with AWS A2.4
.
SD-03 Product Data
Tanks[; G][; G, [_____]]
Manufacturer's descriptive data, specifications, technical literature, and catalog cuts for
each tank supplied.
Mixers[; G][; G, [_____]]
Manufacturer's descriptive data, specifications, technical literature, utility requirements,
performance charts and curves, and catalog cuts for each mixer supplied.
Clarifiers[; G][; G, [_____]]
. Manufacturer's descriptive data, specifications, technical literature, utility requirements,
performance charts and curves, and catalog cuts for the clarifier.
Instrumentation and Control[; G][; G, [_____]]
Manufacturer's descriptive data, specifications, technical literature, utility requirements,
performance charts and curves, and catalog cuts for each instrument and control component supplied.
Spare Parts
Spare parts data for each different item of equipment and materials specified.
Regulatory Requirements
Permits, certifications, and/or substantive regulatory requirements before work starts plus
copies of applications for permits and certifications not required until later, along with a
schedule for obtaining them.
Pre-startup Testing[; G][; G, [_____]]
. A pre-startup test plan identifying the procedures and methods that will be used to verify
the integrity, calibration, and operability of the equipment, piping, electrical wiring, and
instruments and control systems. The plan shall specify acceptance criteria and tolerances
to be achieved during the pre-startup testing.
Startup and Operation[; G][; G, [_____]]
List of the P/C/F system and specifying its required performance criteria when operated using
contaminated water. The test plan shall describe the operating procedures to be followed during
the test period including detailed descriptions of the measurements, record keeping, sampling
and analyses to be performed to document that performance criteria has been achieved. The plan
shall address full-scale operation of all equipment, piping, electrical wiring, and instruments
and control systems included in the P/C/F system.
Proof of Performance[; G][; G, [_____]]
List of the proposed operating conditions for process parameters to be continuously monitored
and recorded. Detailed descriptions of the proof of performance schedule, operating conditions
and parameters, influent sources, and required sampling and analyses shall be included.
P/C/F System[; G][; G, [_____]]
Installation instructions and framed, typed operating instructions for posting which explain
methods of checking the system for startup and normal safe operations, normal and emergency
shutdown operations, and procedures for safely starting and stopping each piece of equipment
within the system.
Qualifications
[One] [_____] [copy] [copies] of qualified procedures and list of identification symbols and
names of certified welders and welding operators prior to the commencement of welding operations.
SD-06 Test Reports
Tests
. Test reports showing the results of factory tests performed.
Field Quality Control[; G][; G, [_____]]
Test reports in booklet form showing field tests performed to adjust each component and to
prove compliance with the specified performance criteria upon completion and testing of the
installed system. Test methods used shall be identified and test results shall be recorded.
Each test report shall indicate the final set point of each control device. Test reports shall
be provided for pre-startup testing and startup performance testing.
SD-07 Certificates
Equipment Certificate of Conformance
Manufacturer's certificates attesting that the equipment meets the specified requirements.
The statement shall be dated after the award of the contract, shall state the Contractor's name
and address, shall name the project and location, and shall list the specific requirements which
are being certified. Certificate shall indicate the methods of testing used.
SD-10 Operation and Maintenance Data
Operation and Maintenance Manual Updates
[Six] [_____] copies of operation and maintenance manuals for the P/C/F system containing
the manufacturer's operating and maintenance instructions for each piece of equipment. One
complete set shall be provided prior to the performance of the field test (see Paragraph Tests);
the remaining sets must be submitted prior to startup. Each set shall be furnished in loose
leaf three-hole ring binders. The following identification shall be inscribed on the covers:
the words "OPERATING AND MAINTENANCE INSTRUCTIONS," name of equipment, name and location of
the building, name of the Contractor, and contract number. Cover sheets shall be placed before
instructions identifying each subject. Instruction sheets shall be approximately 216 by 279
mm (8-1/2 by 11 inches,)8-1/2 by 11 inches, with large sheets of drawings folding in. Instructions
shall include, but shall not be limited to, the following:
a. System layout detailing piping, valves, and controls.
b. Approved wiring and control ladder logic diagrams prepared in accordance with ISA S5.1
including a drawing index, legend and symbols list, and abbreviation and identifiers.
c. A narrative control sequence describing startup, operation, and normal and emergency shutdown.
This information shall include the detailed operational narrative described in Paragraph Control
System.
d. Operating instructions for each equipment, instruments and control system including process
monitoring requirements and recommendations for operations reporting to document the results
of all process monitoring.
e. Maintenance instructions for each piece of equipment, including lubrication instructions
and a troubleshooting guide to help the operator determine what steps must be taken to correct
anticipated problems that may occur in the system.
f. Manufacturer's bulletins, cut sheets and descriptive data of equipment; these shall be
submitted after approval of detail drawings, and not later than [2] [_____] months prior to
delivery of the system.
1.8 QUALIFICATIONS
Contractor and subContractors shall demonstrate that their capabilities and experience with similar P/C/F systems
and applications are adequate to supply, install, and operate a P/C/F system to remediate [ground water] [and]
[landfill leachate] [_____] by providing descriptions of at least [2] [_____] P/C/F full-scale remediation projects.
Contractor shall provide a field team (consisting of [ground water] [and] [landfill leachate] [_____] unit operators,
quality control personnel, health and safety personnel, supervisory engineering, and technical staff) qualified
to install and operate the treatment system. Field team personnel shall have a minimum of [_____] years experience
in the installation and operation of similar treatment systems and shall show evidence of satisfactory operation
for each installation. Welding procedures and welders shall be qualified in accordance with the code under which
the welding is specified to be accomplished.
1.9 REGULATORY REQUIREMENTS
NOTE: The designer should review all federal, state, and local regulations
to determine the applicable regulations which may impact the design of the P/C/F
system. Specifically, water regulations should be reviewed to determine the
required effluent quality for a specific site. Air regulations should be reviewed
to determine if tank covers, vents, and emission control devices are required.
Hazardous waste regulations, which cover tank standards and secondary containment,
may apply where the groundwater or leachate being treated is classified as a
hazardous waste.
Contractor shall obtain all permits, certifications, and/or meet the substantive regulatory requirements necessary
for the configuration, installation, startup, and operation of the treatment plant. Work shall meet or exceed
applicable minimum requirements established by federal, state, and local laws and regulations. Contractor shall
notify the Contracting Officer within 30 days of a change in regulatory requirements which may affect the contract.
Equipment, raw materials (including reagents/additives), contaminated materials, and treated materials shall
be safely transported, stored, and handled in accordance with Sections
02120
02120
02120 TRANSPORTATION AND DISPOSAL OF HAZARDOUS
MATERIALS and
01351
01351
01351 SAFETY, HEALTH, AND EMERGENCY RESPONSE (HTRW/UST).
1.10 DELIVERY AND STORAGE
Equipment delivered and placed in storage shall be stored with protection from the weather, excessive humidity
and temperature variation, and dirt, dust or other contaminants.
1.11 PROJECT/SITE CONDITIONS
1.11.1 Environmental Requirements
NOTE: When temperatures are below freezing, the treatment plant equipment may
not function properly and efficiently. The general practice is to avoid the
operation of an outdoor treatment plant during extreme winter weather. In places
where there is a long winter season or in projects where plant operation is
required throughout the year to meet the project schedule, the remediation activities
should be performed inside a building with proper heating and ventilation.
For outdoor operations, piping and equipment should be designed with freeze
protection by insulation and heat-tracing.
P/C/F system shall [be operated continuously] [not be operated] [_____] during the winter when temperatures reach
freezing or below. The system shall be installed [outdoor] [indoor] [_____]. Outdoor equipment shall have [insulation]
[_____] and [heat tracing] [_____]. The system shall be equipped with sufficient lighting as shown on the drawings
for security purposes and for treatment plant operation during inadequate daylight or at night. Refer to Sections
15951
15951
15951 DIRECT DIGITAL CONTROL FOR HVAC AND OTHER LOCAL BUILDING SYSTEMS and
16528A
16528A
16528A EXTERIOR LIGHTING INCLUDING
SECURITY AND CCTV APPLICATIONS for proper heating, ventilation, air conditioning, and illumination.
