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25A-185 (12) a APPENDIX 6.7 PLUMBING SYSTEMS SPECIFICATION, SPE-16040-15400 HVAC PIPING SPECIFICATION, SPE-16040-15500 REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 20 SPE-16040-14002 JA16040\Specs\Final\14002-Rev A.doc COMPRESSED AIR MAIN BY UTILITY CONTRACTOR -CA CAS CONNECT TO VALVE SUPPLIED BY UTILITY CONTRACTOR BY EQUIPMENT INSTALLATION CONTRACTOR EQUIPMENT INSTALLATION CONTRACTOR[-� TO TIE-INTO EQUIPMENT 0 QUICK DISCONNECT 3'-0" FINISHED FLOOR TYPICAL FOR 8 DROPS MiiiAteMaid COMPANY A 12/20/ NEW POUCH LINES ISSUED FOR BID NEW MA88ACHUBE M REV.1 DATE SI CHICD APWD PURPOSE OF ISSUE/REVISION PLUMBING COMPRESSED AIR TIE-IN PFI DESIGN, P . C . PIPING PRPLAN � 960 FEDERAL STREET, BOSTON, MA 1 8 1 -Q 16040 SKFOO FlLEJ:: 16040 DWGS PIAIB SKP-00 APPENDIX 6.6 COMPRESSED AIR TIE-IN SKETCH SKP-00 REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 19 SPE-16040-14002 J:\16040\Specs\Final\14002-Rev A.doc Cl) O O CoN 0 , MN ti0 ~O O o 6 c3 (n Z O W p Z p (D ai 0- CL 0 U CU (n V- O 0 co M CO ti M O Z W co }• O Co d0. � 0 � � O� m o 0 0 N N N I co LL Z O Y Q 'It 'It It NNNd' It '-t O 000000000 ~ 0 Z — NM - - N — M `tt > c z O 3 LO LO Sri co CD L6 Sri Lo' U CO Co CD CO CO 00000 090c:> 000000 O ui ti Li Li ti u.. Li Li LL m CV CV CV CV CV CV CV CV CV w CD CO CO CO CO CO CO CO CO 00) 0) 00000m = L L L S L S L L .0 a aa � aaa. � a. a .a C ca O) O ff co c o � IULU F- m UaLL- 0 0 L U O O o O O ti � � N d � 1` O0O O w- r- N � N N r- z o z o z � W t p p � LL N a) IL CL Cn 04 0) O � 00 O M ti C70 M 0 O z U- CC) O I` O N O O O CO Cn ct 47' M r O z W � '� � It Q M J Q 0 0 0 0 0 0 Q _ N M q r- N f- } m . . U. U. U. U. m c LL 3 0 U-) W W O O m O o 0 0 0 0 u1 p u_ LL u_ ti ii ti Y N N N N N N Q co COOCflCOco d d' 'IT 17 ltI ~ CA CA CD O) Cn O W N �. N z W. O rna cu cu O L o m O a) U) W _ _ O L V L o (1) C - O U C m 5.c Q O O p Q C J 06 m L L 3 O (D O U) a) cm U a� L o U o _°—C H O C 0 o L (D W U Q L a) cn N o .0 v ccn (n o = 0 0 0 N M rno iiU � QUU � c a co N M 'It LA O y0. N. CU cn o o a aaaIL n CL � mz APPENDIX 6.5 GEBO CONVEYOR TAKE-OFF BY PHASE/ SYSTEM SUMMARYS REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 18 SPE-16040-14002 J:\16040\Specs\Final\14002-Rev A.doc TECHNICAL SPECIFICATIONS November 9,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO.G99462 EQUIPMENT INSTALLATION Page 7 of 36 PACKAGING LINE GENERAL CONDITIONS/JOB SITE OVERHEAD LABOR LABOR MATERIAL TOTAL HOURS COST COSTS COST A total of four(4)pouch ink Coders(Video Jet, Dwg.9-462-F-067 not available yet).Two Are Installed at each Geyssel infeed&Two at lid closer discharge. PFI Support drawings(Dwg 9-462-F-068, Sheet 1 of 2 not available et Weber Marking Case Labeler,5100 Series(Dwg.9-462-F-069,not available et Contractor to Fabricate or provide)and Install -Fabricate four 4 Video Jet stand's(Drawing N/A Misc.Steel Material&Installation 1. Overhead protection Filler Feeder chute 2. PVC tubing from conveyors to drains 3. Miscellaneous Start-up Costs Allowance 500 10,000.00 SUBTOTAL(Equipment Installation TOTAL NOTE: The above Quotation Breakdown is required to be completed as part of Quotation Procedures. Failure to complete this form could result in rejection of quotation. Contractor's Name Date END O o0 0 ` TECHNICAL SPECIFICATIONS November 9,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO. G99462 EQUIPMENT INSTALLATION Page 6 of 36 PACKAGING LINE 2. CONSTRUCTION PACKAGE QUOTATION BREAKDOWN PACKAGING EQUIPMENT LINE A & B INSTALLATION GENERAL CONDITIONS/JOB SITE OVERHEAD LABOR LABOR MATERIAL TOTAL HOURS COST COSTS COST 1. Packaging Equipment Installation Two 2 BOSSAR Fillers GMB-4000 Refer. Dwg 9-462-F-050 Two 2 GEBO USA Fillers Feeder Refer. Dwg 9-462-F-051 Two(2) Hi Speed cup check weigher complete with Four 4 rejecters Refer.Dwg 9-462-F-052 One(1)Arrowhead Cooler&Sterilization Unit(Refer. Dwg 9-462-F- 053 Two(2)GEYSSEL Straw Applicator include two Rejecters and chutes. Refer. Dwg 9-462-F-054 Two(2) CERMEX Case Former F282 Refer. Dwg 9-462-F-055 Line A& 9-462-FO58 Line B Two(2)CERMEX AN90 Packer (Refer. Dwg 9-462-F-056Line A) and (Refer. Dwg 9-462-F-059 Line B Two(2)CERMEX C313 Lid Closer (Refer. Dwg 9-462-F-057 Line A)and(Refer. Dwg 9-462-F-060 Line B Two(2) Hi Speed pre-pack check weigher,included with 00 Four(4)rejecters(Refer. Dwg 9-462-F-061) O One rejecter will be installed at each Lid Closer discharge. O Install four(4)S/S GEBO Gravity Roller.(Two at pre-pack check weigher& two at Lid Closer discharge). ___ ��l One(1)PMI srid-25 Shrink Bundler (Refer. Dwg 9-462-062) One 1 PAI 4000 Palletizer Refer. Dwg 9-462-F-063 One(1) ITW Mima, King Cobra Strech Wrapper(Refer.Dwg 9-462- F-064 GEBO Cup Conveyor Refer. Dwg 9-462-F-065, Sheet 1 to 4 GEBO pre-pack&CaseConveyor (Refer. Dwg 9-462-F-066, Sheet 1 to 2 APPENDIX 6.4 QUOTATION FORMAT REV. A PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 17 SPE-16040-14002 J:\16040\Specs\Final\14002-Rev A.doc TECHNICAL SPECIFICATIONS August 25,2000 a G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO.G99061 EQUIPMENT INSTALLATION Page 26 of 36 PACKAGING LINE RUNNING INSPECTION CASE CONVEYOR CHECK SHEET Inspector Conveyor Description Conveyor Number Date Construction Status Inspection Item Complete Incomplete 1. Belt is Running in Correct Direction 2. Belt does not Bind 3. Rollers Turn 4. Gearbox Seals do not Leak 5. Bearings and Shafts Tight 6. Stop Belt Tension Properly Set 7. Conveyor Transition Elevation Set Correctly 8. Sprockets Tight 9. Drive Chain not Binding 10. Rollers and Wheels are Free to Turn 11. No Pinch Points / 12. Divert Arms Work Properly 13. Belt Brakes Function Properly 14. Conveyor Legs Tight 15. No Excessive Vibration or Noise 16. Belt Splicing is Correct 17. Photo eyes Properly Installed &Aligned 18. All Rollers Properly Drive Cases 19. Visual Check For Bent Shafts & Misalignment 20. Round Belt Live Roller Finger Protection Guards in Place 21: Seed is Correct and Data Recorded Contractor Correction Comments: TECHNICAL SPECIFICATIONS August 25,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO. G INC. EQUIPMENT INSTALLATION Page 25 of 36 PACKAGING LINE RUNNING INSPECTION CHAIN CONVEYOR CHECK SHEET Inspector Conveyor Description Conveyor Number Date Construction Status Inspection Item Complete Incomplet e 1. Chain Running in Correct Direction 2. Chain Run In is Complete 3. Broken Link Inspection Complete 4. Bent Link Inspection Complete 5. Gearbox Seals Leak Inspection Complete 6. Gearbox Vent Plus Installed if needed 7. Bearings and Shafts Tight 8. Chain Tracks Straight 9. No Chain Binding 10. No Conveyor Excessive Noise 11. Transfer Chain to Chain Interface Dead Level 12. Chain to Chain Interface Dead Level 13. Dead Plates are Level &at the Correct Transfer Elevation 14. Drive Chain not Binding 15. Conveyor Speed Matches Design Speed 16. Divider Point to Guide Rail Relief Correct 17. Wear Strips Don't Pinch Chain 18. Soap or Water Sprays Workin Properly 19. Chain Return Alignment is Correct and No Interference 20. Drip Pans Protecting Conveyor Below 21. Conveyor Guide Rails Tight/Spaced Correctly 22. Conveyor Legs Tight 23. Record Sprocket and Gearbox Size Changes inside Guard Cover 24. In Line Prox Switches Properly Installed &Aligned Contractor Correction Comments: TECHNICAL SPECIFICATIONS August 25,2000 c G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO. G99061 EQUIPMENT INSTALLATION Page 24 of 36 PACKAGING LINE CONSTRUCTION INSPECTION CASE CONVEYOR CHECK SHEET Inspector Conveyor Description Conveyor Number Date Construction Status Inspection Item Complete Incomplete 1. Infeed Elevation Correct 2. Discharge Elevation Correct 3. Bearings Lubricated 4. Gearbox Filled 5. Bearings and Shafts Tight 6. Correct Belt Installed and Lacing is Correct 7. Chain Tension Properly Set 8. Conveyor Transition Elevation Properly Set 9. Sprockets Tight 10. Drive Chain and Guard Installed 11. Rollers are Free to Turn 12. Conveyor is Level Side to Side �. 13. Guide Rail Splice Installed per the Drawings 14. Guide Rail Downstream Rail Recessed 15. Guide Rail Splice Transition Smooth, Flat&. Deburred 16. . Conveyor Guide Rails Correct width per the Drawings 17. Guide Rails Parallel Vertical &Correct width 18. Guide Rails Tight &at Correct Elevation 19. Conveyor Le s Tight' 20. Conveyor to Machine Elevation Correct 21. Conveyor Support and Braces Installed Per Drawings 22. Conveyor Properly Anchored to the Floor 23. No Conduit Piping, Leg Interference with Cases 24. Operation Platforms if required) Installed 25. Underside Personnel Guard Installed TECHNICAL SPECIFICATIONS August 25,2000 c G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO.G99061 EQUIPMENT INSTALLATION Page 23 of 36 PACKAGING LINE 26. End Caps& Finger Guards Installed 27. Catenary Guard Installed 28. Conveyor is Properly Cleaned 29. Operation Platforms if required) are Installed 30. Proper Drive Train Tension Set if applicable) Contractor Correction Comments: �O c' v TECHNICAL SPECIFICATIONS August 25, 2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO. G99061 EQUIPMENT INSTALLATION Page 22 of 36 PACKAGING LINE CONSTRUCTION INSPECTION CHAIN (CUP) CONVEYOR CHECK SHEET Inspector Conveyor Description Conveyor Number Date Construction Status Inspection Item Complete Incomplete 1. Infeed Elevation 2. Discharge Elevation 3. Bearings Lubricated 4. Gearbox Filled . 5. Bearings and Shafts Tight 6. Correct Chain Installed 7. Chain Installed in Correct Direction 8. Chain to Chain Interface Dead Level 9. Transfer Chain to Chain Interface Dead Level 10. Dead Plates are Level &at the Correct Transfer Elevation 11. Sprockets Tight 12. Drive Chain Installed and Guard Closed 13. Wear Strip S lice Installed per Drawings 14. Wear Strip Splice Transition Smooth and Flat 15. Wear Strips Don't Pinch Chain 16. Guide Rail Splice Installed per the Drawings. 17. Guide Rail Splice Transition Smooth and Flat 18. Conveyor Guide Rails Correct width per the Drawings 19. Conveyor Guide.Rails Parallel 20. Conveyor Guide Rails Tight 21. Conveyor Legs Tight 22. Conveyor to Machine Elevation Correct 23. Conveyor to Machine Elevation Dead Level 24. Conveyor Properly Anchored to the Floor APPENDIX 6.3 INSPECTION CHECK SHEETS REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 16 SPE-16040-14002 J:\16040\Specs\Final\14002-Rev A.doc Fencing Gate sue,. Fencing Gate are hinged to support legs. The position of the gate is shown in the mechanical layout of the _. machine. Align the reflector on the gate to the respective safety photo eye. Then lock the pin on the gate to oa` the floor. _. 14 Air Attachment Do the following to the FRL (fil ter-regulator-lubricator)located on Leg 1. �p 1. Remove the filler plug. 2. Fill the lubricator with SAE#10 oil;replace the plug. 3. Attach the air supply to the FRL. `, Control Console 1. Place the console in the proper location as shown in the machine layout drawing and anchor it rw to the floor. 2. Bring the sealtite and j-box to the support leg 9 1. Install the j-box to the leg at Premark location. 3. Bring the wires from mainframe, heat seal unit or cut/clamp unit,brush assembly,through the ° leg#I to j-box. Connect%wires to respective terminal strips to the matching numbers. • 4. Bring the sealtite for converised system to center (process) conveyor j-box. Connect the Nvire to matching numbcrs. 5. Connect the electrical power to the control console. Do not attempt to power up to the '. system. !!WARNING!! Powering up the system without the service representative's assistance may void the warranty and cause damage to the system. 42 D6 1 Hr Installation/Conveyors T ' First Infeed Conveyor I. Put the conveyor in place and bolt it to the center conveyor. 2. Connect the wires to the center conveyor by joining the matching plugs. 3. Put the plugs inside the wiring box and bolt the sealtite connector plate to the side of the box. • Second Infeed Conveyor �. 1. Put the conveyor in place and bolt it to the first infeed conveyor. : 2. Connect the wires to the first infeed conveyor by joining the matching plugs. 3. Put the plugs inside the iviring tube and bolt the sealtite connector plate to the tube. 3' • Process Conveyor 1. Put the conveyors in place. Make sure the center of the conveyor match to center of the rotating arm shaft. ' 2. Connect the wires from j-box of the conveyor to the console by joining the matching plugs. .3. Put the plug inside the wiring box and bolt the sealtite connector plate to the side of the box. ` • First Outfeed Conveyor I. Put the conveyor in place and bolt it to the center conveyor. ' 2. Connect the wires to the center conveyor by joining the matching plugs. 3. Put the plugs inside the wiring box and bolt the sealtite connector plate to the side of the box. • Second Outfeed Conveyor I Put the conveyor in place and bolt it to the first outfeed conveyor. ' 2. Connect the wires to the first Outfeed conveyor by joining the matching plugs. 3. Put the plugs inside the wiring tube and bolt the sealtite connector plate to the tube. lei acJ J ANCHOR ALL OF THE CONVEYORS TO THE FLOOR f D5 k-4, J aa.s< WVwlvKMitt1 and FKESTKk:i4—n �. 1. Unbolt the downright from the skid. C 2. Clip the wire tic securing the chain to the top of the downright. 3. Slide the downright through the prestretch enough to expose the chain tensioner assembly. 4. Remove the chain tensioner assembly- by first removing the two bolts located at the bottom of the LL downright. r S. Slide the downright so the prestretch is at the "bottom"of the downright. . 6. Rotate the rotor arm away from the column stand (parallel with the mainframe). Remove the access plate located on the end of the rotor arm. 7. Manually lift the downright to a vertical position using care that the prestretch does not crash to the floor. Remove the four bolts from the end of the rotor arm. S. Mount the downright up to the rotor arm using the lifting fixture. The boles in the top mounting plate of the downright will fit perfectly over the two pins in the lifting fixture. Refer to the 02- Drawing of this manual for proper mounting position of the prestretch. The red hoop must be in the forward position when the arm moves in a clockwise direction. 9. Insert two of the 112-13 x 3" long bolts through the two holes of the plate of the downright closest to the center of the arm. Loosely attach the appropriate washers and nuts. 10. Remove the lifting fixture from the downright plate. Push the bottom of the downright toward the d center of the arm in order to get the chain over the sprocket. 11. Hook the chain onto the sprocket located inside the rotor arm; replace the access plate. (see Figure 8.) 12. Bolt the downright to the rotor arm using the 112" bolts and lock washers provided. First insert y� the two 112-13 x 1 112" bolts into the two holes towards the end of the arm. Then remove the two long bolts and replace with the correct length bolts. The bottom, trailing edge of the prestretch , must be 20.81" (20 13!16") from '0'elevation plane(floor). (See drawing in:viachine Leveling L Procedure section.) 13. Connect the 16 pin cable harness plug extending from the downright to the matching socket outside the arm: also connect the air cube from the downright to the socket on the arm. (see Figure 9.) +�d 14. Bolt the reflector assembly to the bottom of the downright. - vro. — �tnfnframc 0 . O.� Rotor arm 0 O W, Rotor arm 16 t'In Quick discon1wrsprocket Chaln able harnDownri=ht Dowfar{=ht a ev dl Figure 8 D3 ^� .v f�'�l 5upport Legs 1. Unbolt the support legs from the pallet. 2. Lift the support legs from the pallet and place them in their approximate final positions. Forks Mainframe , '' ' Rotor Arm ; F , j Flange Connections as a• �•_ � �•J� I I Mq I � I Yfi.� Support le; 't 1 f x� `C.'ys i Support lee f I x _ hn I ioI j,i tis3t I i t$E •s �� ,� •Ehz3 �$sp Forklift truck Figure 3 i<fainframe 1. Bring the forklift near the pallet and gently insert the forks under the Mainframe. Secure the Mainframe to the forklift with a security strap. Unbolt the Mainframe from the pallet and lift the Mainframe as shown in Figure 3. *+ 2. Drive forklift between Support Less and suspend the M ainframe just above flange connections. 3. Align the leg supports under the ylainframe and lo%vtr the forks just enough to insert and arach the connecting bolts. -lghten the bolts per the bolt torque chart supplied in the manual 4. Now the entire unit can be lifted and moved to it's exact permanent Location. S. Using thejack bolts supplied. level the titainframe. This leveling procedure is very important as the Conveyors and Heat Seat levels.vilt be determined from this. The Mainframe can be leveled by releasing the Rotor Arm and checking «ith a bubble Icvc! in Four opposite positions. Note: Before making any adjustments, be sure to consider that the down rightlprestretch ' carriage will need to clear the highest point on the conveyor by 114". iJ 6. anchor the Support Legs according to the torque chart supplied in the manuals. D2 ? » I& asE � 4-41. rat Installation The system is shipped on skids. Before you remove the skids from the truck, inspect for possible damage. If you detect, or even suspect any damage: 1. Make a note on the bill of lading before you accept the machine. 2. Immediately file a claim with the carrier and inform your service representative. Note: Photographs of the damaged area may help to expidate your claim. Unpacking and Preparation 1. Remove the skids from the truck. 2. Remove all of the straps except the straps that attach the rotating arm to the mainframe. They will prevent the arm from rotating during installation. Preassembly Considerations i. Electrical requirements: Refer to the electrical schematic provided. 2. Pneumatic requirements: Dry,clean, lubricated compressed air, 80 PSI(min) at 3 CFM 3. The Heat Seal or Cut/Clamp unit, which ever is specific to your machine,will be placed on the side of the conveyor opposite the chain guard. 4. The bottom of the doimright assembly should clear the conveyor by one to four inches. h' 5. The rotating arm should rotate parollel to the surface of the conveyor. 6. The load should feed along the conveyor as close as possible to the edge opposite the chain guard. 4.0 7. The main drive output shaft must be centered over the load when the installation of the system is complete. This is usually not over the centerline of the wrap conveyor. ` 4' !!WARNING!! DO NOT POWER UP the system without your service re- presentative present. Powering up the system without the representative's assistance may void the warranty and cause damage to the machine. "CAUTION!! It is recommended that the machine and conveyors be bolted to the floor ONLY AFTER optimum operational conditions have been achieved. A few practice runs are advisable to nllow for settling _ and to determine if changes are required. / VN DI per Y'CI o•a 14U.. SECTION D e �� V17 General Safety instructions ' Note: Failure to follow these instructions could result in severe injury. General Considerations i 1. Wear safety glasses that conform to ANSI Standard Z87.1 ` 2. Read the entire manual before operating or servicing this equipment. 