1.11.2 Existing Conditions
NOTE: Provide seismic requirements, if a Government designer (either Corps
office or A/E) is the Engineer of Record, and show on the drawings. Delete
the bracketed phrase in the last sentence if seismic details are not provided.
Sections 13080 and 15070A, properly edited, must be included in the contract
documents.
The P/C/F system shall operate in a [remote] [urban] [industrial] [commercial] [residential] setting. Contractor
shall become familiar with the existing site conditions, including site location, site configuration, topography,
climate, site accessibility, and adjacent land use. The P/C/F system shall be designed for a soil bearing capacity
of [_____]
MPa.psf. Seismic protection shall be in accordance with Sections
13080
13080
13080 SEISMIC PROTECTION FOR MISCELLANEOUS
EQUIPMENT and
15070A
15070A
15070A SEISMIC PROTECTION FOR MECHANICAL EQUIPMENT [as shown on the drawings].
1.11.3 Field Measurement
After becoming familiar with all details of the work, the Contractor shall verify all dimensions in the field,
and shall advise the Contracting Officer of any discrepancy before work begins.
1.11.4 Spare Parts
The Contractor shall submit a list of spare parts with the manufacturer's part number, a current unit price and
source of supply for each different material or equipment specified, after approval of the related submittals
and not later than [_____] months prior to the system startup. List shall include parts recommended by the manufacturer
to be replaced during the first [_____] years of service. A list of special tools recommended by the manufacturer
for each type of equipment furnished including special tools necessary for adjustment, operation, maintenance,
and disassembly shall be provided.
PART 2 PRODUCTS
NOTE: The designer should review the methodologies and results of the previously
conducted treatability testing and other predesign information, along with the
required effluent quality, to determine the types and sizes of equipment, the
chemicals, and chemical dosages to be specified.
As a minimum, the designer should provide a process flow diagram (PFD), a piping
and instrumentation diagram (P&ID), an instrument index, a site layout drawing,
and an equipment layout drawing. The PFD should depict the P/C/F and ancillary
equipment required for the specific water to be treated and display the process
design conditions for each unit. Such process design conditions should include
consideration of minimum, average, and maximum values of each significant parameter
(e.g. pressure, temperature, flow rate, etc.). The P&ID should define all
piping and instrumentation of the system and should include descriptive tag
names for all piping and fittings including materials of construction, tag number,
and line size. The P&ID drawings should also include tag numbers for all
instruments in accordance with ISA S5.1. The instrument index should include
drawings detailing the types of instruments to be used, their range and scale,
related appurtenances, and their associated tag numbers; all such information
must be coordinated with the P&ID.
The designer should verify that the appropriate (on/off, proportional, set point,
etc.) controller to be used in the P/C/F system for chemical feed control is
specified in Section 11242A CHEMICAL FEED SYSTEMS. The designer should provide
a site layout drawing to indicate to an equipment supplier what the general
location of the equipment will be and how much space is available for the proposed
equipment. The designer should also provide a detailed equipment layout drawing
that identifies all the major equipment and their related orientations inside
the site plan. This equipment layout drawing should indicate where off-site
piping and utility lines enter and/or leave the site. If the equipment layout
drawing is only a suggestion or recommendation to the Contractor, the designer
should so state on the drawing.
2.1 STANDARD PRODUCTS
Material and equipment shall be the standard products of a manufacturer regularly engaged in the manufacture
of such products and shall essentially duplicate items that have been in satisfactory use for at least 2 years
prior to bid opening. Equipment shall be new and unused, except for test equipment. Where two or more pieces
of equipment performing the same function are required, they shall be products of the same manufacturer. Equipment
shall be supported by a service organization that is, in the opinion of the Contracting Officer, capable of providing
service, materials, and equipment in an expedient manner.
2.2 TANKS
2.2.1 General Requirements
NOTE: When required by the corrosive nature of stored water, lack of proper
maintenance facilities, or by climatic conditions, this paragraph will be modified
to provide for corrosion allowance.
Determine basic wind speed from ASCE-7. The designer will choose between the
AWWA and API procedures. Use 1200 Pa (25 psf) snow load for most heavy snow
climates; delete snow load where maximum snow is insignificant. In some cases,
local climate and topography will dictate that a value greater than 1200 Pa
(25 psf) be used for snow loading.
In some application, wastewaters may require closed tanks to contain and/or
control air emissions. VOCs from landfill leachate or groundwater from contaminated
plumes can require closed tanks for the entire system. Show all process nozzles,
spare nozzles, vents, drains, and manholes on the P&ID. If tanks are located
inside a room or building, the designer can delete the wind loading requirements.
Contractor shall use manufacturer's standard size tanks whenever possible. Tank construction material and paints,
coatings, or liners shall be compatible with the wastewater to be stored. Tank dimensions shall be selected
to fit the available space as shown on the drawings. Unless noted otherwise on the drawings, each tank shall
include, flanged fittings for inlet, outlet, overflow, and drain. Manholes shall be provided when shown on the
drawings. Hold down lugs shall be provided to anchor the tank to the base. Influent and effluent baffles and
weirs shall be provided to avoid short circuiting. Tank geometry shall be combined with mixer design to avoid
dead spots and excessive turbulence relative to internal tank baffles and mixer orientation. Complete mixing
shall be provided. Tanks to be supplied as part of the P/C/F system shall meet the following nominal size requirements:
Design Hydraulic Retention Time (HRT)
Type of tank minimum maximum
------------- ------- -------
Equalization Tank [2] [_____] hrs
Oxidation/Reduction Tank [5] [_____] min
Precipitation Tank [5] [_____] min
Coagulation Tank [1] [_____] min [2] [_____] min
Flocculation Tank [20] [_____] min
Effluent Holding Tank [5] [_____] min
[_____] [_____] min
[_____] [_____] min
Design, fabrication, and erection of the tank shall be in accordance with [AWWA D100] [API Std 650] [AWWA D103
] except as modified herein. Minimum equipment design life: [_____] years. Tanks shall be designed for a [basic
wind speed of [_____] km per hourmiles per hour in accordance with ASCE 7 or designed in accordance with [AWWA D100
] [AWWA D103] [API Std 650] wind load design, whichever provides the greater pressure.] [snow load of [1200 Pa25 psf] [[_____] kPapsf].] Factor of safety on overturning of elevated tanks under design wind load shall
be 1.33 minimum. When a footing is required, an inverted truncated pyramid of earth with 2 on 1 side slopes
above top of footing shall be used in determining overturning stability.
2.2.2 Tank Construction Materials
NOTE: Tank shell thickness should be calculated using AWWA D100, AWWA D103,
or API 650 procedures. The strength of the materials of construction for each
tank should include allowances specified herein.
2.2.2.1 Carbon Steel
Carbon steel sheet shall be hot rolled per ASTM A 283/A 283M Grade C with a minimum yield of 476 MPa;40,0000
psi; minimum thickness shall be 3.4 mm.10 gauge. Structural steel shall conform to ASTM A 36/A 36M and [AWWA D100
] [AWWA D103] [API Std 650] for steel tanks.
2.2.2.2 Polyethylene
Polyethylene tanks shall be manufactured in accordance with ASTM C 582.
2.2.2.3 Stainless Steel
Stainless steel shall conform to the material specification for 304SS, 316SS, 316LSS, 317SS.
2.2.2.4 Structural Steel
Structural steel shall conform to ASTM A 36/A 36M.
2.2.2.5 Fiberglass
Fiberglass tanks shall conform to ASTM D 3299.
2.2.3 Corrosion Allowance
NOTE: The designer should specify a minimum corrosion allowance for wetted
surfaces giving consideration to the types of liquids to be stored, the vapors
above the liquids, and the atmospheric environment. It is expected that some
tanks in the P/C/F system may have a low pH and some may have a high pH, and
others will have contaminants and chemicals at varying concentrations. A corrosion
allowance can be calculated using available corrosion rate information from
material suppliers or National Association of Corrosion Engineers (NACE) standards.
The designer should take into account the changes in temperature over the range
of operating conditions and the effects of liquids and vapors on the materials
of construction.
Corrosion allowance is dependant upon the materials of construction and finish coatings and shall be as follows:
For a lined interior finish, the corrosion allowance shall be [0.0 mm0.0 inches] [_____]. For a coated or painted
interior finish, the corrosion allowance shall be [0.0 mm0.0 inches] [_____]. For tanks with no protective
finish, the corrosion finish shall be [0.0 mm0.0 inches] [_____].
2.2.4 Shop Fabrication
All welding shall conform to [AWWA D100] [AWWA D103] [API Std 650] using ASME certified welders. Shell seams
shall be full penetration using Sub Arc Welding (SAW). Other seams shall be made with [Gas Metal Arc Welding
(GMAC)] [Shielded Metal Arc Welding (SMAC)] [Flux Cored Arc Welding (FCAW)] [Submerged Arc Welding] processes.
2.2.5 Bolts
Bolts used in the shell joints shall meet the requirements of Section 2.2 of AWWA D103. Bolts used in tanks
designed under [AWWA D100] [API Std 650] shall meet the requirements as specified in [AWWA D100] [API Std 650
].
2.2.6 Gaskets
All bolted connections shall incorporate gaskets of suitable chemical resistance for the service. Gaskets used
to seal bolted joints in tanks shall meet the requirements of AWWA D103 Section 2.10.
2.2.7 Accessories
2.2.7.1 Manholes and Pipe Connections
Manholes and pipe connections shall meet the minimum requirements of [AWWA D100] [AWWA D103] [API Std 650].
Number, type, elevation, orientation, and size of manholes and pipe connections shall be [as shown on the drawings]
[provided by Contractor].
2.2.7.2 Baffles, Weirs, and Overflow Pipes
NOTE: Design each tank with an overflow that will pipe, channel, or otherwise
direct an overflowing tank to a containment area or to the next tank in the
system. If a weir or exit pipe is plugged and cannot pass the maximum process
flow rate, wastewater must be contained to prevent spills.
Inlet baffles shall be designed to dissipate influent flow energy at maximum flow rates and to avoid short circuiting
to effluent weirs. Weirs for the tanks shall consist of an overflow weir and outside drop pipe, adequately supported
and capable of discharging the design flow rate with [_____] mminches of head. [Top of the weir shall be [_____]
mminches below [the top edge of the tank] [overflow height].] [Weir shall be located as indicated.] All tanks
shall have emergency overflow outlets to direct overflow of wastewater to a containment area. Overflow pipe
shall terminate 300 to 600 mm1 to 2 feet above grade and shall be fitted with a flapper valve or screen to prevent
ingress of birds, insects, or small animals of any kind. Design of internals shall meet the requirements of
[AWWA D100] [AWWA D103] [API Std 650].
2.2.7.3 Vents
NOTE: Vents on covered tanks should be designed to allow vapor control systems
to be attached. Design tank vents in accordance with guidelines published in
the American Institute of Chemical Engineers (AICHE) G3 "Guidelines for Safe
Storage and Handling of High Toxic Hazard Materials" (1988), and API Publication
2557 "Vapor Collection and Control Options for Storage and Transfer Operations
in the Petroleum Industry" (1993).
On covered tanks, vent shall be welded to a cover plate on the roof. Vent shall be tank manufacturer's standard
type mushroom vent with bird and insect screen. Vent shall be designed as specified by [AWWA D100] [AWWA D103
] [API Std 650]. The open area of a vent screen shall be sized 50 percent in excess of the [_____] L/second
gpm pump-in rate and [_____] L/secondgpm pump-out rate. Screening for vent shall conform to [AWWA D100] [AWWA D103
] [API Std 650] ensuring fail-safe operation in the event that screen frosts over. The bottom of the screen
shall be sufficiently elevated for snow consideration in the area.
2.2.7.4 Ladders and Safety Devices
An outside access ladder shall be provided on tanks greater than 1.5 m5 feet in height. Ladders and safety
devices shall be provided in accordance with [AWWA D100] [AWWA D103] [API Std 650]. Location of ladders shall
be as shown on the drawings. In addition, safety cage, rest platforms, roof ladder handrails, and other safety
devices shall be provided as required by federal or local laws or regulations.
2.2.7.5 Scaffold and Cable Support
Tanks shall include attachment rings or hooks on the inside and outside of closed top tanks, at four points at
the top of walls, to secure scaffolding and cable support during maintenance activities.
2.2.7.6 Miscellaneous Tank Accessories
Miscellaneous tank accessories, such as support legs, saddles, skirts, lifting lugs, etc., shall conform to [
AWWA D100] [AWWA D103] [API Std 650].
2.3 CHEMICAL FEED SYSTEMS
NOTE: The designer must verify that appropriate (on/off, proportional, set
point) controller is specified in Section 11242 CHEMICAL FEED SYSTEMS.
Chemical feed systems shall be provided in accordance with Section
11242
11242
11242 CHEMICAL FEED SYSTEMS. Control signals
and wiring to the chemical feed controllers shall be furnished in accordance with the requirements of this section.
2.4 MIXERS
NOTE: Different types of mixers can be used for a P/C/F treatment system including:
impeller, jet and in-line static mixers. Delete items that are not required.
Impeller mixers are divided into three groups: propellers, turbines, and paddles.
Turbine and propeller mixers are used for rapid mixing applications while paddle
mixers are typically used in flocculation.
Propeller mixers are high speed mixers, operated on low horsepower, which are
used primarily for flash mixing applications. Propeller speeds range from 400
rpm to 1750 rpm. When top entry is required, the propeller mixer is mounted
angled and off center. Where side entry is recommended, the propeller mixer
is mounted horizontally, offset from the centerline of the tank.
Turbine mixers are primarily used in low speed applications where heavy solids
may be generated and a large mixing energy input is required to keep the solids
in suspension. These type mixers can be used for equalization of the wastewater,
flash mixing or flocculation. Turbine speed ranges from 55 to 125 rpm. The
turbine mixer is typically mounted vertical, one half to one diameter off the
floor of the mixing chamber. In an unbaffled tank the unit is mounted off center.
In a baffled tank the unit is mounted on center.
Paddle mixers are low speed mixers whose peripheral paddle speed typically varies
from 0.15 to 0.61 m/sec (0.5 to 2.0 feet/second). Paddle mixers are used primarily
in flocculation applications.
Jet mixers use hydraulic action for mixing resulting in lower capital and operating
costs as compared to impeller mixers. Jet mixers are used only for rapid mixing,
and are not suitable for flocculation due to the high pressure liquid ejected
at the discharge nozzle, which can break up the floc previously formed.
Static mixers are typically installed downstream of chemical addition points
for blending or dispersion applications. They are used in combination with
metering pumps and must be sized based on the flow rate. In-line static mixers
use hydraulics for mixing instead of impellers, requiring no external power
and no maintenance. In-line static mixers have high head losses up to 0.9 m
(3 ft); and the mean temporal velocity gradient G cannot be changed to meet
varying requirements.
Mixers are usually sized based on liquid viscosity, liquid temperature and liquid
density among other parameters. However for each of the mixing locations, at
most sites, it is expected that the viscosity and density will not be significantly
different from water; if that is not the case, the designer should specify the
requirements that the mixing device must meet.
Mixers shall be furnished on each tank or unit as designated on the drawings. On tanks, Contractor shall supply
tank baffles, where required by the mixer design, to achieve complete mixing and mixer support as required.
2.4.1 Equalization Unit Mixer
NOTE: Because the water level in the equalization tank varies, the designer
must specify the minimum water level at which the mixer will be turned off to
avoid burning out the mixer motor.