3. Only trained personnel should operate or service this equipment. 4. Keep the work area uncluttered and well lighted. Signs ' 1. Read ali of the signs on the machine. '2. Do not remove any of the signs. 3. Replace all missing or damaged signs. Operating your Machine Inspect the machine daily for unsafe conditions; replace any worn or broken parts. 2. Be sure that all guards are in place and all safety devices are working property. Do not operate the machine with any safety devices removed. 3. Stretch film produces static electricity during the wrap cycle. Keep away from the film as it is being applied to the load. Your hair or any loose clothing can be attracted to the film. • Never operate this machine in an explosive atmosphere. 4. Keep all unauthorized personnel away from the machine operating area. 3. When you are finished operating the machine, tarn o;jall power. Servicing your Machine 1. Be sure to turn off and lock out all electrical power. 2. Do not stand or walk on the conveyors to service the machine. 3. Follow the maintenance instructions in this manual. 4. Use the correct tools to repair the machine. 5. Never adjust or repair moving parts unless otherwise noted in the manual. 9'L Additional Considerations 1. To ensure groper operation of the machine. use the specified electric power source. rwi 2. Do not exceed our recommended performance limitations. 3. Do not attempt to alter the machine design without our written approval. �. 4. Safety instructions are located throughout this manual to warn the operator and service personnels about potentially hazardous situations. 5. Keep this manual by the machine for referral. 6. When cutting steel or plastic strapping protective glasses and gloves must be worn Maintain one hand upon the section of strap that could whiplash toward you. iAr s� ii Pd � v'z' eN ILL" About this Manual ' This manual describes the automatic overhead sprial wrapping system. It explains the installation,operation, maintenance procedures and basic troubleshooting for a STANDARD SYSTEM. Ifyour specific machine ' " was purchased with any options,i.e.Cut,Clamp,Brush,all instructional and maintenance information will also be included with this manual. This information will be included in sections of the manual where any procedure differs from the STANDARD SYSTEM, Before You Begin Be sure all operators and maintenance personnel read and understand this manual. If you have arty ques- Jt$< lions regarding this machine,contact your service representative. u - When You C all Please have the model and the serial number of your machine available. 77-4 How to Use the Bills of Materials: Shown on the next page is a SAMPLE BILL OF MATERIALS and description of its components. All STANDARD BILLS will have the identification number ending in 9999. Should your machine come with any special options,the ASSEMBLY IDENTIFICATIONNUVII3ER would have a OOXX suffix,i.e. 24]TTXOOOI/OPTION;241TTX9999/STANDARD. Establishing a series ofadditions and deletions ; creates the OPTION BILL OF MATERIAL. In certain instances they can also be all additions or dele- 1A' tions. Whatever sequence number is effected on the STANDARD BILL OF MATERIALS will appear as the sequence number of the part number that has been optioned out. Seethe example on the next page. The OPTION BILLS OF MATERIALS are found directly behind the STANDARD BILL OF MATE- RIAL. The above instrtuctions are used as a divider between the STANDARD BILL OF MATERIAL and THE OPTION BILL OF MATERIAL and will always be printed on colored paper. DO NOT RE- MOVE ANY OF THE COLORED PAGES OR THE BILLS THAT FOLLOW THEM AS THEY PERTAIN TO ANY OPTIONS THAT ARE ON YOUR MACHL�TE AND ARE IMPORTANT �+ WHEN NEEDING TO ORDER SPARE PARTS. AN *If your system is conveyorless, ignore any references to conveyors in this manual, �r i�7 Y`Q WARRANTY The Manufacturer warrants this machinery to be free from defects in material and workmanship tinder normal use and service and will replace at our plant free of charge any parts thereof which shall,within two years from the date hereof,be demonstrated to be defective. It shall be the obligation of the purchaser, after notification to and approval by the Manufacturer, to forward such pans, with transportation and/or mailing charges prepaid, to the Manufacturer or its designated authorized representative. Any parts or components of the machinery which prove upon examination to be defective will be replaced by us. This is in substitution for all other remedies and rights for defects in materials and ` workmanship. This Warranty extends only to the original purchaser from Manufacturer and is not transferable- Repairs made by anyone + other than Manttfacmmr's authorized factory representative shall render this Warranty void.This Warranty does not cover damage resulting from accidents,alteration,misuseor abuse,acts of God,orfailure to follow proper operating instructions and only covers defects in materials and workmanship. Damage caused in transportation or mailing is not coveted by this . Warranty. MANUFACTURER MAKES NO WARRANTY OF MERCHANTABILITY AND NO WARRANTY OF FrINNESS FOR � ANY PARTICULAR PURPOSE. NOR DOES IT `LAKE ANY WARRAN'IY, EXPRESS OR NIPLIED, OF ANY hIATURE WEIATSOEVER WITH RESPECT TO PRODUCTS SOLD BY�Wv-UFACTURER OR THE USE THEREOF 'IL EXCEPT AS IS SPECIFICALLY SET FORTH ON THE FACE HEREOF EVEN THOUGH IT MAY HAVE BEEN N7=GLIGENT. MANUFACTURER SHALL IN NO EVENT BE LIABLE FOR DIRECT, INDIRECT, SPECIAL. INCIDENTAL,CONSEQLEVITAL OR PENAL DA.`LAGES_ MANGrACIURER MAKES NO WARRANTY OF ANY KIND,EITHER EXPRESS OR RAPLIED,TO CONSLtifERS AS THAT TERM IS DEFINED IN THE MAGNUSON- MOSS WARRANTY-FEDERAL TRADE COiv4vfISSION L12ROVE,\,fE`N ACT. First Edition (February, 1994) - The information in this document has been chec[ed for accuracy. However,to increase performance and reliability, we periodically make changes to our products. Therefore,we do not assume any liability for the application of the information in this manual or for the use of the products described therein. Changes will be reported in subsequent revisions. Do not copy this manual. Additional copies may be purchased upon request. td f� Z Copyright 1994 Dkt. 60 KCOB FLA.PNI5 - 02/11191 arJ v 1J N av King Cobra Automatic Overhead Spiral Wrapping System with or without Conveyors + ,U' Owner's Manual Insure best results from your King Cobra Stretch Wrapper use 41L. rt- 1T[/VYMiMa STRETCH FILM Call: 1 -800-662-6462 Stretch your profits with the high quality wrapping films designed # specifically for your ITW Mima Stretch Wrap system. /Twmima 10101 NW 67m Street - t Tamarac,FL 33321 ' Tel.:(951)724-7788 FAX: (954)724-0968 - aJ P'44 rrrt g( V TECHNICAL SPECIFICATIONS August 25,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO.G99061 EQUIPMENT INSTALLATION Page 36 of 36 PACKAGING LINE ANNEXE L INSTALLATION PROCEDURE ITW MIMA KING COBRA STRECH WRAPPER Electrical reconnection procedures The machines are broken down by individual components for shipping and will require the following assembly (from an electrical perspective): Operator Remote Attach remote operator panel, located on top opposite of the main control panel side.of palletizer including bolting 16" x 24" slant face console to the palletizer via pre-tapped mounting holes using bolts provided. Attach (1) length of 3/4" flex and (1) blue hose for data highway to Touchscreen to the base of console and reconnect no more than 40 wires to terminal strip using labels provided by PAI. Outfeed Attach (1) length of 1-1/4" flex from elevator end of palletizer to the junction box located on the side of full pallet conveyor and attach to terminal strip provided in junction box. Belt Infeed Wires for the belt infeed will have to be connected to terminal strip in a junction box on top of the pallet load station area of the palletizer. Note All equipment is assembled and termination points are tested at the factory prior to shipment. All disconnection points are wired temporary these wires are longer than necessary. Upon reconnection wires must be cut to length, stripped and labeled using numbers provided by PAI. TECHNICAL SPECIFICATIONS November 9,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO.G99462 EQUIPMENT INSTALLATION Page 35 of 36 PACKAGING LINE ANNEX K INSTALLATION PROCEDURE PAI PALLETIZER INDEX side seal•21 splice film•9 A H START•4,5 air supply•7 hold down springs 20 T B j teflon cloth• 11 teflon insert• 11 back seal open•20 Installation•7 temperature controller 16 belt conveyor• 19 temperature for operation•20 bouncing of the seal bars 10 thermocouple• 10, 13 K trapped air inside•20 tubular heating elements• 13 C knife blade• 10 W Central Lubrication•7 circuit breaker• 16 M cold bar• 11 Weak seals•20 16 width of desired low density CYCLE START- 1 CYCLE STOP• main fused disconnect 16 polyethylene film 1 maintenance• 1 MANUAL SEAL•4 D N damper• 13 - dancer bars•9 noise• 13 dancer system•5 drive chains• 19 \�U dwell time• 12,20 E poor seals 10 POWER ON• 16 electric supply•7 EMERGENCY• 16 R Erratic ram•20 excessive film•20 regulator• 18 Repair kits• 18 F rubber strip• 11 Film feed rollers•5 S film roll diameter•8 Film tension•9,20 film tension roller•9 seal bar• flow control• 18 Seal opening• 10 FRL• n seal temperature•20 shock absorber• 10 shrink tunnel 13 shut off valve 18 1 PACKAGING MACHINES INTERNATIONAL , INC . - Clean most chain drives twice a year. Lightly oil with SAE 30. Do not over tighten. - Twice a shift, wipe the hot knife off (switch machine off first). Using a dry soft cloth and not some harsh product that will scratch the teflon cover. The excess film build-up must be removed from the cover. If you wish to extend the life of the hot knife. - The tunnel should be checked once per shift and all film pieces removed. This is essential in order to ensure correct air flow around the product and to prevent damage to the rollers and the belt conveying system. 22 PACKAGING MACHINES INTERNATIONAL, INC. - correct and the seal temperature may have to be edu` 'I �1�C'� e dwell time. It is also possible that the film gauge ight specification. Sporadic seal problems that open on both the fron and back of the sleeve could be caused by the seal carrier alignment being offset, seal jaws that do not meet and/or shock absorbers that are worn or out of position. The seal bar might also be out of alignment or may be warped or offset over its length. The air supply pressure should always be checked when following up on seal problems. The machine should be operating when the air pressure is checked, to ensure that a consistent supply is available. The film supplied to the top and the bottom film feed systems should be identical, and if not, a different set of temperatures and dwell times will be required. Film gauge and consistency is of the utmost importance for a good repetitive seal. Where side seal closure methods are used, ensure that the product is not too close to the mechanism, which could make the lower film "stand up" causing stress and resulting is seal/weld breakage. On single roll holder systems, ensure that the low film alarm lever is removed before replacing the film roll in order not to break the level. Twin roll holders use a photocell alert. A central lubrication system is available. Be sure to read the appropriate pages enclosed with this manual to ensure the correct operation of this system. Lubricate once per week. Where no central lubrication system is supplied, the following areas require lubrication: - Ball and ball bushing bearings, once every two months, add general purpose grease to each bearing and bushing block. - Oilite bearings, once per month add a few drops of 20 weight non-detergent oil to each bearing on the film feed pinch rollers, conveyor idler pulleys, air cylinder clevis joints and all pivot joints. - Tunnel blower shaft bearings, once a month, lubricate with lubriplate #1200-2 or equal. - Worm gear boxes, every six months lubricate with AGMA #8 comp. non-corrosive worm gear oil. - Bevel gear drives, every six months lubricate with SAE 40. - Eurodrive drives, every six months lubricate with approximately 21 viscosity cST. gear oil, AGMA #4, mobile gear #640 or equal. 21 P A C K A G I N G M A C H I N E S I N T E R N A T I O N A L , INC . :Chapter TROUBLESHOO ING If, when the PMI bundler is in position, the air supply pressure gauge drops by 15 PSI or more, a surge tank may be required. Erratic ram or seal bar operation could be caused by low or wet air pressure. Inspect the pneumatic system. If an excessive amount of film is unwound, and the problem is not the dancer low tension film system, then the film feed motor may not be working. Sometimes the film rolls turn but slip on the film. This requires that the upper pinch rollers be checked to ensure that it is moving freely on its guides at each end. Also, check that the hold down springs at each end of the upper pinch roller are compressed to a-height around 1'/25mm. Excessive pressure can cause slippage. The seal bar does not have a standard fixed temperature for operation. That temperature depends on the thickness of the film being used and the speed of the machine. For the first time trial run of a certain film thickness and speed, start with an operation temperature of 350 degrees Fahrenheit (177 degrees Centigrade). If products are,detected leaving the tunnel with the back seal open or loose, ensure that the tunnel temperatures are reduced to increase the speed of the conveyor into the tunnel. If this problem persists remove a product from the line before it enters the tunnel and test the effectiveness of the seal. On totally enclosed products, the trapped air inside the bundle can also weaken this back seal. Perforated film which allows the air to escape might solve this problem. Weak seals are caused by incorrectly threaded film or incorrect film tension. Sometimes on high speed units, the product could be stopping too close to the seal bar. In this case, increase the time delay controlling the stopping position of the product. Where the seal pulls open on the front of the product, verify that the air cool jets on the hot knife are working and aligned. Observe that the film tension is 20 PACKAGING MACHINES INTERNATIONAL, INC . Chapter CONVEYORS All belt conveyor pulleys on PMI bundlers are crowned or V grooved to assist with belt tracking. A chain driven conveyor has one or more sprockets attached to a roller and is driven by roller chain. For single strand type drives a chain take up is provided. Rollers should all be kept clean and oiled periodically. The roller flight or low tension accumulating roller conveyors have free turning rollers. The shafts are supported at each end by chains. If a product is stopped while the conveyor is running, the rollers roll freely under the product without causing any friction or damage. Automatic surge acceleration is designed to separate products and is created by placing a rubber friction pad against the bottom of the roller flight rollers, causing the rollers to roll in a forward position. Belt driven live roller conveyors carry the product on stationary rollers which are turned by a belt passing beneath them. The belt moves in the opposite direction from the product. The conveyor chains and the drive chains are to be tightened after the first 20 hours of operation. Also the tension of the main drive chain is to be checked at least once per month. The table top chain used is Rexnord Model LF821, which is made of a low friction thermoplastic. 19 PACKAGING MACHINES INTERNATIONAL , INC . Chapter PNEUMATIC CO The PMI bundler has a single common three way safety shut off valve which automatically bleeds off trapped air when shut off. This valve may be locked during maintenance. The system is inside the frame. The shut off valve supplies a filter/regulator/lubricator, which in turn supplies the manifold mounted valve bank assembly. The regulator has a toggle type drain valve. This drain valve may be used whenever the bowl reaches one third full. All valves are of the single solenoid type which return to their home position when the power is switched on. The flow control screw controls the speed with which the cylinder returns to its home position. A screw on the opposite side controls the speed in the opposite direction. Do not set the speed so that the mechanism bounces against the end stops. Sandwich type regulators are mounted between flow controls and manifold where it is desired to operate a valve at reduced pressure. Repair kits are available for both valves and cylinders. Rodless air cylinders are used for long stroke applications. These cylinders have built in adjustable air cushions at each end. Rodless cylinders require extra lubrication. The solenoid valves can be as many as required. 18 PACKAGING MACHINES INTERNATIONAL , INC . �D 11 J) O� 17 PACKAGING MACHINES INTERNATIONAL , INC . Ghaptier ELECTRICAL CONTROLS Each bundler is provided with a wiring diagram in universal ladder form. All PMI bundlers are provided with a main fused disconnect or circuit breaker through the door interlock. There are one or more transformers to provide 115 volt AC to the control circuit and seal heaters. The red "EMERGENCY" control button shuts off ALL electric power and air supply. The "ON" button energizes the tunnel motors, the seal heaters, manual seal close circuit and the drive motor. The bundler will.not run in the event of a motor overload. The "CYCLE START" and the `CYCLE STOP" buttons control the operations of the bundler. Pushing the "CYCLE STOP" button will cause most, but not necessarily all, of the air operated devices to try to return to their home position. The seal bar will always return to its timed cycle. The seal bar has a safety feature in that if the jaws fail to close due to an object being in the way, the seal jaws will open. An Allen-Bradley standard programmable controller is used. Functional capabilities include relay logic, timers, counters, sequencers and shift registers. Each seal bar and each shrink tunnel is provided with its own temperature controller and thermocouple. The temperature controller maintains the set point temperature by cycling on and off. At the back of this manual is a set of important electrical drawings and other vendor information. 16 PACKAGING MACHINES INTERNATIONAL , INC . �o 0a Beplacmg 11x HztngE� WARNING Before any work is started on the machine, especially on electrical parts the main disconnect switch should be switched off and padlocked to secure against it being accidentally switched on again. Remove the cover plate in the heater area. Carefully pull out the heater element assembly. BE CAREFUL, the assembly may still be hot. Remove the defective tubular heater. Slip in the replacement heating element and fix it in place 'Before closing the cover, check the condition of the wires. 