Mixers shall be a [propeller] [turbine] [paddle] [jet] type mixer. Number of mixers: [_____].
a. Propeller, turbine, or paddle mixers shall meet the following requirements. Mounting: [[top] [side]
[bottom] entering] [_____]. Mixer speed: [constant] [variable] at a maximum rpm of [_____]. Variable
speed turndown ratio shall be [4:1] [_____]. Mixer shall be designed to develop a velocity gradient
(G value) not less than [300] [_____] sec-1. Mixers shall be mounted [angled and off center] [horizontally
offset from the centerline of the tank] [vertical off center] [_____] of the mixing chamber. Shaft construction:
[carbon steel] [316 stainless steel] [_____]. Impeller construction: [carbon steel] [316 stainless
steel] [_____]. Mixer bearings shall be designed to operate continuously at full load for [100,000 hours]
[_____] before replacement.
b. Jet mixer shall consist of, but shall not be limited to, a jet motive pump to circulate liquid in
the mixing basin; jet mixing nozzle assembly, retrieval system and in-basin secondary fluid lines. Jet
mixer shall be designed to obtain a maximum mean velocity of [100] [_____] sec-1 or G(t) values of [104]
[_____]. The jet motive pump shall be driven by submersible non-clog units. Motors shall operate on
230/460 volt, three phase, 60 hertz power supply. Nozzle assembly and piping shall be made of [plastic]
[or] [stainless steel] [_____] material to prevent corrosion by process liquid.
2.4.2 Precipitation Unit Mixer
Mixing shall be supplied by a [propeller] [turbine] [jet] [in-line static] type mixer. Number of mixers: [_____].
a. Propeller or turbine type mixers shall meet the following requirements. Mounting: [[top] [side]
[bottom] entering] [_____]. Mixer speed: [constant] [variable] at a maximum rpm of [_____]. Variable
speed turndown ratio shall be [4:1] [_____]. Mixer shall be designed to develop a maximum velocity gradient
(G value) not less than [300] [_____] sec-1. Mixers shall be mounted [angled and off center] [horizontally
offset from the centerline of the tank] [vertical off center] [_____] of the mixing chamber. Shaft construction:
[carbon steel] [316 stainless steel] [_____]. Impeller construction: [carbon steel] [316 stainless
steel] [_____]. Mixer bearings shall be designed to operate continuously at full load for [100,000 hours]
[_____] before replacement.
b. Jet mixer shall consist of, but shall not be limited to, a jet motive pump to circulate liquid in
the mixing basin; jet mixing nozzle assembly, retrieval system and in-basin secondary fluid lines. Jet
mixer shall be designed to obtain a mean velocity of [25-100] [_____] sec-1 or G(t) values of [103-104]
[_____]. The jet motive pump shall be driven by submersible non-clog units. Motors shall operate on
230/460 volt, three phase, 60 hertz power supply. Nozzle assembly and piping shall be made of [plastic]
[or] [stainless steel] [_____] material to prevent corrosion by process liquid.
c. In-line static mixers shall meet the following requirements. Maximum precipitant feed rate: [_____]
L/s.gpm. In-line static mixers shall have a helical shaped element which is made of the same material
as the housing wall. Sealing edge between the element and housing wall shall create an integral unit
without pieces to fatigue or vibrate. In-line static mixers shall incorporate the required number of
elements to provide complete mixing at all design conditions. Mixer shall be sized to fit [_____] mminches diameter conveying pipe. Materials of construction: [carbon steel] [stainless steel] [polyethylene]
[polypropylene] [FRP] [Teflon] [_____].
2.4.3 Coagulation Unit Mixer
Mixing shall be supplied by a [propeller] [turbine] [jet] [in-line static] type mixer. Number of mixers: [_____].
a. Propeller or turbine mixers shall meet the following requirements. Mounting: [[top] [side] [bottom]
entering] [_____]. Mixer speed: [constant] [variable] at a maximum rpm of [_____]. Variable speed turndown
ratio shall be [4:1] [_____]. Mixer shall be designed to develop a velocity gradient (G value) not less
than [300] [_____] sec-1. Mixers shall be mounted [angled and off center] [horizontally offset from
the centerline of the tank] [vertical off center] [_____] of the mixing chamber. Shaft construction:
[carbon steel] [316 stainless steel] [_____]. Impeller construction: [carbon steel] [316 stainless steel]
[_____]. Mixer support shall [be included] [not be included] [_____]. Mixer bearings shall be designed
to operate continuously at full load for [100,000 hours] [_____] before replacement.
b. Jet mixer shall consist of, but shall not be limited to, a jet motive pump to circulate liquid in
the mixing basin; jet mixing nozzle assembly, retrieval system and in-basin secondary fluid lines. Jet
mixer shall be designed to obtain a mean velocity of [25-100] [_____] sec-1 or G(t) values of [103-104]
[_____]. The jet motive pump shall be driven by submersible non-clog units. Motors shall operate on
230/460 volt, three phase, 60 hertz power supply. Nozzle assembly and piping shall be made of [plastic]
[or] [stainless steel] [_____] material to prevent corrosion by process liquid.
c. In-line static mixers shall meet the following requirements. Maximum coagulant feed rate: [_____]
L/s.gpm. In-line static mixers shall have a helical shaped element which is made of the same material
as the housing wall. Sealing edge between the element and housing wall shall create an integral unit
without pieces to fatigue or vibrate. In-line static mixers shall incorporate the required number of
elements to provide complete mixing at all design conditions. Mixer shall be sized to fit [_____] mminches diameter conveying pipe. Materials of construction: [carbon steel] [stainless steel] [polyethylene]
[polypropylene] [FRP] [Teflon] [_____].
2.4.4 Flocculation Unit Mixer
Mixers shall be [turbine] [paddle] type mixers. Number of mixers: [_____]. Mounting: [[top] [side] [bottom]
entering] [_____]. Mixer speed: [constant] [variable] at a maximum rpm of [_____]. Variable speed turndown
ratio shall be [4:1] [_____]. Mixer shall be designed to develop a maximum velocity gradient (G value) no more
than [100] [_____] sec-1. Mixers shall be mounted [angled and off center] [horizontally offset from the centerline
of the tank] [vertical off center] [_____] of the mixing chamber. Shaft construction: [carbon steel] [316 stainless
steel] [_____]. Impeller construction: [carbon steel] [316 stainless steel] [_____]. Mixer support shall [be
included] [not be included] [_____]. Mixer bearings shall be designed to operate continuously at full load for
[100,000 hours] [_____] before replacement.
2.4.5 Effluent Holding Unit Mixer
Mixing shall be provided by a [propeller] [turbine] [jet] [in-line static] type mixer. Number of mixers: [_____].
a. Propeller or turbine mixers shall meet the following requirements. Mounting: [[top] [side] [bottom]
entering] [_____]. Mixer speed: [constant] [variable] at a maximum rpm of [_____]. Variable speed turndown
ratio shall be [4:1] [_____]. Mixer shall be designed to develop a velocity gradient (G value) not less
than [300] [_____] sec-1. Mixers shall be mounted [angled and off center] [horizontally offset from
the centerline of the tank] [vertical off center] [_____] of the mixing chamber. Shaft construction:
[carbon steel] [316 stainless steel] [_____]. Impeller construction: [carbon steel] [316 stainless steel]
[_____]. Mixer support shall [be included] [not be included] [_____]. Mixer bearings shall be designed
to operate continuously at full load for [100,000 hours] [_____] before replacement.
b. Jet mixer shall consist of, but shall not be limited to, a jet motive pump to circulate liquid in
the mixing basin; jet mixing nozzle assembly, retrieval system and in-basin secondary fluid lines. Jet
mixer shall be designed to obtain a mean velocity of [25-100] [_____] sec-1 or G(t) values of [103-104]
[_____]. The jet motive pump shall be driven by submersible non-clog units. Motors shall operate on
230/460 volt, three phase, 60 hertz power supply. Nozzle assembly and piping shall be made of [plastic]
[or] [stainless steel] [_____] material to prevent corrosion by process liquid.
2.5 CLARIFIERS
NOTE: This paragraph specifies only inclined plate or tube settlers. The inclined
plate or tube settler requires minimum space, no moving parts (therefore minimizing
maintenance), less potential for short circuiting, and generally lower capital
and operating costs than conventional clarifiers. For metallic sludges, the
overflow rate typically ranges from 2.1 to 4.2 L/s/sq. m (360 to 720 gpm/sq.
ft.) and generally will not exceed 5.9 L/s/sq. m (1000 gpm/sq. ft.).
Clarifier shall be an inclined [plate] [or] [tube] settler and shall be designed to meet the following conditions:
a. Influent pH: Maximum [_____], Minimum [_____].
b. Solids Loading: [_____] kg/day.lbs/day.
c. Effluent TSS: [_____] mg/L.
The effective surface overflow rate shall be [_____] L/m3/m2.sgpd/ft2 and the detention time shall [2] [_____]
hours at the design flow rate. Clarifier shall consist of, at a minimum, the following accessories: influent
distribution system, a separator module consisting of [corrugated plate packs,] [inclined tube packs,] skimmer
mechanism with scum collection trough, sludge removal system, effluent collection flumes, access ladder, operating
platform, associated piping, fittings, sampling valves, and a sludge hopper.
2.5.1 Clarifier Vessel
The bottom and sides of the clarifier vessel shall be 6 mm1/4 inch minimum thickness carbon steel plate meeting
or exceeding ASTM A 36/A 36M. Inlet, outlet, overflow, and drain connections shall be provided on the vessel.
Structural steel framework shall be an integral part of the vessel to make it self-supporting. The clarifier
shall be designed for seismic forces in accordance with paragraph Existing Conditions.
2.5.2 Influent Distribution and Effluent Collection Systems
Influent distribution system shall be supplied to dissipate the entrance energy and to equalize flow to the separator
module. Weirs and baffles shall be included to control the local velocities and to eliminate short circuiting.
Adjustable weirs shall be supplied along each effluent collection flume to maintain uniform flow distribution.
2.5.3 Separator Module
The separator module shall be formed by [parallel corrugated plates placed [38 mm 1-1/2 inches] [[_____] mm
inches] apart] [inclined tubes at [45] [60] [_____] degrees from the horizontal]. The separator module shall
be removable for maintenance and inspection. Separator module shall be constructed of corrosion resistant materials.
[Corrugated plate packs] [Tube packs] shall be [fiberglass reinforced plastic] [polypropylene] [coated steel]
[stainless steel] [_____].
2.5.4 Skimmer and Sludge Collection/Thickening Devices
Mechanical skimmer and drive shall continuously collect floating scum and remove it to a collection trough.
Sludge holding compartment shall be equipped with hopper bottom having sides tapering downward at an angle not
less than [55] [_____] degrees above horizontal for sludge collection. Sludge hopper shall be [fixed] [removable]
[_____] and shall be equipped with a vibrator pack for sludge thickening. Sludge hopper shall provide a minimum
of [_____] Lgallons of sludge storage. A flanged outlet shall be provided for each hopper which connects to
a pump for sludge removal.
2.5.5 Miscellaneous
Clarifier shall be supplied with a steel platform around the perimeter complete with ladder, handrail, and toe
plates. Painting shall conform to Sections
09900
09900
09900 PAINTS AND COATINGS and
09964
09964
09964 PAINTING: HYDRAULIC STRUCTURES,
unless otherwise indicated.
2.6 PIPING/VALVES
Piping and valves for chemical feed systems shall be in accordance with Section
11242
11242
11242 CHEMICAL FEED SYSTEMS.
Low point drains shall be installed in interconnecting piping.
2.7 PUMPS
Pumps shall conform to the following requirements. Pumps for specific services and accessories shall be as specified.
2.7.1 Water Pumps
NOTE: Water pumps include, but are not limited to, the following: equalization
transfer pumps, water pumps for chemical dilution, and effluent water recycle
and discharge pumps. Water pumps may be horizontal or vertical centrifugal
pumps. Delete and/or add paragraphs to meet job requirements.
Water pumps shall be designed in accordance with Sections
11211
11211
11211 PUMPS: WATER, CENTRIFUGAL and
11212
11212
11212 PUMPS: WATER,
VERTICAL TURBINE.
2.7.2 Chemical Metering Pumps
NOTE: Chemical metering pumps may be piston, positive displacement diaphragm,
or balanced diaphragm pumps. The unit application depends on the pressure involved,
corrosiveness of the chemical, feed rate, accuracy required, viscosity and specific
gravity of the fluid, other liquid properties, and the type of control.
Chemical metering pumps shall be manufactured and installed in accordance with Section
11242
11242
11242 CHEMICAL FEED SYSTEMS.
2.7.3 Sludge Pumps
NOTE: Sludge pumps may be centrifugal, diaphragm (air operated) or progressive
cavity. The unit application depends on the pressure involved, the pumping
rate (constant or variable), the specific gravity of the sludge and the type
of control.
Sludge pumps shall be manufactured and installed in accordance with Section
11310
11310
11310 PUMPS: SEWAGE AND SLUDGE.
2.8 ELECTRICAL WORK
2.8.1 General
Electrical equipment and wiring shall be in accordance with Section
16402
16402
16402 INTERIOR DISTRIBUTION SYSTEM and shall
conform to
NFPA 70. Circuit installation shall be in accordance with Sections
16370A
16370A
16370A ELECTRICAL DISTRIBUTION
SYSTEM, AERIAL and
16375A
16375A
16375A ELECTRICAL DISTRIBUTION SYSTEM, UNDERGROUND.
2.8.2 Electric Motors
NOTE: Electrical motor driven equipment should be provided complete with motors,
motor starters, and controls.
Contractor shall provide for each motor a circuit breaker type combination motor circuit protector, complete
with properly sized thermal overload protection on each phase, along with a hand-off-automatic (HOA) selector
switch; red and green pilot lights; manual reset pushbutton; and all other appurtenances necessary for the motor
control specified. Each motor shall be of sufficient capacity to drive the equipment at the specified capacity
at or below a 1.0 service factor and without exceeding the nameplate rating of the motor when operating at the
specified electrical system voltage and frequency. Each electric motor-driven piece of equipment shall be driven
by a chemical/mill duty, [explosion-proof] [totally-enclosed fan cooled (TEFC)] [totally-enclosed non-ventilating
(TENV)] [_____] motor rated for continuous duty at a 40 degrees C ambient temperature. Motor shall have a [1.15]
[1.0] [_____] service factor. All motors shall conform to the respective sections of NEMA MG 1. Three phase
motors shall be squirrel-cage induction type having normal-starting-torque and low-starting-current characteristics.
Motors shall have sufficient power and torque so that the nameplate power rating, without consideration of the
service factor, shall not be exceeded under any operating condition. Adequate thrust bearings shall be provided
in the motor to handle any thrust forces that are transmitted to motor under any operating condition. Three
phase motors shall be rated 230/460 volts, 60 hertz. Fractional horsepower motors shall be 115 volts, 60 hertz.
All motor nameplate information shall be stamped on the attached nameplate per the requirements of NEMA MG 1.
Motors shall have a premium efficiency design, class F insulation, automatic thermal protection of the stator
windings, and standard NEMA frame ratings.
2.9 INSTRUMENTATION AND CONTROL
NOTE: Instrumentation and control systems are used in water treatment to ensure
consistent quality, to optimize process reliability, to assist operating personnel
in monitoring process operations, and to minimize operating costs. The measurement
and control instruments may range from a simple control panel indicator to a
complex, multi-component, programmable logic controller based system.
In developing the scope of the instrumentation and control system design, the
designer should consider the following parameters: size of the plant, type and
complexity of the treatment process, type of vendor-supplied controls, amount
of funds available, current design standards, discharge compliance criteria,
special interfaces with other control systems, and the ability of the owner
to properly maintain a control system. Generally, the designs of P/C/F systems
incorporating manual operation would be limited to batch processes in which
the control of pumps and chemical addition is accomplished by operator action.
The continuous operation of P/C/F systems usually involves more complex control
schemes. Chemical addition can be manually or automatically proportioned to
flow and/or to other process feedback signals generated by process instrumentation.
The degree of automation incorporated into the system design generally depends
upon the complexity of the treatment system, the remoteness of the site, the
planned level of operator attention, and the duration of the project. Systems
designed for unattended operation would require the greatest degree of automated
system controls. Control schemes may include the use of remotely located programmable
logic controllers, remote data telemetry, and telecommunication systems.