15 R PACKAGING MACHINES INTERNATIONAL, IN -wC�apter ` l SHRJNK TUNNELS The PMI shrink tunnels use electronically heated, recirculating forced hot air to cause the film to shrink and conform to the product shape. The air is forced through specially ductile 360 degree channels (thus the air supply is controlled or diffused, rather than just being a large column of hot air in a confined space) to ensure that an all around shrink is obtained at the lowest possible temperature. A sprocket driven belt-over-platform conveyor is used to carry the bundle through the tunnel. The belt is made of a high temperature resistant nylon glass materials. The tubular heating elements are mounted on one side of the machine so they can easily be removed by taking out the tray. A radial blower driven by an AC motor draws air through the element tray and into the channels throughout the tunnel. The inside of the tunnel has a series of diffused holes, which are fully adjustable, to ensure that the air direction reaches the product and shrinks the film. On the inside perimeter of the infeed and exit of the tunnel, there is access to pin-shaped damper handles to allow for this adjustment of the air flow and direction. The thermocouple is located inside the tunnel, and this allows the temperature controller to switch the bank of elements on and off as necessary. The blower assembly is mounted from the outside for easy maintenance access. Correck'ngNoire in t&Bhw Wlhee& If noise occurs in the blower wheels' chamber, loosen up set screws on the bearings, move the shaft in or out until noise disappears. Tighten up set screws. Make sure the pulleys on the blower wheel and the blower motor are lined up parallel. 14 • PACKAGING MACHINES INTERNATIONAL, INC. A good test of the effectiveness of the film seal is to attempt to pull it apart after having allowed the seal to cool • If films separates without tearing, more heat or longer dwell time is required. * If film tears along the seal line, heat or dwell time is excessive. * The best result is for the film to tear, not the seal or the weld. The hot knife can have vortex air cooling vents on the side of,the exterior cover to ensure that the hot knife exterior does not become over heated. The exterior cover has been designed to eliminate a large quantity of metal from this holder. This assists in keeping the hot bar section cool. i 13 PACKAGING MACHINES INTERNATIONAL , INC.. j The hot bar has a teflon insert that can be replaced where worn or when film sticks to the surface. " The film seal or weld is made by clamping two layers of film between the hot bar and a cold unheated rubber bar. In the event of problem, the hot bar can be quickly replaced by removing the bolts and the electrical disconnect. The seal bars are constructed with twin parallel heating elements, a thermocouple, insulation and a knife blade, assembled between two teflon coated aluminum bars. ngT9,7m m4,&dInl2 Remove hot bar from the seal frame on the machine, remove screws holding insert assembly and lift assembly out of sealbar. Clean the two bars using a light solvent if necessary. Rinse and wash with a powder detergent. Rinse thoroughly. Replace the thermocouple and sandwich the knife between the two insert halfs in that way that the sharp edge faces up and the dull edge is flush with the bottom . of the inserts. Prepare the screws by coating them with an anti-seize product. Check that the knife is not overlapping the support ledge. Check that the thermocouple is in the special recess and the electric's are not reversed. DO NOT TIGHTEN THE SCREWS. Stand the hot bar on a flat surface , push the insert assembly into the mounting halfs and press down on the knife blade using a block of wood. Tighten the adjacent screw while keeping pressure on the blade. Tighten all screws in this manner, and ensure that the exposed knife blade is the same height the entire length of the seal bar. Repairing the cold bar requires that the bar be dismantled and cleaned. Apply adhesive to the bar, and then place a heat resistant rubber strip on top and position the rubber accurately. Invert the bar onto a flat surface with even weight distribution for 4 to 8 hours. Trim excess adhesive and install teflon cloth without over tightening the cloth. To install the hot bar and cold bar, shut the air pressure off and manually close the seal jaws. Check the alignment of the two bars. Loosen the seal bar mounting bolts and reposition the bar to ensure correct alignment with the other bar. 12 PACKAGING MACHINES INTE.RNAT-1.ONA INC. Chapter SEAL BAR FRAME & OPERATION The seal bar frame holds the seal bar and all the parts needed to allow the cross seal bar to work. The seal bar is operated by one or two air cylinders controlled by an electric solenoid valve. These cylinders have a cushion to assist the two heavy duty shock absorbers provided for silent operation of both seal closing and opening functions. The air cylinders raise the lower seal carrier which, through two chain linkages, also causes the upper seal carrier to lower until the hot bar and cold bar meet. Seal opening is measured between the two hot and cold bar surfaces, and must be at least 0.375"/9.525mm - less than twice the cylinder stroke. if you adjust, be sure to tighten the lock nut. The self adjusting shock absorbers must be positioned so that all but the last 0.0625"/1.5875mm on their 1"/25mm of travel is used. Check with feeler gauge. _ The seal closing shock absorber must be set to eliminate any and all bouncing of the seal bars when the bars close. If the bars bounce, the lower film will pull out of the sealing area resulting in poor seals, or no seal on the back of the bundle. The chains linking the upper and lower carriers are provided with take-up adjustments. Finger pressure on chains should cause a 0.3751/9.525mm deflection. Hot cross seal bars consist of two parallel heated surfaces with a special knife blade embedded midway between them. The heated surfaces form two seals, one for the back of the wrapped product and one to rejoin the ends of the two film supply rolls. The hot knife separates the wrapped bundle from the flm supply rolls. A thermocouple located within the hot bar monitors the actual temperature in relation to the set temperature. The machine will only operate when the hot bar is at the required temperature. 11 • PACKAGING MACHINES INTERNATIONAL, INC . roll of film to load onto the back holder. `J 10 PACKAGING MACHINES INTERNATIONAL, INC . through separate DC driven motors and are controlle swi h on the film tension roller mechanism or with the ng ti FILM LOW TENSION ROLLER OPERATION The film tension reducing roller operation is designed to create a reservoir of film, under constant light tension, to meet the demands of the seal bar coupled with the flow of the product. Film is received from the powered roller dispensers and is threaded through a series of rollers often referred to as the dancer bars. Once sufficient film is threaded into the system, the rollers will move away from the proximity switch controlling the film feed clutches or motors, thus stopping the film feed. As film is removed from this reservoir, it will again operate the proximity switch, restarting the film feed. The upper and lower film dispensing systems are independent of one another and are controlled by the dancer bars and PLC. Film tension is produced by the weight of the dancer bars. Unwind the film according to the film threading diagram supplied with your bundler. Do not omit a loop through the dancer rollers or you will find that there is insufficient film to wrap the largest product and, more importantly, you will create excessive film tension. The pivoted dancer arm can be raised until its rollers are above the stationary rollers, which allows you to pass the film between the pivoted and stationary rollers. At this time you can release the dancer arm and the film will be threaded. To splice the new roller onto the used supply roll, it will be necessary to prepare the new roll as described below: Load a new roll onto the film holder. Apply some two sided tape across the width of the film. Once the low film alert has warned you that the supply roll is ending, watch for a suitable moment to stop the machine and then tape the new roll to the old roll. The above step could also be performed with an optional film splicing bar. By splicing the new and old film together. Start the machine, and the new film will be pulled through the system. Once a bundle has been made with both old/new film, and the old film is finished, remove the core from the film holder and move the new film forward in its place. A handle/film-pusher is built into the spare film drawer slide to help the operator transfer the spare roll of film into the active film position. Prepare another 9 PACKAGING MACHINES INTERNATIONAL, .J,4 C � r J1--\� LOW DENSITY POLYETHYLENE FILM LOADING AND UNLOADING The film system is set up to accommodate four rolls of film, wound onto 31775mm internal diameter cores. The film's outside diameter can be up to 14"/360mm and can vary downwards, dependent on the weight and width of the roll. A winch and hoist system is recommended for lifting the extra heavy roll onto the machine. To ensure accurate film threading and tracking, the film width may not exceed the seal bar length (width of the bundler). NOTE: To calculate the approximate weight of a 1411/360mm roll of film, multiply 4.6 lbs. per inch width of film. For metric rolls multiply 2.0 per 25mm width of film. Depending on the model you have purchased, you will find either a two or four roll holder capacity on the machine. The second roll for both the upper and lower holder is to assist in splicing this unused roll onto the end of the roll at present being unrolled. This saves time by not having to rethread the system when changing rolls. A roll of film can either be placed onto free turning rollers or have a shaft placed through the center of the roll for mounting onto the film unwind station. The film rolls should be mounted near the center of the unwind system, and adjusted if necessary, so as to ensure that the film is centered during the dispensing of the film to the seal bar. Where more than one film width is to be used, it is recommended that.you mark the position on the holder or.shaft for each size. This will assist in change overs to new sizes. The film is unwound by passing film from each supply roll through a pair of rubber vulcanized power film rolls. The lower rollers in each case are driven 8 PACKAGING MACHINES INTERNATIONAL , INC. C#�apter INSTALLATION AND CENTRAL LUBRICATION Installation Your PMI Shrink-Wrap Bundling Machine has been fully tested at the factory prior to delivery to your company. The PMI Bundling machine must be removed from the crate and inspected for any damage. Please notify the factory of any transit damage (a photograph is preferred). The spare parts package (if ordered), should also be unwrapped and thoroughly inspected. Place the bundler into the requisite position on your floor, and level the system using the adjustable leveling screws on the machine. There is a +2" (+50mm) adjustment from the standard elevation of 32"/812mm. Connect the air supply to the safety shut-off valve provided. Check that 80 PSI dry air pressure is available. Connect the electric supply to main disconnect on the machine. Please check that the supply is equal to the voltage marked on the bundler panel label. Central Lubrication If the bundling machine is equipped with the central lubrication system refer to the 'LUBRIQUIP Centralized Lubrication Systems" enclosed. NOTE: There are exposed grease points that are not part of the central lubrication system. These points should be greased periodically. PACKAGING MACHINES INTERNATIONAL , INC . s PACKAGING MACHINES INTERNATIONAL, INC. FILM FEED CHARACTERISTICS AND OPERATIONAL PROCEDURES 1. Film feed rollers are driven by DC motors. 2. Full authority dancer system with proximity switches, control film feed. 3. Start-Stop is controlled with a clutch. 4. Photo eye reads product and starts the upper film roller only. Film amount has been predetermined and threaded through the dancer bars. As product is conveyed through the curtain of film, a photo eye reads product. When photo eye is made, a momentary delay is encountered. Same as the upper, the lower film rollers operate through the dancer and proximity switch. 5 PACKAGING MACHINES INTERNATIONAL, INC. TO MAI'CE A MANUAL SEAL OPERATIONAL 1. Press "CYCLE OFF". NOTE: If there are any malfunctions 2. Open guard door. always reset the machine by 3. Reach into the machine and pull the upper and lower films into the pushing the seal area. Film should be of adequate length to alleviate film "EMERGENCY tension and should lay on the conveyor. STOP"button and start the 4. Close the guard door. NOTE: laws will close even if the doors are procedure over open. (ONLY IN MANUAL MODE) again. 5. Press the yellow "CLOSE" button to activate the seal jaws and make the seal. 6. Open the guard door and remove the excess plastic. 7. Close doors. 8. Push "CYCLE START" button. 9. Machine is ready for operation. 4 PACKAGING MACHINES INTERNATIONAL , INC._ iC�a er t p TO START THE BUNDLING SHRINK4NRAP MACHINE a> Connect the air main to the connector on the machine. b) Connect the electrical main to the disconnect plug on the machine. c> Push the POWER ON button. a) Wait until the seal and tunnel temperatures equal that of the temperature controller set points. e) Push the Cycle ON button. p You are now ready to feed products through the system. 3 PACKAGING MACHINES INTERNATIONAL , INC. �Chap�er � o oPERATIoNAu. o �o PiiOCEDURE Generallnformation Il personnel should be fully trained before attempting to operate this bundling film overwrapping machine. The overwrap machinery must not be operated without guards or other safety devices. All Utilities (air Sz electrical) must be turned off BEFORE any person reaches into the machine in order to carry out maintenance, adjustments or problem solving. The emergency stop (large red push/pull button) shuts off the electrical power and the air supply by pressing (pushing) the button. Use caution since air operated devices must be considered live and may attempt to return to home position. The bundling process is a heat process, thus all parts of the machine must be considered "HOT" to touch or to work on, for AT LEAST ONE HOAR AFTER SHUTDOWN. The correct width of desired low density polyethylene film should be loaded onto the top and bottom film holders. The film from each front holder is fed through the easy feed, low tension dancing rollers (see Film Loading Diagram), and a cross seal is manually made. This drape of film, formed from both top and bottom front rolls, should hang before the seal bar assembly. In production, when product goes through the web of film onto the discharge area, the cross seal is activated and creates the sleeve over the product as well as creates a new web of film for the next product. The discharge conveyor than carries the product,into the hot air oven which will cause the film to shrink around the product. 1 • Table of Contents Introduction I CHAPTER 6 CHAPTER 1 Shrink Tunnels 13 Operational Procedure 1 Heating Elements 14 General Information i CHAPTER 7 CHAPTER 2 Electrical Controls 16 Start-Up 3 To Make a Manual Seal 4 CHAPTER 8 Film Feed Characteristics 5 Pneumatic Controls. 18 CHAPTER 3 CHAPTER 9 Installation 7 _Conveyors 19 Central Lubrication 7 CHAPTER 10 CHAPTER 4 Troubleshooting 20 Film Loading&Unloading 8 Film Feed Operation 9 APPENDIX A Electrical Diagrams A CHAPTER 5 APPENDIX B Seal Bar,Frame &Operation 10 Mechanical Drawings B Teflon coated Inserts 11 Recommended Spare Parts APPENDIX C Literature C a Instruction & Parts Guide ©PMI,Inc. 531 Bonnie Lane,Elk Grove Village,IL 6000" Phone 847.640.8451 •Fax 847.640.8732 blurne vk PACKAGING MACHINES INTERNATIONAL, INC. kiswu(:6m & Patis Gt de M s ✓ ' TECHNICAL SPECIFICATIONS November 9,2000 BOOMERANG PROJECT G.C.C.S. INC. EQUIPMENT INSTALLATION PROJECT N0.G99462 Page 34 of 36 PACKAGING LINE ANNEX 3 INSTALLATION PROCEDURE SHRINK BUNDLER 05-1.1 AI-00 FR 16:03 GEYSSEL FAX HR, +49 221 59569420 S. 10 T CffEL I'll- Operating instructions for Applicator Series 404 SOnmSwasa-iwN w 22 4- Operation u�m' -8.18- Transport in works t transport in works of a one track applicator with a pallet trolley K 1 J j I n ; transport in works of a one track appricatar with a fork lift truck i ► ►166074aarv,uw_c.00c 8.18 12o+m-wn ? 2000-05-05 �10 00 x•49 221 59569420 i�received i TECHNICAL SPECIFICATIONS August 25,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO. G99061 EQUIPMENT INSTALLATION Page 33 of 36 PACKAGING LINE ANNEXE I INSTALLATION PROCEDURE STRAW APPLICATOR Jam,. �l Filler Feeder D990722,D000099,D000100 4. Install the Infeed chute assembly, locating the ends as specified on the installation drawing. The discharge elevation of the chute must align directly with the infeed section of the seed screw and base plate. The maximum elevation error at the transfer is +0, - 1/16 inches in the direction of travel. The connection must be square to the centerline of the screw within +/-0.5 degrees. 5. Attach the customer supplied exit conveyor at the disharge of the sweep. The conveyor must be square with the filler and Filler Feeder centerlines within +/- 0.5 degrees. The elevation of top of the discharge belt must be +0 to—1/16 in relative to the top of the index conveyor flights. 6. Locate the main electrical enclosure in its permanent location as near to the filler feeder as possible. Install water tight conduit between the main enclosure and the intermediate electrical enclosure. Reconnect the wiring as shown on the electrical prints. Also, attach the main power to the disconnect as shown on the prints. 7. install an air supply to the pneumatic enclosure as shown on the assembly print. 8. Check all mechanical connections for accuracy and correct alignment. Check all electrical connections for correct installation. Correct any discrepancies. ti• 2 of 2 Filler Feeder D990722,D000099,D000100 1 SETUP AND INSTALLATION 1.1 Shipping configuration, inspection, and weights The filler feeder machine will be shipped on two pallets, partially disassembled. The machine will consist of four(4) major sub sections: • The index conveyor and sweep assembly • The feed screw and frame • The infeed chute • The main electrical enclosure Miscellaneous small parts will be packed in separate shipping boxes. And attached to the pallets. When the equipment arrives, inspect the shipment for any obvious damage. If damage is detected, notify the carrier and Gebo USA immediately. The approximate shipping weight of the Filler Feeder is 1330 KG (2926 lb.). 1.2 Uncrating and handling The equipment should be moved to the installation sites on the shipping pallets if possible,to prevent damage. Carefully remove the equipment and shipping cartons from the pallets after reaching the -- installation area. Compare the items with the shipping list and note any discrepancies. When lifting the equipment from the pallet,lift from under the frame only. Use caution to avoid damaging any wires,cables,or pneumatic piping. 1.3 Machine installation Installation of the filler feeder is a simple process: 1. Locate the index conveyor into position under the Filler pouch drop position as shown on the layout and installation drawing. The Filler Feeder should be square with the Filler and centered on the product centerline as shown on the print. The maximum allowable tolerance is +/- 1/32 in on the centerlines, +/- 1/16 in. at the infeed and discharge elevations, and less than +/-0.51 out of square relative to th, filler product centerline in the direction of travel. 2. Adjust the Index conveyor legs to achieve the correct elevat' .aX� e flights as specified on the installation drawing. 3. Install the Feed Screw subassembly and frame. .t - 9. 1 of 2 TECHNICAL SPECIFICATIONS August 25,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO.G99061 EQUIPMENT INSTALLATION Page 32 of 36 PACKAGING LINE ANNEXE H INSTALLATION PROCEDURE FILLER FEEDER COOLER 2. Reconnect electrical wires according to the wire labels and print. Use care when running the wires through the conduit. Ensure that the wires are not being pinched or rubbed. 3. Check to be sure all the guards and safety signs that were removed for shipment and installation are replaced. 1.3.3. Electrical Installation Checkout ❑ Disconnect all loads before applying power. (Remove the,fuses, breakers, starters, etc.) ❑ Check the power sources. (They should be within f 10% of designed.) _Main Power- At the main control cabinet, apply power to check. _Control Power- After the main power is checked, trip the circuit breaker to the transformer and check the power. Also, check to see if there is any voltage between ground and neutral. ❑ Check all hard-wired circuits. Review wire number connectors. _E-Stops _Cabinet Lights `Cooling Tower ❑ Line by line, check all the inputs for proper ON and OFF positions. Manually trip each sensor to ensure it is operating correctly. ❑ Line by line, check all the outputs for proper device connections (force them if applicable). Note: The PLC program must he downloaded to do this. ❑ Check to be sure all loads (the drive belts and chains) have been removed from the drive motors. Install the fuses and "jog" each motor(verify motor identification/function)to ensure correct rotation. Directional arrows should be on each motor. ❑ Check the direction of rotation of the pumps and blowers. ❑ Check the drive parameters and overload protection devices. (Refer to the electrical schematic drawings for the proper settings.) Installation ' 1-13 MENME/Sit COOLER 1.3. Electrical Installation 1.3.1. Electrical Cabinet The customer is to install the cabinet in the desired location. I �,I Do not touch ANY exposed live parts in the electrical cabinet. Touching any hazardous voltage may result in equipment damage, serious personal injury or death. 1. Remove the skidding. 2. Place the electrical cabinet in position as shown on the electrical layout drawing. Eyebolts are provided for use in installing the electrical cabinet(s). 3. Level the electrical cabinet. 4. Bolt the electrical cabinet securely to the floor. 1.3.2. Component Reinstallation See the layout drawing for the electrical power requirements. Trained and authorized personnel only should install power sources such as electric,pneumatic, hydraulic, water, and steam. Installations must comply with all applicable codes,regulation and instructions in this manual. 1. After the mechanical installation of all major components is complete, reinstall the following parts that are sometimes removed for shipment. • Electrical control boxes Q • Wireways • s Conduit run • Electric eyes and sensors • Limit switches Refer to the match-marked electrical assemb awing for assistance in re-assembly. Installation 1-12 c / I COOLER Trained and authorized personnel only should install power sources such as electric,pneumatic,hydraulic, water, and steam. Installations must comply with all applicable codes, regulations, and instructions in this manual. 1.2.11. Connect the Fresh Water Supply Lines at designated points The connection of plant fresh water is the responsibility of the customer. 1.2.12. Connect the Steam Lines at designated points The connection of the steam lines is the responsibility of the customer. Ensure that all applicable federal, state, and local codes have been met. 1.2.13. Connect the Drain Lines The customer is responsible for connecting the plant drain lines to the Cooler. 1.2.14. Connect the Pneumatic Lines Connect the plant air supply line to the cooler pneumatic system(60— 100 PSI required). Check the hosing and connections to ensure that there are no leaks. Installation 1-11 MUMM/Sil COOLER 1.2.6. Install the Hot Water Tunnel and Conveyors Locate the Hot Water Tunnel upstream of the cooler as required for proper processing of the product. Install the conveyors into and from the tunnel. Adjust the conveyor height to suit the container line using the adjustable legs. If removed for shipment, install the pump. Level the pump assembly using the adjustable legs on the pump's mounting bracket. 1.2.7. Install Pumps & Piping The pump,motor, and strainer assembly for each zone has been removed for shipment. Reassemble at this time. Check the color coding to ensure that the correct pump assembly is installed on the correct zone. Reassemble all the piping and flange fittings. Be certain the gaskets are in place and bolt the flanges together. The fittings are color coded and numbered to assist in reassembly. Tighten the flanges in a crisscross manner. Adjust the pump legs to the proper height. Tighten the locking nuts. 1.2.8. Install the Spent Water Tank Place the Spent Water Tank adjacent to the cooler. Reassemble the piping. 1.2.9. Mount the Evaporative Blowers Mount the blowers on the top of the Cooler as shown on the layout drawing. Use the supplied marine sealant on the joint between the bottom blower flange and the top of the Cooler. Connections from the blower discharge flange to the customer supplied duct work system is the responsibility of the customer. NOTE: The top of the Cooler is designed to only support the weight of the blower. The Cooler has not been designed to support the weight of the customer supplied duct work system. The customer supplied duct work system must be supported by other means. Ensure that all applicable federal,state, and local codes have been met. 1.2.10. Install the Air Knife and Blower If the air knife has been removed fbr shipment, reattach it at the discharge end of the Cooler. It should be set so it blows the excess water off the containers and =�` into the Cooler. If the blower was removed, remount it on top of the Cooler and connect the'ar hoses to the air knife with stainless steel hose clamps. Position the air knife discharge 1/4" above the tallest container and equidistant' above the Cooler belt. Mark the height on the bracket and Cooler frame. DO NOT shorten air hoses. Installation 1-10 ,ib...r—.OJ%. . COOLER 5. Thread the belt over the carryways, around the sprockets, and over the return support tubes. 6. The chain should be installed "banjo string tight." These belts tend to stretch at first and should be checked for tension as follows: —Check the belt tension at the end of the first day. Remove links if necessary. —Check it again at the end of five days. Remove links if necessary. —Check after 20 days of operation. Remove links if necessary. 7. Check the entire system for levelness. Using a builder's level on the main belt, level the machine in both the lengthwise and crosswise direction. The conveying belt should not be more than 1/16" (0.0052 ft.)out of level. 1.2.4. Install the Container Discharge Conveyor 1. If the conveyor chain is not installed, install it at this time. 2. Position the discharge conveyor up to the discharge end of the Cooler. Adjust and level the assembly using the adjusting slots on the legs. 3. Using the "L"brackets,bolt the conveyor to the Cooler. These 4"wide by -9-1/2"long brackets bolt to the side of the cooler body and also the side of the discharge conveyor. The brackets are slotted,providing vertical and horizontal adjustment of the conveyor. Adjust so the transfer of containers is as smooth as possible. Typically, the container drop at point of transfer is set to 1132". .1.2.5. Install the Container Infeed Conveyor Components 1. If the conveyor chain is not installed at time at shipment, install it now. 2. If the drive assembly was removed for shipment, remount the drive and gearbox. 3. Adjust the conveyor so the transfer of containers is as smooth as possible. Typically the drop from the infeed to the main belt is set at approximately 1/32". The conveyor can be adjusted in three directions using the attachment brackets. —It can be adjusted sideways toward or away from the cooler using the slots in the crosspiece. —It can be adjusted forward and reverse by moving the brackets in.the angle crosspiece. —The height can be adjusted using the adjusting bolts,; U Installation 1-9 COOLER 17. To complete the joining of the sections, each internal joint from the top of the internal vertical side wall down must be filled with caulk, so the surface is level and flush. See photo. 18. Using the provided Primer, prepare the internal joint. Allow the primer to dry. Sample pieces of 19. Apply the marine sealant Cooler Joining Surfaces into the joint cavity and Compressed Gasket Fill so sealant is smooth flat with a small level with the inside putty knife. Use sufficient surface of the cooler. hand pressure on the putty l 6 knife to force the sealant down into the joint cavity. 20. Install the remaining rY ` Cooler sections in this Figure 1-1 Sample of Cooler Sealant Fill manner until all sections are installed. All sections must be "Level, Square,and True." 21. Upon completion of the installation, check the inside comers of the cooler and "shoot"elevations of each joint. 22. Tighten the locking nuts of each leg pad. 1.2.3. Install the Main Cooler Belt WARNING: The conveyor belting is extremely flammable. Before welding near the belt,remove the belting or cover it with welding shields. 1. MatTop chains are typically supplied in 10 foot lengths with connecting pins for each section. Inspect each section for chips. Repair if necessary. 2. Before connecting strands, use one strand to check for proper guide Figure 1-2 TwistLockTM Pin Retention clearance, sprocket alignment, and direction of travel. 3. Lay the sections on the conveyor carryway and connect. -' 4. Insert the connecting rod and lock the rod in place. See Figure 1-2 J� TwistLockTM Pin Retention. ✓ ' Installation 1-8 AkMSEISJI COOLER follows. From the gasket side,push the leader guide through the gasket and the bolt hole. Cut the hole in the gasket material. —From the outside,put the bolts through the bolt hole in the frame,then through the gasket. —Place the round 1/4"thick spacers on the bolts. These spacers should fit in the holes that were cut in the gasket. 10. Prepare the next section(Module #4). —Clean the next section's connecting surface with cleaner provided. —Using the marine sealant provided, caulk around all the bolt holes. —Caulk all the way around the connecting surface, ensuring that when the two sections are put together,the sealant will form a watertight bond to the gasket. —Ensure that the joint will be watertight. 11. Position the second section against the first section. If necessary, readjust the legs to get the units level, square, and true. 12. Bring the sections together. Be sure the 1/4" spacers are on the bolts. 13. If internal plumbing needs to be connected, at the same time someone must be inside the cooler to insert the gaskets and bolt the piping together. Bolt all Ranges together evenly, using a crisscross pattern. 14. Fasten the bolts on the sides first, bottom next, and top last. Finger tighten only. 15. With wrench, continue drawing the two sections together, compressing the gasket to 1/4" (or half the thickness of the gasket). Bolt uniformly, all the way around, crisscrossing the bolt pattern. Use an equal amount of torque on all bolts. 16. Any marine sealant that is squeezed out inside the Cooler during the draw- down process must be allowed to cure, then carefully cut away before proceeding with the next internal sealing procedure. Installation 1-7 COOLER 1.2. Mechanical Installation 1.2.1. Moving the Components With the machine skidded, move the sections into the final assembly area. DO NOT attempt to slide the Cooler on the bottom of the Cooler legs or height adjusting bolts as damage may occur. If not skidded,use machine"skates"or pneumatic pads to move the equipment. NOTE: If the Leg Pads were removed for shipment, they will need to be replaced. If they were totally lowered, screw them partially out and adjust as necessary to attain a level installation. 1.2.2. Install the Cooler Sections TAKE NOTE: The position and elevation of the first section determines the position and elevation of the entire machine.'Make certain the.first section is installed correctly. 1. Locate Module 45 (Fresh Water Rinse/Cooling Zone#3) of the Cooler. Move it to its approximate final position, remove the skidding, and insert the leg pads. 2. Remember that the positioning,and elevation of this section determines the placement of the entire machine. 3. With the leg pads, adjust to the elevation shown on the drawings and level this section lengthwise and crosswise. Cooler must be "true, square, and level" 4. Double-check to ensure the first section is positioned correctly. 5. Locate Module#4. 6. Place it in position adjacent to the installed first section. 7. With the leg pads, level and adjust this section so it is at the same level and square with the first section. The bolt holes must be aligned. 8. If there are internal plumbing connections between these two sections,they-------- will need to be connected while butting the two sections together. 9. Gasket installation instructions for cooler section (#5): —Clean the section's connecting surface with cleaner provided. —Using the 2"wide gasket material, peel away the protective paper and place the sticky side of the gasket on the surface to be joined to t he next section. —Use the sealant to caulk the joints where the gasket.material must be cut. —At each bolt hole, cut a hole in the gasket material with the tool provided as Installation 1-6 13EISSE/Si/ �--- � �--�-- COOLER markers on another, and yellow markers on the third. This will prevent installation of similar components on the wrong section. Match-marking is NOT done in an alphanumeric sequence of assembly. Parts labeled "1" or "A" are not necessarily the first parts that must be assembled. Match-marking letters or numbers are for reference only. Refer to the installation instructions for proper sequence of assembly. 1.1.7. Sequence of Installation The following is the order in which the components are to be installed. Refer to the layout drawing. 1. Module#5 (Fresh Water Spray&Cooling Zone#3) —Drive/Discharge section of the cooler 2. Module 44 (Cooling Zone 92 &#3) —With Pump and Blower 3. Module#3 (Cooling Zone #1 &#2) —With Pump and Blower 4. . Module#2 (Cooling Zone #11) —With Pump 5. Module #1 (Infeed Section) —Idler End of Cooler& Cross Conveyor 6. Main Cooler belt. 7. Container Discharge Conveyor 8. Container Infeed Conveyor . 9. Connecting Conveyors&Hot Water Tunnel 10. Pumps and Piping —Reassemble the exterior pumping and piping for each zone 11. Remount the Evaporative Blowers on top of the Cooler. 12. Remount the Air Knife hose and hardware. 13. Reassemble/remount any other components as may be required. 14. Electrical, Pneumatic, Water, and Steam connections. Installation 1-5 COOLER 6. Ensure that the area around the Cooler is well lit. If necessary,install additional lighting around the site. CAUTION Be sure the lifting and moving capacities are adequate. Attempting to lift and move the machine components with an inadequate device is dangerous to both personnel and equipment. 1.1.4. Mating to Existing Equipment Any installation using equipment that is already installed requires extra care in locating the Cooler. The Cooler may need to be connected to the customer's infeed and discharge lines. Be sure the Cooler location will facilitate the connection to these lines. A CAUTION Interfacing two pieces of equipment may create additional hazards. When the Cooler is interfaced with additional equipment, ensure that no hazards are created or that adequate safety devices and guards protect any such hazards. 1.1.5. Required Equipment for Installation 1. Two (2) or three (3) lift trucks with the following capabilities: • 8000-pound capacity • 6-foot forks 2. Man-Lift(or Ladders) 3. 460v/3ph/60Hz power supply for welders 11Ov/1ph/60Hz power for hand tools, lights, etc. 60 psi for pneumatic tools 1.1.6. Match-Marking ,.-� Match-marking is the markings on two surfaces 1ha o`in together during assembly. Match-marking (numbering) i ne in the Busse/SJI plant. Two surfaces that join together are marked with the same letter,number, or letter/number combination. For example, part "A"joins to part "A", or part 116" joins to part "6." Match-marking is usually done with adhesive letters or numbers, or is stamped. If the equipment has multiple similar components, the match- marking is also color coded. For example red markers on one section,blue Installation 1-4 COOLER Do not attempt to circumvent any safety features. Any attempt to do so may result in injury to personnel and/or damage to the machine. Equipment modifications without prior written approval by Busse/SJI or the use of unauthorized component parts may result in unsatisfactory performance, equipment damage, or serious personal injury. Unauthorized modifications may void Busse/SJI's warranty. Take time to look over the installation drawings and instructions before starting the installation. 1.1.3. Site Preparation 1. Check the area where the machine will be installed. If the floor is not level, components may need to be shimmed or, if necessary, floor reconstruction considered ensuring a level installation. The machine must be true, square, and level for proper and trouble-free operation. 2. Be sure the area is broom cleaned. Be sure all equipment,hardware,tools, etc. not required for the installation are removed from the area,. Be sure that all possible hazards or unsafe conditions are noted, marked, blocked off, and/or corrected. 3. Plan for the movement of the machine from the receiving area to the installation site. Consider the side and vertical clearances, floor conditions,changes in elevation, and the amount ofd e ed to maneuver turns. Make plans to bring the component a si in proper installation sequence(i.e. the first piece to be i t � a unloaded and brought to the site first). 