The designer should consider how the P/C/F system will be operated for each
site-specific application. The equipment used in a P/C/F system can be supplied
to operate either in a batch or a continuous mode of operation. A batch operation
may be more economical than continuous operation when wastewater flows are small
(less than 0.6 L/s (10 gpm)), or are intermittent from sources such as a small
landfill leachate recovery system or small ground water pumping wells. When
the wastewater flows are larger than 0.6 L/s (10 gpm), continuous operation
should be used. In the continuous mode of operation, all equipment would run
uninterrupted and the wastewater would be fed to the system at a controlled
rate.
If a batch operation is used, the designer must decide whether treatment can
be performed in one single tank or if multiple tanks are required. In a single
tank, the required chemicals for precipitation, coagulation, and flocculation
are added sequentially to the same tank at a mixing intensity appropriate for
the chemical being added. Following chemical addition, all mixers would shut
down to allow a quiescent time for settling to occur. The settled sludge on
the bottom of the tank could be drawn off and the supernatant adjusted for final
pH. The water can be stored in this one tank until it is analyzed and discharged,
or a separate tank can be used to store the water. This type of system is appropriate
for sites that generate small amounts of water where the time to treat one batch
does not exceed the time to generate a volume of water to be treated. A flow
equalization tank must be provided to receive the water while treatment is occurring
in the batch tanks.
Alternatively, if more frequent treatment is required, batch treatment can employ
multiple tanks where one volume of water is pumped sequentially through the
precipitation, coagulation, flocculation, and clarification tanks. The equipment
used in this system would be the same as for a continuous operation, except
that the instrumentation and controls would be designed to allow intermittent
pumping, mixing, and chemical addition rather than continuous. In either mode
of operation, the controls can be designed to operate the system with 1) manual
control, 2) semiautomatic control, or 3) automatic control. The designer must
select the control scheme appropriate for the site considering the complexity
of the system and personnel availability.
In manual control, the operator will start only one process at a time (e.g.,
precipitation, coagulation, flocculation, clarification, etc.) and check the
results of each before starting next operation. In semiautomatic control, the
operator must be present to start the P/C/F system and transition from one process
to another will be controlled automatically using either an electronic or pneumatic
distributed control system. In automatic control, the entire system will operated
without an operator. The normal running of the system is linked to one or more
governing factors (tank level, flow rate, etc.) which will start up each system
when set points are reached. Maximum reliability of a fully automated system
can be obtained by using a logic control system which checks that the orders
given have been received and carried out and, if not, stops the operations and
alarms the operator. All controls should have manual override.
The instrumentation and control system shall be [batch] [on-off in response to influent flow] [manual] [semi-automatic]
[automatic] [_____] with complete electrical power, control and instrumentation as specified or recommended by
the equipment manufacturer for the safe operation and supervision of the P/C/F system. The instrumentation and
control package for the P/C/F system shall be supplied as indicated on the drawings. Probes for pH and oxidation
reduction potential (ORP), measuring devices, and level sensors specified in the following four subparagraphs
shall be of materials resistant to chemical attack over a pH range of 2 to 12, and suitable for a temperature
range from [0 to 100] [_____] degrees C[32 to 212] [_____] degrees F and for the liquid to be monitored. All
enclosures for pH, flow, and level sensors and transmitters shall be rated NEMA 4X.
2.9.1 pH Monitoring/Control
pH probes shall be provided [where indicated on drawings] [on the effluent line of each reactor] for the purposes
of pH monitoring and/or pH control through an associated control device (PLC, single loop controller, etc.).
Probes shall be easily removable without interrupting service. Probe materials shall be resistant to operating
pressures of up to [_____] kPapsi. The probes shall be interconnected to associated transmitters/indicators
that are located preferably in the main control panel. Probes shall be connected to a micro processor based
pH analyzer having a 4 digit readout with 13 mm1-1/2 inch high letters and an isolated 4 - 20 mA DC output signal
proportional to the pH. The accuracy of the pH unit shall be plus or minus 0.5 percent of full scale.
2.9.2 ORP Monitoring/Control
An oxidation reduction potential (ORP) probe shall be provided [where indicated on drawings] [_____] for the
purpose of ORP monitoring and/or control. Probe shall be easily removable without interrupting service. Probe
materials shall be resistant to operating pressures of up to [_____] kPapsi. The probes shall be interconnected
to associated transmitters/indicators that are located preferably in the main control panel. Probe shall be
connected to a micro processor based pH analyzer having a 4 digit readout with 13 mm1-1/2 inch high letters
and an isolated 4 - 20 mA DC output signal proportional to the ORP. The accuracy of the ORP unit shall be plus
or minus 0.5 percent of full scale.
2.9.3 Flow Monitoring/Control
Flow measuring devices shall be provided [where indicated on drawings] [on the influent line] [on the effluent
line] for the purpose of flow monitoring and/or control. Measuring devices shall be easy to maintain without
interrupting service. Measuring devices shall be resistant to operating pressures of up to [_____] kPapsi.
Measuring devices shall be connected to a microprocessor based flow analyzer having a digital readout with 13
mm1-1/2 inch high letters and an isolated 4 - 20 mA DC output signal proportional to the flow. The accuracy
of the flow monitoring unit shall be plus or minus 0.5 percent of full scale. The type of flow meter selected
shall be fully coordinated with the application involved as shown on the drawings to assure that the flow meter
meets all installation and operational criteria (upstream and downstream distances from appurtenances, minimum
and maximum flow velocities, degree of required accuracy, full pipe flow, etc.).
2.9.4 Level Monitoring/Control
Level indicator gauges of the direct-reading type, equipped with a shutoff valve, shall be provided on the discharge
side of the tank. Gauges shall have 150 mm6 inch dials, shall be stem mounted, and shall conform to ASME B40.100
. Accuracy of gauges shall be Grade A in accordance with ASME B40.100. Gauges shall be calibrated in kPa and
psipsi in not more than 10 kPa and 2 psi2 psi increments from 0 to 350 kPa and 0 to 50 psi0 to 50 psi in excess
of the normal operating pressure at the tank. All level (float) switches shall be mechanically actuated with
Form C contacts. All electronic level sensing devices shall include a sending unit that transmits an analog
or discrete signal, as required for the application, to an associated control panel or control device. Level
monitoring/control sensors shall be provided [where indicated on drawings] [_____]. Sensors shall be easily
removable without interrupting service. All analog level sensor shall be connected to a microprocessor based
level indicator and/or controller as required by the application having a 4 digit readout with 13 mm1-1/2 inch
high letters and an isolated 4 - 20 mA DC output signal proportional to the level to be measured.
2.9.5 Control System
NOTE: The designer should include a detailed operating and control procedure
in this paragraph to explain the control philosophy for each component of the
P/C/F system. This operating and control procedure should include all information
required for system start-up, continuous operations, and normal and emergency
shut-down operations. This procedure should include all operating set points
for pump starting/stopping/alarming/shutdown, all normal/alarm/shutdown pH values,
all normal/alarm/shutdown ORP values, all normal/alarm/shutdown liquid levels,
as well as all other normal/alarm/shutdown values for any other control or processing
equipment. This procedure should delineate all normal operational values for
each component of the P/C/F system.
The control system shall be designed to operate as shown on the drawings and described in the operating and control
procedures provided [below] [as an attachment]. All alarms and/or shutdowns shall consist of both visible alarm
lights and audible alarm signals on either the main control panel, or on a remote microprocessor controller screen.
The alarms and shutdowns shall function through a first-out-sequence annunciation. Alarms shall be provided
for high and low water and chemical levels, high and low pH values, and high and low ORP values. Automatic shutdowns
shall be provided for each system when a control value or an operational system ranges out of normal operational
limits where personnel safety is a concern, where mechanical damage can occur to process equipment, or where
the process excursion has the potential to violate discharge water quality criteria; such shutdowns can occur
for both high and low conditions. Power failures and equipment failures shall initiate an alarm as well as an
orderly and automatic shutdown of the treatment system. [Auto-dialing to an indicated remote location shall
be provided to report each alarm or shutdown that stops the movement of process water through the treatment system
or stops chemical feed systems. The Contractor shall be responsible for providing the associated telephone line
for the auto-dialer system.] Control power transformers, relays, adjustable timers, auxiliary contacts, switches,
or additional equipment required to interconnect the treatment equipment to a monitoring/control system shall
be provided. Conduit and wiring between control panels, treatment components, and all control devices shall
be furnished.