4. Make sure there are adequate electri- atic services available. —460v/3ph/60Hz power supply�f`pr ers — 110v/1ph/60Hz power fo tools, lights, etc. —60 psi for pneumatic tools 5. Mark the location of the entire machine on the floor in advance. Refer to the machine layout drawing for dimensions. Installation 1-3 �u �'SaI COOLER 1.9. Preliminary Installation 1.1.1. Receiving and Inspection Busse/SJI recommends hiring professional millwrights, industrial machine movers and handlers,to unload the machine„move it to the installation site, and set up the equipment. When the Cooler is received, and before unloading it, visually inspect the machine to assure that no damage has occurred during transport. If damage or loss is noted, immediately have the carrier, or its representative, inspect the damage. It is your responsibility to handle all claims with the transport company. (See the "Terms and Conditions of F,quipment Sale"section of the BusselUl proposal.) Carefully unload the equipment. Inspect the machine, crates,and/or cartons for damage and verify contents with the packing list. Ensure that all the components are at the installation site—checked against invoices/bill of lading. Report any discrepancies or damage immediately. Check for loose items (nuts, bolts, washers, etc.) before releasing the carrier. Once all the main components are accounted for,the installation process may begin. 1.1.2. Installation Safety Refer to the General Safety Instructions in the Introduction Section before installing any equipment. Power sources, such as electric, air,, hydraulic, water, and steam, should be _ installed by trained and authorized personnel only. Installations must comply with ALL applicable codes and standards; local, state, federal, and otherwise. -)';``.\ ACAUTION V'J Be sure the load capacities of the lifting and movin ices are adequate (see requirements following). Attempting to lift and move the machine components with an inadequate device is dangerous to both personnel and equipment. See Required Equipment for Installation section. Before working on equipment, always turn off and lock out the service utility supplies (electrical,pneumatic, water. steam etc.). Also,before servicing the, equipment, bleed the air pressure from all the devices to prevent sudden or unexpected operation. Installation 1-2 SE/S611 �- �--i-- COOLER Section 1 - Installation 1. Table of Contents...........................,....................................................1-1 1.1. Preliminary Installation................................................................................................... 1-2 1.1.1. Receiving and Inspection.................. 1.1.2. Installation Safety.................................................................................................... l-2 1.1.3. Site Preparation.......................................................................,............................... l-3 1.1.4. Mating to Existing Equipment................................................................................ l-4 1.1.5. Required Equipment for Installation....................................................................... 1-4 1.1.6. Match-Marking....................................................................................................... 1-4 1.1.7. Sequence of Installation.......................................................................................... l-5 1.2. Mechanical Installation...................................................................................................1-6 1.2.1. Moving the Components........................................... ............................................. 1.2.2. Install the Cooler Sections 1.2.3. Install the Main Cooler Belt................................................................................... 1-8 1.2.4. Install the Container Discharge Conveyor............................................................. 1-9 1.2.5. Install the Container Infeed Conveyor Components.............................................. 1-9 1.2.6. Install the Hot Water Tunnel and Conveyors....................................................... 1-10 1.2.7. Install Pumps &Piping ....................................................................................... 1-10 1.2.8. Install the Spent Water Tank................................................................................ 1-10 1.2.9. Mount the Evaporative Blowers .......................................................................... 1-10 1.2.10. Install the Air Knife and Blower........................................................................ 1-10 1.2.11. Connect the Fresh Water Supply Lines at designated points............................. 1-11 1.2.12. Connect the Steam Lines at designated points................................................... 1-11 1.2.13. Connect the Drain Lines ..................................................................................... 1-11 1.2.14. Connect the Pneumatic Lines.............................................................................. 1-11 1.3. Electrical Installation.................................................................................................... 1-12 1.3.1. Electrical Cabinet................................................................................................. 1-12 1.3.2. Component Reinstallation.*................................................................................... 1-12 1.3.3. Electrical Installation Checkout........................................................................... 1-13 1.4. Drawing List ................................................................................................................. 1-14 CustomerLayout Drawing..........................................................................................D-28586 Rev 5 MachineAssembly...........................................................................................:.................M3059621 ElectricalAssembly.....................................................:.......................................................E3059621 Installation 1-1 f I 73- A.AF.O.."Oft-A"" COOLER 1. Table of Contents This is a sample of the Installation Instructions for Coolers Discard this page -used for indexing purposes only Figure1-1 TwistLockTM Pin Retention.......................................................................................................................1-8 Installation 1-1 • TECHNICAL SPECIFICATIONS November 9,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO. G99462 EQUIPMENT INSTALLATION Page 31 of 36 PACKAGING LINE ANNEX G INSTALLATION PROCEDURE COOLER & STERILIZATION UNIT TECHNICAL SPECIFICATIONS August 25,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO.G99061 EQUIPMENT INSTALLATION Page 30 of 36 PACKAGING LINE ANNEXE F INSTALLATION PROCEDURE PRE-PACK CHECK WEIGHER TECHNICAL SPECIFICATIONS August 25,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO.G99061 EQUIPMENT INSTALLATION Page 29 of 36 PACKAGING LINE ANNEXE E INSTALLATION PROCEDURE CUP CHECK WEIGHER EQUIPMENT ASSEMBLY PROCEDURE : F272/C313 UNLOADING Our machines are normally shipped by truck. WARNING/ADVICE Except otherwise specified,the customer is responsible for unloading the equipment and transporting it to the installation site. The goods hoist must take into account the weight of the different parts which make up the machine. As a precaution,we recommend to use a high safety factor compared to the weights given in the table on next page. WARNING ! Some elements indicated on the machine stand higher than the bottom frame and thus require some precautions when moved. Our machines have to be handled using pallet trucks or other conveying equipment, positioned as follows: -either under the tube framework(take care to insert a protection part to prevent painting from being damaged) (1), -or directly under the U-shaped reinforcing pieces designed to that end (2). O O /Z O t 1 2 y EQUIPMENT ASSEMBLY PROCEDURE : AN90 UNLOADING Our machines are normally shipped by truck. WARNING/ADVICE Except otherwise specified,the customer is responsible for unloading the equipment and transporting it to the installation site. The goods hoist must take into account the weight of the different parts which make up the machine. As a precaution,we recommend to use a high safety factor compared to the weights given in the table on next page. WARNING!Some elements indicated on the machine stand higher than the bottom frame and thus require some precautions when moved. Our machines have to be handled using pallet trucks or other conveying equipment,positioned as follows -either under the tube framework(take care to insert a protection part to prevent painting from being damaged)(1), -or directly under the U-shaped reinforcing pieces designed to that end(2), -or with a rudder-bar to handle the upper part(3). O O 3 2 INDICATIVE WEIGHT FOR THE TWO-AXIS ROBOTIC PACKER AN90 : 4 00 g TECHNICAL SPECIFICATIONS August 25,2000 BOOMERANG PROJECT G.C.C.S. INC. EQUIPMENT INSTALLATION Page 28 of 36 PROJECT NO.G99061 PACKAGING LINE g ANNEXE D INSTALLATION PROCEDURE: . CERMEX TRAY FORMER / CASE PACKER / LID CLOSER ZA mmillawk- INSTALLATION BOSSAK g• .cn=; 3.- If not properly aligned, you have to adjust the walking beam of the grippers. For this 1 purpose, you have to access the machine a from the rear part. Remove the rear guard ® o which is located furthest from the control pa- nel. Loosen the bolts (1) which attach the ° driving wheel to the Globoidal Indexer ° (U.G.I.). Loosening these bolts allows you to move the wheel with regard to the U.G.I. Now return to the front of the machine and move the grippers' walking beam until obtaining a perfect alignment of the grippers with the bottom wedge blower station. After having carried out this operation, tighten the bolts (1)which attach the driving wheel to the U.G.I. and re-install the rear guard. I April 27,ZOOD 6 INSTALLATION BOSSAR -� I� :oeG:C3&i`...`:` .i.`.4'•i.s•iG+e'i•"C4'S- .. i,,.»:WV,Y9Y,.,`..Kn'V i-.. cr.,..yib•x.t.,.beeff![i1�YS:u1!'J.*kk:+M�•.f t', "OUINAS ENVASADORAS HORIZONIAIES S �f 4. MACHINE START UP Once placed the machine in its production location in the factory and after having checked that the power supply has been properly connected, you have to proceed to the machine start up. • Machine preparation: I 1.- Check on the control , x panel that the emergency stop switch is not actuated. Should it be actuated, you have to turn it in the direction of the arrow. This STOP way, the switch ( mushroom ) remains operative. The red LED on the right illuminates when � the emergency stop switch is actuated. 2.- Push the black button with the POWER reading above. Now the orange LED on its right illuminates indicating that the machine is prepared (ready for service). - 3.- For operating the machine push the green button with the reading "START". • Synchronising the grippers with the bottom wedge blower station: 1.- Jog the machine with the intermittant button until the pouch walking grippers are in a position right under the machine stations (suction cup station, bottom wedge blower station, doser station, etc.). At this point, the >_ grippers are in a stop position (even when the intermittant button is pushed, grippers remain in stop position). o 0 �I FL;-Fj 2.- When the grippers are in stop position, verify that the center of the grippers is aligned with the center of the bottom wedge blower station. I O n O Bottom wedge blower station h\ \ April 27,2000 ! I INSTALLATION ROSSQR ,�� ■ '>'.a"`'iee�'d2?ti6A7i1"e .,:�:vie.r+•^e+-+:.•r,.er'>s-..1,'.'..i. °•-:1'y�;`<y t3'•-.tee'-c:` sxa---.- ».�."+•>=T'°.,,""*=33"'Yt'G"'+.n'x'. MAOVINAS ENVASADORAS MOIItON1AlE5 ■ 1.- Once connected the machine to the power supply, turn the main switch to the ON position. This switch is located on the control panel. 2.- Check if the vacuum pump is connected. For this purpose you check on the control panel in the selector menu of the ' touch screen that the selector with the reading "VACUUM PUMP" is actuated 0 (green color). 3.- Press the control panel's push button "INTERMITTANT" until the suction cups at the suction cup station just start to separate. That is the right moment for the suction cups to apply the vacuum. As a trial, you cover the suction cup with a piece of film or touch it with a finger. When the pouch is drawn towards the suction cup, is this a sign that the phases are correct. When, otherwise, the pouch is not drawn towards the suction cup because instead of applying the vacuum the suction cups blow the air out, you have to interchange two of the three phases (A, B, C) between each other. r ��. ta r, The control panel is located on the left side "r frame of the machine, right next to the pouch i F feed stores and contains all the command de- L} vices(switches,push buttons,controllers,etc.). The "INTERMITTANT" push _ button can be pushed from two INTERMITTA'�}T, SUCTION different points at the machine. - PUMP One is located on the control F N panel and the other one is an extendable push button which 10F allows the operator to advance the machine from any working point while carrying out any ' maintenance Work. Pu p position,it causes a Intermittant buffo ntiai jogging of the machine. For safety reasons you may Vacuum pump Pump Pump never use the two push buttons (screen) Selector working stopped at the same time. April 27,2000 4 INSTALLATION � .�._IK h.� . ,.... ROSSAR At + Astya s,i"k z.x<.:r:;,;,..�t., 1X.NS.....,,nl.: . .,c-...w.v,+�.e.,a..?8..+w:§tJO$v�µw';q�.�!I;uy((«,4p..x,hyFyl[.yT ;.r: 3'y MOUINAS ENVASADOEAS NOEIZONIAIES 3. MACHINE PLACEMENT AND CONNECTIONS Make sure that the installation of the various supply line pp y s to the machine (electrical, pneumatical, refrigeratering fluid when used and raw material (product) are prepared and ready for service. BOSSAR is only responsible for the correct per- formance of the delivered machine. That means, all the necessary supply lines for feeding the machine with product are the customer's responsibility. The machine must be located on a firm and even surface without any pronounced unevenness (less than 5%). Otherwise, the machine's stability would be affected causing vibrations and accidental movements which would have a negative influence on the production process. Once the machine is placed in its final position, you have to put a spirit level on the machine stand to balance it. The bubble has to be between the two center lines. This is achieved by balancing the various machine support legs. For this purpose, you lift the machine bottom with a trarispallet. Open the fixed guards of the machine to reach the 1 bases. For opening them, you use a large plane screwdriver, press down the lock and you will see how 2 it submerges, then you make a quarter turn (900) and release pressure. If you want to lift the machine, .3 . loosen the jam nut O, turn the. bases, clockwise "O" with a handtool following the reductions mprovided for this purpose. If you want to lower the machine, turn the base counterclockwise "0". Once the machine is balanced, tighten the jam nut U for avoiding bases modifications due to possible vibrations. Finally close the cover and repeat the same procedure having in mind that when for opening you have turned it in one sense, then for closing you have to turn it in the opposite sense. According to your electrical installation, the machine will be provided with three phases, neutral and earth plug. For the current machine, the installation is triphase with an earth plug. Phase A is the BLACK cable, phase B the RED cable and phase C the BLUE cable. The earthing cable is YELLOW WITH A GREEN STRIPE. Before connecting the machine to the power supply, make sure that the tension indicated on the CE plate is the same as you have. If connection is not done correctly, the motors without frequency converter will turn in the opposite direction. For examining the position of the phases you have to make the following check: April 27,2000 3 8- MINSTALLATION BOSSAR mn -OUINAS ENVASADORAS MORIZONWES • For moving the hopper(a) use a portable hoist or a hoist. Position the three support legs of the hopper on the quantity gauge tray (b) in the place provided for the fastening of the hopper(c). The hopper has to be positioned in such a way that the product level viewer remains on the front of the machine. The machine support legs are joint with warps to avoid accidental movement of the machine during transport. The warps have to be removed for unpacking the NK machine. Pass the ropes through the eye hooks (d) on the left and 0 right side of the top, as indicated b in the figure on the right. Lift the machine with a portable hoist or a d hoist and remove the bottom of the case. For moving the machine to its operation place you can follow two different procedures depending Wooden pallet on the means you have at your disposal. If you dispose of a portable hoist, you can transport the machine to its definite operation place for the following start up after having removed the bottom of the case or pallet. If you do not dispose of a portable hoist, you have to move the machine by placing two transpallets between the bases of the bottom as shown in the figure below. Then lift the machine and move it with utmost care to its final location. Using this procedure, it is advisable due to the heavy machine weight that several persons carry out this operation to avoid hits to the machine. o M �� P0 April 27,2000 2 I INSTALLATION ROSSAR � i6f�Y�s{Mi�w+u6 li.vrShcul::a:.w..m...:e+W�r.0 aetrniwL v.n.f...0 ......,..ae-.rr,I:......-Yrw<.....�v+w vss. iouW. `w.h• MAQUINAS ENVASADOEAS MOIIZON(AIES 1. INTRODUCTION When finished and checked, the BOSSAR machines are packed for transport. If the destination country is on the same continent and transport will be effected by road, the machine will be packed on a pallet and sealed with an impermeable plastic cover. If the destination country is not on the European continent, the machine will be packed in a wooden case, and if transport is done by ship, the machine will be additionnally sealed airtightly to avoid possible corrosions due to sea salt. Both, the pallets and the cases vary in size, depending on the machine and accessories and its various dosage mechanisms. The GMB-4000-PMP machine will be packed in a case with the following measures: 2,2 m (2200 mm) width, 2,5 m (2500mm) height and 6,3 m (6300 mm) length. The machine an case weigth is over 7.790 kg. These measures are approximate and can be modified. 2. MACHINE UNPACKING AND TRANSPORT TO LOCATION The first thing to do is unloading the machine.from the truck. For this purpose you need a hoist or a portable hoist. Pass the belts (ropes) between the two rear crossbeams of the case bottom such as shown in the figure below. Lift the case and place it on the ground. When placed on the ground you have to remove the wooden Il k Wooden case sidewalls of the case, the seal, the cardboard and the plastic bubble covers which protect o -��;=1 ,• ,�. the machine edges. Due to transport reasons, the belts of , the entrance pouch ` feed store and the `� hopper of the doser Q have been taken to pieces. Before moving the machine, it is advisable to put the entrance belts and the hopper in their places.. Place the pouch feed stores (1) on their supports (2), and the hopper (3) on the tray (4) above the machine. April 27,2000 INSTALLATION BOSSAR •�r-.- .•.- ---- -„y,;a ;,.wA-,iyt5�,ic..'i;;�d4�+YeiirkY,¢..i��1w3 Tdv..LMsvti!L�bsnw°�ii�ei�iX13:5iawec�x '' MAOUINAS FNVASADOM$HORI2ONTAlES ! TABLE OF CONTENTS 1. INTRODUCTION....................................................................................1 2. MACHINE UNPACKING AND TRANSPORT TO LOCATION.......1 3. MACHINE PLACEMENT AND CONNECTIONS......................... 3 4. 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V (�R r.'kh �d 1� :I '�� F r(.K � i,TM!' �ci . } �� l Y *ri .7 .h t.S�... F •L J k ��� �, 7." �y; t �#f� 3 '�.. v. �m�� is fat. ,z '•rii r �'y>< - �,c, t :ace _ vaq �_ -"�".^�,I. i"�' '��4: ..5a�'ge�� r� ,, r +xc ;�a'S H.�t't��� .�y� �1hlySY�K w4 a<ir�"d,�at����� _ b�d�k���t4 ,c.,.vs c m. ��'�'VS`ew ��i�. � � �r� 4."ht�4.�•,c•'"S Y Ir'tl A�; i��+Fd J f r fr r� 1 c u S ��r i y�. .i 1!t 7Q �:.^: `Lj���.. r,.5'^��..��•���e ���� �. �, W 3C ,� ��,]� �v,Sry;,�� ��,hriraztr� q'���.B-�yJti��i° �'` `'x'"-;�+t�i{, -t.^.{ {r... ;L 5.��.` �"'it� ���h'"; f'c'"r '-ti��+r. -r 1 �„ x ;`.. ,,y A h �'' ,ate. ':il•. .`.i i r� t �„ -y, TECHNICAL SPECIFICATIONS August 25,2000 G.C.C.S. INC. BOOMERANG PROJECT PROJECT NO.G99061 EQUIPMENT INSTALLATION Page 27 of 36 PACKAGING LINE ANNEXE C INSTALLATION PROCEDURE BOSSAR FILLER O� c% rte• J APPENDIX 6.2 INSTALLATION PROCEDURES-PACKAGING EQUIPMENT REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 15 SPE-16040-14002 J:\16040\Specs\Final\14002-Rev A.doc TECHNICAL SPECIFICATIONS November 9,2000 G.C.C.S.INC. BOOMERANG PROJECT PROJECT NO.G99462 EQUIPMENT INSTALLATION PACKAGING LINE 9-462-F-066 PREPACK&CASE 9-462-M-001 To be Installed as per Gebo installation procedures SHEET 1 TO 2 CONVEYORS sheet 1 TO 2 9-462-M-057 sheet 1&3 9-462-M-058 sheet 1 TO 3 9-462-F-067 VIDEO]ET 9-462-M-058 Four (4) supports are ed sheet 1 of 3 and in I ® re to n their sup justed to be able print on products. Y TECHNICAL SPECIFICATIONS November 9,2000 G.C.C.S. INC. BOOMERANG PROJECT " PROJECT NO.G99462 EQUIPMENT INSTALLATION PACKAGING LINE 01 _MED . . N FILLER 9-462-M-056 Two(2)Bossar Fillers are to be insta 9-462-F-050 sheet 1 of 2 9-061-M-057 O o sheet 1 of 3 9-462-F-051 FILLER FEEDER 9-462-M-056 Two(2) Fi unted on Bossar sheet 1 of 2 Filer. 9-061-M-057 Filler,a Fille Pave D be attached together sheet 1 of 3 TO avoid ative movement from each other. 9-462-F-052 CUP CHECK 9-462-M-056 Two (2) CUP CHECK WEIGHER to be installed as WEIGHER sheet 1 of 2 Gebo installation procedure. Each CHECK 9-061-M-057 WEIGHER's panel view is positioned next to the sheet 1 of 3 check weigher. 9-462-F-053 COOLER& 9-462-M-056 One (1) COOLER AND one (1) sterilization unit are STERILIZATION sheet 1 of 2 to be installed. UNIT 9-061-M-057 sheet 1 of 3 9-462-F-054 STRAW APPLICATOR 9-462-M=058 Two (2) STRAW APPLICATOR are to be installed. sheet 1 of 3 Doors openings (Operator access) of each STRAW APPLICATOR is the mirror of the other (Type 462 . for Line B &463 for line A). 9-462-F-055 TRAY FORMER 9-462-M-0567 Two(2)TRAY FORMER are to be installed. 9-462-F-058 sheet 1 of 2 9-462-F-056 AN90 GANTRY 9-462-M-057 Two(2)AN90 GANTRY PACKER are to be installed. 9-462-F-059 PACKER sheet 1 of 3 Doors openings (Operator acoess) of each PACKER is facing the other. 9-462-F-057 C313 LID CLOSER 9-462-M-058 Two (2) LID CLOSER are to be installed. Doors .9-462-F-060 sheet 1 of 3 openings(Operator access)of each LID CLOSER is facing the other. 9-462-F-061 pRE-pACK CHECK 9-462-M-057 Two (2) PRE-PACK CHECK WEIGHER are to be WEIGHER sheet 1 of 3 installed. 9-462-F-062 PMI SIRD-25 9-462-M-057 One (1) SHRINK BUNDLER SIRD-25 Is to be SHRINK BUNDLER sheet 1 of 3 installed. 9-462-F-063 PAI 4000 9-462-M-058 One(1)PAI 4000 PALLETD-ER is tD be installed. PALLETIZER sheet 1 of 3 9-462-M-059 sheet 1 of 2 9-462-F-064 KING COBRA 9-462-M-059 One (1) IiW MIMA KING COBRA STRECH STRECH WRAPPER. sheet.1 of 2 WRAPPER is to be installed. 9-462-M057 9-462-F-065 CUP CONVEYORS 9-462-M-001 To be Installed as per Gebo installation procedures SHEET 1 TO 4 sheet 1 TO 2 9-462-M-056 sheet 1 TO 2 9-462-M-057 sheet 1 of 2 9-462-M-058 sheet 1 TO 2 r APPENDIX 6.1 DRAWING CROSS REFERENCE REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg., 14 SPE-16040-14002 JA16040\Specs\Final\14002-Rev A.doc Y 5.3 CHANGE ORDERS All change orders must be approved by the PFI Site Manager. In order for the Subcontractor to apply for a change order he will be required to demonstrate that the work involved was not included in the original scope of work as defined by the specification and drawings. All change order quotes shall have all materials and time listed separately for review by the Project Manager. 5.4 STAFFING PLAN The installation Subcontractor's proposal should include a staffing plan to perform the scope of work as outlined within the schedule requirements shown in section 4.0. The staffing plan should include shift plans, supervisory staffing, and rigging and millwright labor staffing. Subcontractor should also indicate if they intend to draw labor from the local market or bring in labor from outside the Northampton area. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 13 SPE-16040-14002 J:\16040\Specs\Fina1\14002-Rev A.doc 4.3 SCHEDULE TRACKING A. The Installation Subcontractor must provide a schedule consistent with the Owner's start-up requirements for the entire project with weekly updates. The start-up dates on the schedule must meet the dates included in this document. The PFI Site Manager has the right to:request additional manpower if the schedule is not met. If the Subcontractor is falling behind on his schedule and cannot satisfy the PFI Site Manager that the schedule can be achieved, the PFI Site Manager may bring in a second contractor to assist the first. B. The Subcontractor will submit daily time sheets using Purchaser's format(not included), to document the hours spent installing each piece of equipment listed in the time sheet. All supervisory labor will be accounted from the time sheets. 5.0 INSTALLATION SUBCONTRACTOR'S PROPOSAL 5.1 BASIS OF EVALUATION A. The installation Subcontractor's proposal will be evaluated on the basis of staffing capability, technical capability, schedule commitment and cost. Completeness of the proposal package will be taken as evidence of Subcontractor's ability to perform the scope of work as described. B. With his proposal the Subcontractor should provide a reference list of installations of similar types of equipment in operation. Reference contacts and phone numbers should also be included. Company brochures and marketing material describing standard services should also be included. 5.2 INSTALLATION QUOTATION A. The installation Subcontractor's proposal must contain a quotation breakdown for labor and material costs to perform the complete installation as outlined in this specification and the referenced drawings. The format for the quotation breakdown is contained in Appendix 6.4. This form must be completed in its entirety as part of the contractor's proposal. To assist in the estimating of the GEBO conveyor installation, a summary of the 6 phases required in the estimate is contained in Appendix 6.5. This summary is approximate and is not intended as a substitute for the drawings. The drawings should govern in defining the scope of work. B. The installation Subcontractor should include 500 start up labor hours and a $10,000 start up allowance for materials to cover the commissioning of the 2 packaging lines. Any and all expenditures from this allowance will require the PFI Site Manager approval prior to starting the work. REV. A PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 12 SPE-16040-14002 J:\16040\Specs\Fina1\14002-Rev A.doc 3. Fasteners to have hex heads except where otherwise indicated on the drawings. All bolts to have self-locking nuts. 4. Cadmium plated fasteners are not permitted. G. Gaskets: 16 oz. White neoprene or owner approved equivalent. H. Stainless Steel: Type 304L unless otherwise noted. Stainless steel plates and sheets to have a 2B Finish. 4.0 SCHEDULE AND ADMINISTRATIVE REQUIREMENTS 4.1 EQUIPMENT DELIVERIES Equipment deliveries at the site in Northampton are currently scheduled as follows 2/05/01 -2 GEBO filler-feeders 2/05/01 -2 Hi-Speed puck check weighers with rejectors 2/05/01 - 1 Arrowhead sterilization tunnel 2/05/01 - 1 Arrowhead product cooling tunnel 2/05/01 -2 VideoJet pouch coders 2/05/01 -2 Hi-Speed case check weighers with rejectors 2/05/01 -2 Video Jet case coders 2/05/01 - 1 PMI shrink Bundler 2/07/01 - * 1 GEBO puck accumulator 2/07/01 - *I GEBO empty puck accumulator 2/07/01 - *GEBO plastic chain transfer conveyor—various sizes 2/07/01 - *GEBO chain driven live roller case conveyor 2/15/01 - 1 Blower unit and 2 sets of air knives 2/15/01 - 1 ITW Mima Stretch Wrapper—automated with CDLR conveyor 2/15/01 - 11,760 pucks 2/23/01 - 2 Geyssel straw applicators with rejectors 3/01/01 - 2 Bossar pouch fillers 3/01/01 - 2 Cermex tray formers 3/01/01 - 2 Cermex case packers with rejector 3/01/01 - 2 Cermex lid closers with rejector 4/15/01 - 1 PAI case palletizer with pallet and slip sheet dispensers *6 deliveries starting Feb.7 and ending March 15, 2001 This is a preliminary schedule which is subject to change 4.2 SCHEDULE COMMITMENT The installation Subcontractor must staff the project to complete the mechanical installation by May 4, 2001. Extended shifts with overtime or a two shift operation with overtime should be considered and committed to as required if needed. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg„ 11 SPE-16040-14002 JA16040\Specs\Fina1\14002-Rev A.doc E. It is the Equipment Installation Subcontractor' responsibility to identify and advise the PFI's Site Manager of any and all equipment support legs that may sit on floor drains. The Site Manager is to be notified immediately. He will not install legs without the Site Manager's approval. F. The Installation Subcontractor is responsible for the removal of grease, dirt, stains, labels, fingerprints and other foreign materials from the equipment upon completion. G. The Installation Subcontractor must repair,patch and touch up marred surfaces to specified finish, to match adjacent surfaces at completion of installation. 3.2 INSTALLATION MATERIALS A. Materials shall be new. Seconds or damaged materials will be rejected by the owner, who reserves the right to reject any materials, proposed or installed, which in his opinion fails to meet quality,standards specified. Subcontractor is to remove and replace any rejected materials with acceptable materials at his own expense. B. Installation Subcontractor must provide appurtenances necessary to make complete equipment installation, including: 1. Metal shims, wedges, and leveling plates as required to assure level installation of equipment. 2. Miscellaneous materials such as thread lubricants,bolts,nuts, washers, gaskets, and plugs necessary to complete the installation. Lubricants including thread lubricants shall be food grade and approved by owner prior to their use. 3. Expansion bolts and templates for setting expansion bolts. C. Paint: Epoxy primer, Touch-Up Paint: Compatible with shop coat. D. Shim Material: Type 304 Stainless steel. E. Sealant for Floor: As approved by PFI Site Manager. F. Fasteners: 1. Stainless steel fasteners to be 304 heavy hex head semi finished. 2. Mild steel fasteners to be galvanized. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 10 SPE-16040-14002 JA16040\Specs\Fina1\14002-Rev A.doc 6. PMI Shrink Bundler 7. PAI Palletizer 8. ITW Mima,King Cobra Stretch Wrapper 2.6 MISCELLANEOUS A. The installation Subcontractor is responsible for the fabrication of Overhead Filler Feeder Protections. B. The installation Subcontractor is responsible for the fabrication and installation of 4 Video Jet support stands. 3.0 QUALITY ASSURANCE 3.1 GENERAL A. The installation drawings are intended to show only the general scope of work. All equipment and conveyor systems will be installed in accordance with the approved manufacturer's shop and erection drawings. All work required by the manufacturer to install their equipment and conveying systems including the required alterations, modifications, cutting and field fit-up will be included in this scope of work. Only final vendor drawings and installation procedures delivered with the equipment are to be used for installation. B. All elevations are to be taken from the floor high point. The specific benchmark for equipment installation will be determine by PFI's Site Manager at the start of the installation. The Installation Subcontractor is responsible to insure each piece of equipment is properly leveled and field verifies all specified elevations C. Prior to completing the construction,the Installation Subcontractor will complete an"Equipment Installation Construction Inspection Check Sheet",provided by PFI's Site Manager for the equipment and conveyors installed. Appendix 6.3 contains samples of construction:inspection and running inspection check sheets for the GEBO conveyors. These sheets shall be filled out by the equipment supplier's onsite representative and the Subcontractor. The Equipment Installation Subcontractor will also enter the date, in the "Complete"column, when the work was finished and inspected. As conveyors and equipment are completed and inspected, the completed check list will be forwarded to the PFI's Site Manager on a regular basis. The construction will not be considered "complete"unless a completed check sheet for each equipment is submitted to PFI's Site Manager. D. The Installation Subcontractor will verify all conveyor speeds with GEBO service representative after installation. This will entail running and checking the speed . and making the appropriate adjustment if required. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 9 SPE-16040-14002 J:\16040\Specs\Fina1\14002-Rev A.doc properly, supply and install floor anchors, install chains, adjust guide rails, and join drip pans together for a fully operational system. 11. Drip pans are already installed on cup conveyors. The Equipment Installation Subcontractor is responsible to assure correct cascading of drip pan, by adjusting brackets. The Equipment Installation Subcontractor is responsible to provide and install—PVC tubing(2" diameter) from the conveyor drains to floor drains. 12. Only the hanger brackets on conveyor frame to attach the hangers are supplied with the conveyors(see Dwg. 9-462-F-008), therefore all other steel to support the elevated conveyors will be supplied by the Subcontractor(unless otherwise noted). Overhead supported conveyors are more easily installed using a crane (note that gas powered machines are not permitted in the plant). 13. Uncrate, assemble, level and install Case Conveyors completely with all necessary hardware for a complete operation. Subcontractor to install per GEBO Installation drawings (supplied prior to construction) and under GEBO's supervision only. 14. Elevated conveyors in the design which are not supported from the floor will require overhead hangers and supports supplied by the equipment installation Subcontractor. Elevated conveyors will be supported from the building steel which is at(approximate)20 ft. above finish floor. 15. Where platforms go over conveyors,the equipment installation Subcontractor is responsible for installing a deflector pan underneath grading. 16. Tie-ins of utility piping and connections to equipment from the main headers is the responsibility of the installation Subcontractor. 2.5 INSTALLATION PROCEDURE—PACKAGING EQUIPMENT A. Appendix 6.2 contains installation,procedures for a portion of the filling and packaging equipment to assist the rigging/millwright Subcontractor in developing the estimate to perform the scope of work. Final procedures will be provided for all equipment to the selected Subcontractor prior to the start of installation. The appendix 6.2 contains procedures for the following equipment. 1. Bossar Fillers 2. Cermex Tray Formers/Case Packers/Lid Closers 3. Arrowhead-Busse/SJI Cooler and Sterilization Unit 4. Gebo Filler Feeders S. Geyssel Straw Applicators REV. A PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 8 SPE-16040-14002 JA16040\Specs\Fina1\14002-Rev A.doc the drip pans together and install the protection covers over the drive and idler shafts. Note: Drip pans on the full puck and empty puck accumulators are not pre- installed and are the responsibility of the installation contractor. B. The Equipment Installation Subcontractor is responsible for : 1. Adjusting all guide rails and mechanical actuators horizontally and vertically for a correct running of the conveyors, in order for the cups to be properly guided and oriented. Guide rails will not be adjusted prior to shipment. 2. Adjusting all dead plate and roller transfers for smooth transfer of the cups and cases, without tipping or stopping on the transitions. 3. Adjust chain to chain wear strips on all parallel transfers for proper handling of the cups. 4. Install all guide rails splice plates such as the cup contact surface of the guide rail is flush. 5. Adjust any/all mechanical actuators(proximity switches) so that there is not interference with the chains or the guide rails. 6. Replace or repair any/all materials lost or damaged during handling and installation per the existing conveyor schedule (i.e.broken studs,bent pans, any damage to conveyor frame,bed and supports). 7. Tie-ins of conveyors should be performed so as to obtain a 100% functional system. Splice joints for the conveyor frame and guide rail should be flush with an overlap on the wear strips between adjoining' sections. 8. Any and all cut to suit sections of the cup conveyors as specified by GEBO will be done by the contractor. 