2.9.6 Control Panel Enclosures
All required control panels for the control system shall be rated NEMA 4X [fiberglass] [stainless steel] and
shall be sized to assure that adequate internal space is available for all components specified and/or required
with an allowance of no less than 30 percent spare space. To the greatest extent possible all instrument transmitters
shall be installed in or adjacent to the control panel enclosure.
2.10 STRUCTURAL SKIDS
Where a P/C/F system has structural skids, skids shall be fabricated in accordance with Section
05120
05120
05120 STRUCTURAL
STEEL.
2.11 PAINT/COATINGS
NOTE: Section 09964 is a Civil Works guide specification.
Paint and coatings work shall be in accordance with Sections
09900
09900
09900 PAINTS AND COATINGS and
09964
09964
09964 PAINTING: HYDRAULIC
STRUCTURES.
2.12 INSULATION/HEATING/VENTILATION
NOTE: In cold climates, exposed pipe, valves, pumps and equipment should be
insulated and/or heat traced to prevent freezing. Tanks should be insulated
and heated to keep the tank contents above freezing temperatures.
Contractor shall provide insulation for pipes, valves, pumps, tanks, instrumentation and controls, and other
equipment in accordance with Section
15080
15080
15080 THERMAL INSULATION FOR MECHANICAL SYSTEMS.
2.13 NAMEPLATES
Each major item of equipment shall have the manufacturer's name, address, type or style, model or serial number,
and catalog number on a plate secured to the item of equipment.
2.14 SPECIAL TOOLS
One set of special tools, calibration devices, and instruments required for operation, calibration and maintenance
of the equipment shall be provided, as recommended by the manufacturer.
PART 3 EXECUTION
3.1 EXAMINATION
NOTE: The designer will determine if the examination by the Contracting Officer
is to apply to all equipment or only to special items to be inspected.
After equipment is delivered to the site and prior to installation, Contractor shall examine the treatment plant
equipment for any damage, defect, or deterioration. Results of this pre-installation examination shall be documented
and submitted to the Contracting Officer for review. [Contracting Officer will also conduct this examination
independently.] Based on the examination, the Contracting Officer has the right to reject damaged, defective,
or deteriorated equipment. Surface damage to equipment shall be corrected according to the manufacturer's requirements.
Costs associated with the delay caused by the rejection shall be borne by the Contractor.
3.2 PREPARATION
Prior to performing installation, the Contractor shall verify that construction equipment used at the site is
of sufficient capacity and in good mechanical condition. All specified preconstruction submittals shall be provided
to the Contracting Officer.
3.3 INSTALLATION
Equipment shall be handled with extreme care to prevent damage during placement. Equipment shall be installed,
except as otherwise specified, as indicated on the drawings, and in accordance with the manufacturer's written
instructions [and under direct supervision of the manufacturer's representative] [_____]. Installation shall
include furnishing all materials required for initial operation. Equipment shall be properly leveled, aligned,
and anchored in place in accordance with the manufacturer's instructions. Supports shall be provided for equipment,
appurtenances, and pipes as required. Piping runs shall be straight and evenly supported. Valves shall be installed
with stems horizontal or above the pipe centerline. Flanges and unions shall be installed where valve and equipment
maintenance may require disassembly. P/C/F system shall be provided complete and ready for operation. Plumbing
work shall conform to the requirements of [Section
15400
15400
15400 PLUMBING, GENERAL PURPOSE] [_____].
3.3.1 Foundations
Foundations for tanks, clarifier, and other equipment shall be constructed of reinforced concrete in accordance
with Section
03300A
03300A
03300A CAST-IN-PLACE STRUCTURAL CONCRETE, except as shown or specified herein.
3.3.2 Excavating, Filling, and Grading
Excavating, filling, and grading shall conform to the applicable requirements of Section
02300
02300
02300 EARTHWORK.
3.3.3 Cathodic Protection
Cathodic protection shall be provided on steel tanks and clarifiers, conforming to Section
13111A
13111A
13111A CATHODIC PROTECTION
SYSTEM (STEEL WATER TANKS).
3.3.4 Welding
Tank welding shall be performed in accordance with [Section 8 of AWWA D100] [AWWA D103] [API Std 650].
3.3.5 Erection
Tank erection shall be performed in accordance with [Section 10 of AWWA D100] [AWWA D103] [API Std 650].
3.3.6 Field Painting
NOTE: Section 09964 is a Civil Works guide specification.
Painting shall be in accordance with Sections
09900
09900
09900 PAINTS AND COATINGS and
09964
09964
09964 PAINTING: HYDRAULIC STRUCTURES.
Stainless steel, galvanized steel, and nonferrous surfaces shall not be painted.
3.3.7 Inspections and Testing
Tank inspection and testing shall be in accordance with Section 11 of AWWA D100. Mill and shop inspections [are
not required] [are required and shall be performed by an approved commercial inspection agency]. Contractor shall
perform the hydrostatic test. Final hydrostatic test shall be performed before painting.
3.3.8 Radiographic Inspection and Testing
Tank radiographic inspection and testing shall be in accordance with Section 11 of AWWA D100. Radiographic inspections
[are not required] [are required and shall be performed by an approved commercial inspection agency]. All testing
shall be performed before painting.
3.4 FIELD QUALITY CONTROL
3.4.1 Inspection
NOTE: The system's P&ID and the as-built drawings are used to verify that
all equipment, piping, and valves are installed according to plans and specifications.
The electrical one-line diagrams and wiring diagrams are useful to verify the
electrical and instrumentation systems. Grounding of equipment should also
be inspected. Vendor's certified shop drawings and equipment operating manuals
should be used to check the equipment installation and operation.
After the installation is complete, each component will be inspected by the Contracting Officer to verify that
the components of the system are properly installed according to drawings and specifications. Any discrepancies
found shall be corrected and work affected by such deficiencies shall be at the Contractor's expense.
3.4.2 Tests
Each piece of equipment shall be subject to an operational test, under the supervision of a factory representative
and may be observed by the Contracting Officer. Test shall demonstrate that the equipment is not defective and
is in safe and satisfactory operating condition. Contracting Officer shall be notified [7] [_____] days prior
to the dates and times for acceptance tests. Each unit shall be given a running field test in the presence of
the Contracting Officer for a minimum of [2] [_____] hours. If any deficiencies are revealed during the tests,
such deficiencies shall be corrected by the manufacturer and the tests shall be repeated.
3.4.3 Manufacturer's Service
Services of a manufacturer's representative who is experienced in the installation, adjustment, and operation
of the equipment specified shall be provided. Representative shall supervise the installation, adjustment, and
testing of the equipment. Up to [5] [7] [10] [_____] days of service shall be provided.
3.5 STARTUP AND OPERATION
NOTE: Pre-start-up procedures should be provided for each component of the
P/C/F system and procedures should be provided for start-up of the whole system.
The startup plan must include pre-startup checkouts, pre-startup testing, and
the actual startup. The following sections describe startup operations of a
P/C/F treatment system. The startup procedure follows a planned sequence of
events for each component of the system.
3.5.1 Hydrostatic Tests
NOTE: The test pressure should not exceed 130 percent of the rated pressure.
Testing of pipe and fittings should be specified in the same section where the
pipe is specified in.
After installation, all tanks shall be tested for leaks or damage in shipment. The tanks shall be hydrostatically
tested [to [_____] kPapsig] [as indicated in the schedule] or 1.5 times the system operating pressure, whichever
is greater. The tanks shall be tested for a period of [24] [___] hours. The Contractor shall furnish testing
plugs or caps, all necessary pressure pumps, pipe connections, gauges, other equipment, and all labor required.
Damage or leaks in tanks shall be repaired or tanks shall be replaced at the Contractors expense. Joints of
air lines shall be tested using a soapy water solution to detect leaks.
3.5.2 Pre-startup Checkout
NOTE: The pre-startup checkouts are designed to verify the integrity of the
system components prior to pre-startup testing.