9. If a section has to be cut to suit,please note the following: a. Cross members if necessary,will have to be re-installed on the cut to suit section. b. Return rollers if necessary, will have to be re-installed on the cut to suit section. C. Drip pans, if supplied,will have to be cut to suit. 10. Unload,uncrate,prepare for installation and install completely all conveyors as per GEBO installation drawings and as per notes in paragraph of this document,under GEBO supervision. Level conveyors REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 7 SPE-16040-14002 JA16040\Specs\Fina1\14002-Rev A.doc r F. To understand the utility piping, a set of PFI plumbing and HVAC piping drawings (LATER) and specifications has been supplied with this specification for reference only. Included in the set of PFI reference drawings are: 1. Plumbing drawing 16040 13-01 Legend and Notes (LATER) 2. Plumbing drawing 16040 B-07 First Floor Above Slab Piping Part Plan (LATER) 3. Plumbing Specification SPE-16040-15400 Plumbing Systems 4. HVAC drawing 16040 H-400 First Floor Piping Plan(LATER) 5. HVAC Specification SPE-16040-15500 Mechanical Piping 6. Civil drawing 16040 C-02 Site Plan Construction Laydown Plan 7. Architectural drawing 16040 A-04 Partial First Floor Plan Equipment layout 2.2 EQUIPMENT INSTALLATION A. The rigging millwright Subcontractor will be required to provide a complete installation of all equipment as outlined in Section 1.0. The installation must satisfy the quality requirements as outlined in Section 3.0. B. All equipment locations are to be verified by the PFI Site Manager prior to final equipment placement. C. All equipment must be rigged for movement and placement as specified in the manufacturer's installation package (see attachments). D. All equipment is to be leveled and secured to the floor as specified in the manufacturer's installation package (see attachments). 2.3 COMBINED LOADS A. All equipment supports provided by the installation Subcontractor shall be designed for seismic forces and in accordance with the Massachusetts Building Code and local codes in effect at the site. B. All equipment shall be secured to the floor or supporting structures in accordance with national, state and local codes for seismic forces. 2.4 GEBO CONVEYOR INSTALLATION A. All GEBO conveyors are shipped in section. The gear boxes, guide rails,motors, and drip pans are factory installed,hence the contractor shall make the final assembly of the sections with the supplied leg supports, install the chain on all conveyors, finalize and adjust the guide rails,transfer plates and rollers, connect REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 6 SPE-16040-14002 JA16040\Specs\Fina1\14002-Rev A.doc f Manager can contract with appropriate personnel to clean the area and charge back the Subcontractor for the service. G. The Subcontractor's employees will be required to adhere to the same rules and regulations as followed by the employees at the Minute Maid plant. Subcontractor should be aware that this is an operating food plant and shall comply with all plant rules. In addition to safety requirements, this will include smoking policies and personal hygiene requirements. H. The installation Subcontractor shall not climb or walk on any conveyors or packaging equipment. If this rule is not adhered to, the contractor will repair all damages to equipment due to walking at no additional cost to the owner. 2.0 DETAILED SCOPE OF WORK AND DOCUMENTATION 2.1 BID PACKAGE INSTALLATION DRAWINGS A. The rigging/millwright mechanical installation scope is documented in detail on the GEBO's bid package installation drawings revision 1 dated 11/20/00. A set of drawings has been supplied with this specification. The drawings are broken down into 5 major groups. 1. 1 Drawing -Key Plan of the general area 2. 2 Drawings-Plan layout 3. 10 Installation Drawings -Preliminary for bid package 4. 21 Vendor Drawings—Packaging equipment and conveyors 5. 5 Detail Drawings Plus two miscellaneous drawings showing utility drops. B. The rigging/millwright Subcontractor should understand that these drawings are issued for bid purposes only. Approved installation drawings issued for construction will be provided to the successful bidder. C. The issued for construction installation drawings for the GEBO conveyors will be 1/4 scale,color coded for each of the 6 phases of conveyor, and call out detailed identification of all motors, conveyor chains and conveyor sections. They will also contain detailed cut to suit instructions and installation procedures. D. Appendix 6.1 provides a cross-reference listing of the vendor drawings and the corresponding installation drawing containing the vendors equipment. E. The vendor equipment drawings are for reference only to communicate the equipment size and complexity to the installation contractor. Certified manufacturers drawings of machines will be issued for construction to the successful bidder. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 5 SPE-16040-14002 J:\16040\Specs\Fina1\14002-Rev A.doe 1.4 SAFETY PROCEDURES A. The rigging/Millwright Subcontractor must adhere to Minute Maid safety procedures as well as OSHA requirements. This will include contractor's labor using personnel protective equipment designated by the Site Manager while on the job site. This may include hairnets, hard hats, safety glasses with side shields, hearing protection, and work shoes. B. Minute Maid does not loan equipment to Subcontractors. Subcontractor is to furnish all necessary equipment to execute the work. 1.5 SITE CONDITIONS AND COORDINATION A. The rigging/millwright contractor must coordinate all activities with PFI's Site Manager to minimize interference with plant operations and with other Subcontractors performing work at the site. The rigging/millwright Subcontractor shall examine drawings of related construction packages to become aware of any conditions that may effect their work and to coordinate their work with the work required in the other packages. Related construction packages will include process piping, electrical, and structural. Drawings and specifications for the related packages will be available from the PFI Site Construction Manager. The equipment must be installed in accordance with the construction schedule. B. Storage space will be provided adjacent to the installation area in the facility. The equipment must be segregated upon receipt and stored in an orderly manner in accordance with the installation schedule in order to minimize handling. C. The installation area will have a new slab with an epoxy floor surface and below surface trench drains.'The rigging/millwright Subcontractor must take adequate precautions to protect finished floors from gouging or scratching caused by movement of large equipment. Finished floors and drains must also be protected from chips or cutting oil used in the installation through the use of splatter blankets and drop cloths. Subcontractor will be held responsible for any damages incurred during the installation. D. The Subcontractor shall provide protective measures for the protection of the building structure and property. E. The Subcontractor will be required to provide a trash container on the site for the removal of all scrap materials, including crating, generated during the installation process. It is the Subcontractor's responsibility to ensure that the container is replaced as soon as it is full. F. The Subcontractor shall be responsible for cleaning the immediate work area on a daily basis while performing the work. This includes daily"broom clean"tidying up of the work area. If the Subcontractor fails to clean the area,the PFI Site REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 4 SPE-16040-14002 J:\16040\Specs\Fina1\14002-Rev A.doc 21. Some double handling of equipment may be necessary depending on the installation sequence,progress and delivery. 1.2 EQUIPMENT SUMMARY Following is a summary of the equipment included in the rigging/millwright and utility piping scope of work. All equipment will be purchased and delivered to the Minute Maid site for unloading and installation by the rigging/millwright contractor. 1. 2 Bossar pouch fillers 2. 2 GEBO filler-feeders 3. 2 Hi-Speed puck check weighers with rejectors 4. 1 Arrowhead sterilization tunnel 5. 1 Arrowhead product cooling tunnel 6. 2 Geyssel straw applicators with rejector 7. 2 VideoJet pouch coders 8. 2 Cermex tray formers 9. 2 Cermex case packers 10. 2 Hi-Speed case check weighers with rejector 11. 2 Cermex lid closers with rejector 12. 2 Video Jet case coders 13. 1 Blower unit and 2 sets of air knives 14. 1 PMI shrink bundler 15. 1 PMI jib crane (floor mtg.) for shrink bundler 16. 1 Weber case labeler 17. 1 PAI case palletizer with pallet and slip sheet dispensers 18. 1 ITW Mima, King Cobra stretch wrapper—automated with CDLR conveyor 19. 1 GEBO puck accumulator 20. 1 GEBO empty puck accumulator 21. 1640 feet(approx)of GEBO plastic chain transfer conveyor—various sizes 22. 260 feet(approx)-of GEBO live roller case conveyor 23. All control and electrical panels supplied by the equipment manufacture, and GEBO, including the 26 (approx)MCC panels on the mezzanine. (rigging only) 1.3 WORK NOT INCLUDED IN SCOPE The following work necessary to provide a complete installation of the filling/packaging line is not included in the rigging/millwright Subcontractors scope of work. This work will be performed by others. 1. Concrete or epoxy floor work required to prepare floor for setting of equipment 2. Electrical wiring for power and controls 3. Mounting of instrumentation on equipment 4. Structural steel platform REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 3 SPE-16040-14002 J:\16040\Specs\Fina1\14002-Rev A.doc i 4. Transport and set the equipment in the final location per the layout drawings, including placement of all equipment electrical panels and auxiliary equipment. 5. Assembly of equipment per manufacturers drawings and instructions. 6. Provide labor and materials to pipe all utilities from the main headers to the terminating point on the equipment, approximate 15 to 20 ft. Utilities will include compressed air, process water, and steam. See Appendix 6.6 for compressed air tie-in piping sketch. 7. Provide 6 Back Flow Devices on process water line at equipment. (3) %"Watts model No. 9D (3) 2"Watts model No. 009 8. Cut to suit conveyors as indicated on drawings to achieve final dimensions and set positions. 9. Installation of conveyor leg supports, overhead supports for elevated conveyors, and transfer chains. 10. Adjust, align and modify as required all conveyor guide rails,wear strips, and transfers to provide a complete, functional installation. 11. Properly level all equipment to the correct height to accommodate the sloped floor of the project. 12. Unless otherwise specified, upon approval of PFI's Site Manager, anchor equipment to the floor and seal the floor penetration with an epoxy sealant approved by the PFI Site Manager. Unless otherwise specified, floor anchors for machinery shall be stainless steel. 13. Inspecting and checking all conveyor equipment for suitability for system startup. This will include checking for cleanliness,proper lubrication, and confirming conveyor speeds. Subcontractor must complete an "Equipment Installation Construction Inspection Check Sheet"provided by the Site Manager for all equipment and conveyors installed. Sample check sheets are included in Appendix 6.3. 14. Provide labor and materials to support the commissioning and startup of the packaging line. 15. Provide all hardware and materials for supporting overhead conveyors. This includes all cross members and cantilevers required, and attachments to the overhead steel structure. 16. Provide all necessary hardware and materials for field fit situation that maybe encountered during the installation of the equipment. This includes all transfer connection points between the conveyor section and process and packaging equipment. 17. Cooperate and work with GEBO's site crew, electrical Subcontractor in scheduling, rescheduling installation activities, as necessary. 18. Provide materials as necessary to make splices at conveyor/equipment interface. 19. Subcontractor shall provide structural steel supports for hung conveyors, provide miscellaneous supports as required,where required. 20. Subcontractor shall provide all piping connections to equipment— compressed air,process water, steam, etc. as shown on drawings. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 2 SPE-16040-14002 JA16040\Specs\Fina1\14002-Rev A.doc PACKAGING LINE EQUIPMENT INSTALLATION SECTION 14002 1.0 GENERAL 1.1 SCOPE OF WORK SUMMARY A. This specification, together with the attachments, establishes the requirements for the rigging and millwright work for the mechanical installation and utility piping tie-ins of the Minute Maid pouch filling and packaging line equipment at The Minute Maid Co. in Northampton, Massachusetts. All work covered by this specification is indicated on the equipment layout drawings and equipment lists. B. The rigging/millwright Subcontractor will be responsible for providing a complete installation of the equipment systems in a condition ready for operation and in accordance with the manufacturers installation instructions. The Subcontractor's installation must conform to quality assurance guidelines outlined in section 3.0 of this specification. The fact that some information or details may not be specifically included in the scope of this specification does not relieve the Subcontractor from their obligation to provide a complete and safe installation in conformance with all governing codes. C. The work to be provided under this specification includes all labor, supervision, materials, installation equipment, safety equipment, tools, and supplies necessary to provide a complete equipment installation. Any ancillary or complementary equipment and services, though not specifically mentioned in this specification, but are required for a through and diligent installation, must be provided by the selected contractor and included in the bid. It is assumed that the installers bidding on this contract have experience in the assembly and installation of similar packaging and conveying equipment and understand the accessories and hardware required for the installation. Basic installation instructions for equipment are included in this specification and some technical supervision during installation will be provided at the job site. However, the selected contractor, if they are unsure of what is required for the proper installation of a particular machine,may be required to contact the manufacturer for clarification. Manufacturer's contacts and phone numbers will be provided. During commissioning and startup of the packaging line,technical support will be provided by the equipment manufacturer's service representative. D. The scope of work includes the following: 1. Receiving, offloading and inspecting all equipment from the truck at the dock of the Minute Maid facility. 2. Transporting equipment from the dock to the staging area adjacent to the installation area(single level transport). 3. Uncrating the equipment„ REV. A PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 1 SPE-16040-14002 JA16040\Specs\Fina1\14002-Rev A.doc TABLE OF CONTENTS 1.0 GENERAL...............................................................................................................................1 1.1 SCOPE OF WORK SUMMARY.............................................................................................1 1.2 EQUIPMENT SUMMARY.....................................................................................................3 1.3 WORK NOT INCLUDED IN SCOPE ....................................................................................3 1.4 SAFETY PROCEDURES........................................................................................................4 1.5 SITE CONDITIONS AND COORDINATION.......................................................................4 2.0 DETAILED SCOPE OF WORK AND DOCUMENTATION................................................5 2.1 BID PACKAGE INSTALLATION DRAWINGS...................................................................5 2.2 EQUIPMENT INSTALLATION...................................................................:.........................6 2.3 COMBINED LOADS ..............................................................................................................6 2.4 GEBO CONVEYOR INSTALLATION..................................................................................6 2.5 INSTALLATION PROCEDURE-PACKAGING EQUIPMENT.........................................8 2.6 MISCELLANEOUS.................................................................................................................9 3.0 QUALITY ASSURANCE ...........................,,...........................................................................9 3.1 GENERAL...................................................,............................................................................9 3.2 INSTALLATION MATERIALS........................................................................................... 4.0 SCHEDULE AND ADMINISTRATIVE REQUIREMENTS ..............................................11 4.1 EQUIPMENT DELIVERIES.................................................................................................11 4.2 SCHEDULE COMMITMENT ..............................................................................................11 4.3 SCHEDULE TRACKING .....................................................................................................12 5.0 INSTALLATION CONTRACTOR'S PROPOSAL ..............................................................12 5.1 BASIS OF EVALUATION.............................:......................................................................12 5.2 INSTALLATION QUOTATION..........................................................................................12 5.3 CHANGE ORDERS...............................................................................................................13 5.4 STAFFING PLAN .............:....................................................................................................13 APPENDIX 6.1 DRAWING CROSS REFERENCE APPENDIX 6.2 INSTALLATION PROCEDURES-PACKAGING EQUIPMENT APPENDIX 6.3 INSPECTION CHECK SHEETS APPENDIX 6.4 QUOTATION FORMAT APPENDIX 6.5 GEBO CONVEYOR TAKE-OFF BY PHASE/ SYSTEM SUMMARYS APPENDIX 6.6 COMPRESSED AIR TIE-IN SKETCH SKP-00 APPENDIX 6.7 PLUMBING SYSTEMS SPECIFICATION, SPE-16040-15400 HVAC PIPING SPECIFICATION, SPE-16040-15500 REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. i SPE-16040-14002 J:\16040\Specs\Final\14002-Rev A.doc f PFI DESIGN, P.C. SPECIFICATION FOR PACKAGING LINE EQUIPMENT INSTALLATION SPE-16040-14002 1 �C � a_ z' ca n , c=m The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 Rey.. DateA, Descri Lion ' Admin.F Prie tired ecked A 12/20/00 Issue for Bid KAB B HIVI Client Approval: lient: Date: c 3.13 TRAINING A. Provide a minimum of 24 hours total of owner training, throughout the contract period for personnel designated by the Owner. 