Components subjected to the pre-startup checkout shall include the following items:
a. Foundations shall be checked to verify that they are placed and sealed properly;
b. System shall be checked to verify that all equipment has been properly installed and connected;
c. Rotating equipment which requires lubrication shall be checked to ensure that manufacturer's procedures
have been followed;
d. Equipment shall be level and checked for proper alignment, anchored, and static ground wires installed;
e. Piping, flange bolts, gaskets, and hoses shall be checked to ensure that connections are tight, and
flushed clean;
f. Valves shall be checked for position and operability and flushed clean;
g. Electrical wiring and lighting shall be checked to verify that wiring has been completed correctly;
h. Continuity checks shall be performed on wiring loops;
i. High/Low liquid level alarms on tanks, as well as pump on/off level controls, shall be checked for
proper installation and response;
j. Chemical feed systems shall be checked for proper installation;
k. Chemicals shall be checked for proper type, required quantity and mixing; tanks shall be filled;
l. Lockout devices and site security devices shall be checked for proper installation.
3.5.3 Pre-startup Testing
NOTE: The pre-startup testing of the system should be performed to verify the
integrity of each component and of the whole system prior to actual startup.
Each component of the system shall be subjected to the pre-startup testing as described below:
a. Piping and hoses transporting liquid shall be pressure tested on clean water for at least one hour,
with no loss of pressure at 1.5 times the working pressure; tanks shall be pressure tested at the maximum
hydraulic head using clean water;
b. Electrical wiring shall be tested to verify that there is no wiring damage or deterioration that
could cause injury to personnel or damage to equipment;
c. Power shall be turned on to test equipment and control systems only after the electrical systems
are tested and certified ready for operation;
d. Lighting shall be tested and put in service to support work in all areas of the plant;
e. Rotating equipment such as pumps, mixers, and blowers, if used, shall be tested for correct direction
of rotation by bumping the starter manually;
f. Each pump shall be operated for a minimum of [4] [_____] continual hours at operating or test conditions.
Tests shall assure that the units, controls and instrumentation have been installed correctly, and that
there is no over-heating, vibration or excessive noise;
g. Depending on the complexity of the control system, testing can proceed from this point to verify
that manual and automatic controls function properly and control valves open/close. All tanks shall
be filled and emptied to determine if high and low level alarms sound at the prescribed liquid level;
h. Safety shutdown sequences, controls/alarms and interlocks in the control system shall be tested to
ensure that they are installed properly and functioning as intended;
i. Each emergency shutoff switch shall be clearly labeled and tested to determine that it works properly;
j. Electrical "lockout" devices with padlocks shall be tested to ensure that power has been disconnected;
k. Instrumentation shall be calibrated before systems are put into service. Pressure and temperature
gauges shall be tested against standardized gauges. Where NIST SP 250 calibration standards exist, they
shall be utilized.
3.5.4 Startup Performance Testing
NOTE: The startup check and functional performance tests should be performed
in accordance with the manufacturer's recommended procedures. The startup should
proceed following a startup plan prepared well in advance. Performance testing
begins with equipment or components, proceeds through systems, and ends with
the complete treatment system passing its performance specifications and contractual
requirements testing.
Startup testing shall not be initiated until after each component of the system has been demonstrated to meet
the requirements of the pre-startup testing and until written approval has been received from the Contracting
Officer. Once steady state operation is achieved, a functional performance test shall be performed as described
in the following startup checklist:
a. Check flow rates, pH, and contaminant levels of the wastewater feeding the reactor tank;
b. Check pump operating points to verify that the actual operating point matches the pump curve specification
for flow and pressure;
c. Start/stop pumps from all control mechanisms;
d. Check that current draw and voltage balance match specifications for all phases;
e. Check the reagent feeding systems to verify that the actual chemical feed rate is within the specified
accuracy range;
f. Check the pH in the reactor to verify that operating values are within the design range;
g. Adjust the reagent feed rates, and the pH control system as required to achieve maximum metal removals;
h. Monitor the composition of the effluent to verify that it meets the specified performance requirements.
i. Check the clarifier overflow rate to verify that it is within the design range;
j. Check the sludge collecting device to verify that it is operating properly, and no sludge is overflowing
the weir;
k. Check the control system to verify that the system operates within set parameters; and
l. Check the monitoring systems and instruments to verify that they hold calibration.
m. A successful performance test shall include [48] [_____] hours of operation processing water from
the design influent source at design capacity and meeting effluent requirements with less than 20 percent
down time. Any deficiencies shall be corrected and performance checks successfully completed before
the system will be accepted. Equipment not capable of performing as specified shall be replaced or upgraded
at no additional cost. The Contractor shall submit Proof of Performance and Equipment Certificate of
Conformance as specified in the Submittals paragraph.
3.5.5 Field Training
NOTE: The field training provided by the Contractor must be modified if the
process will be operated by the Contractor for the first year.
Upon completion of the installation and at a time designated by the Contracting Officer, the Contractor shall
conduct a field training course for a representative of the Government in the operation and maintenance of equipment
furnished under the contract. These field instructions shall cover all the items contained in the operation
and maintenance instructions. Training shall be provided for a total period of [8] [16] [_____] hours per day
for a period of [5] [_____] days of normal working time and shall start after the system is functionally complete
but prior to final acceptance tests. Field instructions shall cover the items contained in the operating and
maintenance instructions, as well as demonstrations of routine maintenance operations. A video tape of the field
training course shall be prepared as a permanent record for future training use.
3.5.6 Operation and Maintenance Manual Updates
NOTE: The O&M Manual is intended for use by operating personnel and should
be adapted to the particular features of the equipment installed; therefore,
the document must be written for the operator.
The O&M manual shall include the following:
a. General description of the treatment process;
b. A detailed description of equipment;
c. Process flow diagram;
d. Piping and instrumentation diagrams;
e. Certified drawings for equipment components and equipment layout;
f. Practical operating procedures including performance testing, influent, and effluent concentrations,
and trend analysis of influent;
g. A complete set of fully updated and annotated piping and instrument diagrams, process flow diagrams,
instrument indexes, control ladder logic diagrams, description of controls, alarms, interlocks, instrument
interface, and maintenance procedures;
h. Specialty items such as type of oil and grease, desiccants, tools, analytical instruments, etc.;
i. Initial startup procedures;
j. Emergency and scheduled shutdown procedures;
k. Monitoring and quality control, spill controls;
l. Equipment specifications;
m. A list of modes of failure for each piece of equipment;
n. Fault/failure analysis, and trouble shooting guide;
o. List of spare parts;
p. Process safety and protective equipment requirements; and
q. Record keeping (electronic or other) requirements.
In order to plan all the inspection and maintenance operations required for plant operation, a maintenance schedule
shall be provided. The maintenance schedule must include:
a. Scheduled maintenance procedure for each piece of equipment;
b. Sensor and measurement device calibration frequency;
c. Periodic reports regarding consumption of chemicals such as acid, caustic, polymer, and coagulants;
d. Electronic or other recording data;
e. Personnel training requirements;
f. The time required for each maintenance task;
g. Equipment shutdown and lock and tag requirements during maintenance/repair; and
h. Mothballing and preservation procedures for equipment layaway.
The entire schedule and the results of each task shall be recorded for future analysis. Other items shall be
included as follows:
a. Spare parts list with suppliers and costs;
b. Plant utility requirements such as electrical, air, drinking water, service water, telephone, and
sewer;
c. Detailed safety procedures for chemical handling; and
d. Name, address, and telephone number of technical personnel to contact in case of an emergency related
to the treatment system.
Final acceptance of the P/C/F system will not be given until these documents have been supplied, reviewed, and
approved.
3.5.7 System Operation by Contractor
The first period of operation shall not be initiated until after the Contractor has successful completed all
work and received written approval from the Contracting Officer. The Contractor shall continue to operate the
system for a period of [30 days] [6 months] [1 year] [_____]. The Contractor shall be responsible for operations,
process monitoring, maintenance, chemical testing, and record keeping during operation in conformance with this
specification.
-- End of Section --