3.14 FIELD QUALITY CONTROL A. All work, materials and equipment shall comply with the rules and regulations of applicable local,province, and federal codes and ordinances as identified in Part 1 of this Section. B. Contractor shall continually monitor the field installation for code compliance and quality of workmanship. All visible piping and or wiring runs shall be installed parallel to building lines and properly supported. C. Contractor shall arrange for field inspections by local and/or state authorities having jurisdiction over the work. D. These systems require validation, all equipment purchases and installed to be selected accordingly. ++END OF SECTION 15900++ REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 17 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc c C. Control Panels Programming 1. Provide programming for the system as per specifications and adhere to the strategy algorithms provided. All other system programming necessary for the operation of the system but not specified in this document shall also be provided by the Control System Contractor. Embed into the control program sufficient comment statements to clearly describe each section of the program. The comment statements shall reflect the language used in the sequence of operations. D. Demonstration: A complete demonstration and readout of the capabilities of the monitoring and control system shall be performed. The contractor shall dedicate a minimum of 16 hours on-site with the Owner and his representatives for a complete functional demonstration of all the system requirements. This demonstration constitutes a joint acceptance inspection, and permits acceptance of the delivered system for on-line operation. 3.11 CLEANING A. This Subcontractor shall clean up all debris resulting from his or her activities daily. The Subcontractor shall remove all cartons, containers, crates, etc. under his control as soon as their contents have been removed. Waste shall be collected and placed in a location designated by the Construction Manager or General Contractor. B. At the completion of work in any area,the Subcontractor shall clean all of his/her work, equipment, etc.,making it free from dust, dirt and debris, etc. C. At the completion of work, all equipment furnished under this Section shall be checked for paint damage, and any factory finished paint that has been damaged shall be repaired to match the adjacent areas. Any metal cabinet or enclosure that has been deformed shall be replaced with new material and repainted to match the adjacent areas. 3.12 PROTECTION A. The Subcontractor shall protect all work and material from damage by his/her work or workers, and shall be liable for all damage thus caused. B. The Contractor shall be responsible for his/her work and equipment until finally inspected,tested, and accepted. The Contractor shall protect his/her work against theft or damage, and shall carefully store material and equipment received on site that is not immediately installed. The Contractor shall close all open ends of work with temporary covers or plugs during storage and construction to prevent entry of foreign objects. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 16 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc y t D. Valves -Actuators shall be mounted on valves with adapters approved by the actuator manufacturer. Actuators and adapters shall be mounted following manufacturer's recommendations. Actuators mounted outside shall be rated for exterior use. 3.8 IDENTIFICATION OF HARDWARE AND WIRING A. All wiring and cabling, including that within factory-fabricated panels, shall be labeled at each end within 2" of termination with a cable identifier and other descriptive information. B. Permanently label or code each point of field terminal strips to show the instrument or item served. C. Identify control panels with minimum 1 cm letters on laminated plastic nameplates. D. Identify all other control components with permanent labels. Identifiers shall match record documents. All plug-in components shall be labeled such that removal of the component does not remove the label. 3.9 CONTROLLERS A. Provide a separate Controller for each major piece of HVAC equipment. Points used for control loop reset such as outside air or space temperature are exempt from this requirement. B. Building Controllers and Custom Application Controllers shall be selected to provide a minimum of 15% spare I/O point capacity for each point type found at each location. If input points are not universal, 15% of each type is required. If outputs are not universal, 15% of each type is required. A minimum of one spare is required for each type of point used. C. Future use of spare capacity shall require providing the field device, field wiring, point database definition, and custom software. No additional Controller boards or point modules shall be required to implement use of these spare points. 3.10 PROGRAMMING A. Provide sufficient internal memory for the specified control sequences and trend logging. There shall be a minimum of 25% of available memory free for future use. B. Point Naming: System point names shall be modular in design, allowing easy operator interface without the use of a written point index. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 15 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc ' N. Flexible metal conduits and liquid-tight, flexible metal conduits shall not exceed 3' in length and shall be supported at each end. Flexible metal conduit less than 1/2" electrical trade size shall not be used. In areas exposed to moisture, including chiller and boiler rooms, liquid-tight, flexible metal conduits shall be used. 3.6 INSTALLATION OF SENSORS A. Install sensors in accordance with the manufacturer's recommendations. B. Mount sensors rigidly and adequate for the environment within which the sensor operates. C. Room temperature sensors shall be installed on concealed junction boxes properly supported by the wall framing. D. All wires attached to sensors shall be air sealed in their conduits or in the wall to stop air transmitted from other areas affecting sensor readings. E. Install duct static pressure tap with tube end facing directly down-stream of air flow. F. Sensors used in mixing plenums, and hot and cold decks shall be of the averaging type. Averaging sensors shall be installed in a serpentine manner horizontally across duct. Each bend shall be supported with a capillary clip. G. All pipe mounted temperature sensors shall be installed in wells. Install all liquid temperature sensors with heat conducting fluid in thermal wells. H. Wiring for space sensors shall be concealed in building walls. EMT conduit'is acceptable within mechanical and service rooms. I. Install outdoor air temperature sensors on north wall complete with sun shield at designated location. 3.7 ACTUATORS A. Mount and link control damper actuators per manufacturer's instructions. B. To compress seals when spring return actuators are used on normally closed dampers,power actuator to approximately 5° open position,manually close the damper, and then tighten the linkage. C. Check operation of damper/actuator combination to confirm that actuator modulates damper smoothly throughout stroke to both open and closed positions. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 14 SPE-16040-15900 J:\16040\Specs\Fina1\15900 Rev A.doc ,t t C. Do not install Class 2 wiring in conduit containing Class 1 wiring. Boxes and panels containing high voltage may not be used for low voltage wiring except for the purpose of interfacing the two (e.g. relays and transformers). D. Where class 2 wiring is run exposed,wiring shall be run parallel along a surface or perpendicular to it, and bundled, using approved wire ties at no greater than 10 ft(3 m) intervals. Such bundled cable shall be fastened to the structure,using specified fasteners, at 5 ft. (1.5 m) intervals or more often to achieve a neat and workmanlike result. E. All wire-to-device connections shall be made at a terminal blocks or terminal strip. All wire-to-wire connections shall be at a terminal block, or with a crimped connector. All wiring within enclosures shall be neatly bundled and anchored to permit access and prevent restriction to devices and terminals. F. Maximum allowable voltage for control wiring shall be 120V. If only higher voltages are available, the Control System Contractor shall provide step down transformers. G. All wiring shall be installed as continuous lengths,where possible. Any required splices shall be made only within an approved junction box or other approved protective device. H. Install plenum wiring in sleeves where it passes through walls and floors. Maintain fire rating at all penetrations in accordance with other sections of this specification and local codes. I. Size of conduit and size and type of wire shall be the design responsibility of the Control System Contractor, in keeping with the manufacturer's recommendation and NEC. J. Control and status relays are to be located in designated enclosures only These relays may also be located within packaged equipment control panel enclosures. These relays shall not be located within Class 1 starter enclosures. K. Follow manufacturer's installation.recommendations for all communication and network cabling. Network or communication cabling shall be run separately from other wiring. L. Adhere to Division 16 requirements for installation of raceway. M. This Contractor shall terminate all control and/or interlock wiring and shall maintain updated(as-built)wiring diagrams with termination's identified at the job site. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 13 SPE-16040-15900 J:\16040\Specs\Fina1\15900 Rev A.doe 1 ,I l 3.3 EXAMINATION A. The project plans shall be thoroughly examined for control device and equipment locations, and any discrepancies, conflicts, or omissions shall be reported to the Architect/Engineer for resolution before rough-in work is started. B. The Subcontractor shall inspect the site to verify that equipment is installable as shown, and any discrepancies, conflicts, or omissions shall be reported to the Architect/Engineer for resolution before rough-in work is started. 3.4 GENERAL WORKMANSHIP A. Install equipment,piping,wiring/conduit parallel to building lines (i.e. horizontal, vertical, and parallel to walls)wherever possible. B. Provide sufficient slack and flexible connections to allow for vibration of piping and equipment. C. Install all equipment in readily accessible location as defined by Chapter 1 Article 100 part A of the NEC. Control panels shall be attached to structural walls unless mounted in equipment enclosure specifically designed for that purpose. Panels shall be mounted to allow for unobstructed access for service. D. Verify integrity of all wiring to ensure continuity and freedom from shorts and grounds. E. All equipment, installation, and wiring shall comply with acceptable industry specifications and standards for performance, reliability, and compatibility and be executed in strict adherence to local codes and standard practices. 3.5 WIRING A. All control and interlock wiring shall comply with the national and local electrical codes, area classification drawings, and Division 16 of these specifications. Where the requirements of this section differ with those in Division 16, the requirements of this section shall take precedence. B. Where Class 2 wires are in concealed and accessible locations including ceiling return air plenums, approved cables not in raceway may be used provided that: 1. Circuits meet NEC Class 2 (current-limited)requirements. (Low-voltage power circuits shall be sub-fused when required to meet Class 2 current-limit.) 2. All cables shall be UL listed for application, i.e. cables used in ceiling plenums shall be UL listed specifically for that purpose. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 12 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc 2.7 COMPRESSED AIR SUPPLY A. Dry filtered 100 psig compressed air shall be available at the site. This Subcontractor shall tie into the existing 3/4" air lines indicated on the contract documents. Initial tie-in into the compressed air mains will be by the Plumbing Contractor. B. All compressed air piping,PRV valves, etc. from the 3/4" tie-in points indicated on the contract documents shall be provided and installed by this Subcontractor. 2.8 COMPRESSED AIR PIPING A. The entire Automatic Temperature Control system shall be designed so that the maximum pressure drop on any main and branch is 1/2 psig at maximum air consumption. All instrument air piping may be type M hard or soft temper copper tubing or polyethylene tubing. The tubing shall be provided as follows: 1. Exposed: Schedule 40 black steel with threaded fittings. Final termination to control devices may be made with a short run of single copper tubing (18" max.). 2. Inside panels and unit enclosures: Polyethylene tubing. 3.0 EXECUTION 3.1 SEQUENCE OF OPERATIONS A. Refer to contract documents for all control sequences and diagrams. 3.2 ADDITIONAL FIELD SERVICES A. Provide services of control supplier's field engineer to supervise work specified in other Sections: 1. Installation of automatic valves and separable wells furnished under this Paragraph. 2. Provision of necessary valved pressure taps,water drain and overflow connections and piping. 3. Provision of auxiliary contacts on magnetic starters with buttons and switches in required configurations. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg., 11 SPE-16040-15900 JAI 6040\Specs\Fina1\15900 Rev A.doc F. Transformer. Power supply for the ASC must be rated at minimum of 125% of ASC power consumption, and shall be fused or current limiting type. 2.4 CONTROL ACTUATORS A. Provide PRV to reduce air supply pressure from 80 psig to required control air supply pressure. Compressed air mains are currently located in the project area crawl space. B. All valve actuators for modulating service shall be designed to afford the following: 1. 100% surplus power to move the actuator from full open to full closed travel. 2. Adjustable spring range,both as to starting point and span to allow actual job operating range to be field adjusted. 2.5 CONTROL VALVES A. All automatic valves shall be fully proportioning with packing glands designated for hot or chilled water service. All valve bodies shall be designated for 125 psig service and shall have bronze trim and throttling plug inner valves for modulating control. Valves shall be normally open or closed as required and each shall be sized for the allowable pressure drop. B. All two-way valves shall have external spring adjustment with a self-sealing V- ring packing arranged to tighten the seal as the water pressure increases so that no manual adjustment is necessary. C. All automatic valves and separable sockets shall be furnished by the Temperature Control contractor and installed in the lines by the Mechanical Contractor. 2.6 BACK PRESSURE REGULATORS A. Back pressure regulators shall be provided where indicated on the contract documents. Regulator shall be completely self operated requiring no external power source. B. Valves shall be carbon steel, 303 SS trim and seats,Buna-N diaphragm with flanged end connections. C. Valves shall be equal to Jordan Mark 50 Series. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 10 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc b. Interconnections between internal and face-mounted devices pre- wired with color-coded stranded conductors neatly installed in plastic troughs and/or tie-wrapped. Terminals for field connections shall be UL listed for 600-volt service, individually identified per control/interlock drawings, with adequate clearance for field wiring. Control termination's for field connection shall be individually identified per control drawings. C. Provide on/off power switch with over-current protection and main air gauge for control power sources to each local panel. 2.3 APPLICATION SPECIFIC CONTROLLERS A. General: Application specific controllers (ASC) are microprocessor-based DDC controllers which through hardware or firmware design are dedicated to control a specific piece of equipment. They are not fully user programmable, but are customized for operation within the confines of the equipment they are designed to serve. 1. Each ASC shall be capable of stand-alone operation and shall continue to provide control functions without being connected to the network. 2. Each ASC will contain sufficient I/O capacity to control the target system. B. Environment. The hardware shall be suitable for the anticipated ambient conditions. 1. Controllers used outdoors and/or in wet ambient shall be mounted within NEMA Type 4 waterproof enclosures, and shall be rated for operation at 5F to 150 F(45 C to 65 C). 2. Controller used in conditioned ambient shall be mounted in dust-proof enclosures, and shall be rated for operation at 32 F to 120 F (0 C to 50 Q. C. Serviceability. Provide diagnostic LEDs for power, and communications. All wiring connections shall be made to field removable, modular terminal strips or to a termination card connected by a ribbon cable. D. Memory. The Application Specific Controller shall maintain all BIOS and programming information in the event of a power loss for at least 90 days. E. Immunity to Power and noise. Controller shall be able to operate at 90%to 110% of nominal voltage rating and shall perform an orderly shut-down below 80%. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 9 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc 4. Current Transducers/Sensors: a. For equipment status,provide analog current sensing sensors. Sensors shall be capable of producing analog current value proportional to equipment current load. Current switches shall be self-powered, solid state with adjustable trip current. b. Sensors shall be accurate to f3% of full scale current. C. Sensors shall be capable of reading 125% of full load amps (FLA). 5. Relays a. Control relays shall be UL listed plug-in type with dust cover. Contact rating, configuration, and coil voltage suitable for application. b. Time delay relays shall be UL listed solid-state plug-in type with adjustable time delay. Delay shall be adjustable plus or minus 200% (minimum) from set-point shown on plans. Contact rating, configuration, and coil voltage suitable for application. Provide NEMA Type 1 enclosure when not installed in local control panel. 6. Transformers and Power Supplies a. Control transformers shall be UL listed, Class 2 current-limiting type, or shall be furnished with over-current protection in both primary and secondary circuits for Class 2 service. b. Unit output shall match the required output current and voltage requirements. Current output shall allow for a 50% safety factor. Output ripple shall be 3.0 mV maximum Peak-to-Peak. Regulation shall be 0.10% line and load combined,with 50 microsecond response time for 50% load changes. Unit shall have built-in over- voltage protection. C. Unit shall operate between 0 C and 50 C. d. Unit shall be UL recognized. 7. Local Control Panels a. All indoor control cabinets shall be fully enclosed NEMA Type 1 construction with hinged door,key-lock latch, removable sub- panels. A single key shall be common to all field panels and sub- panels. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 8 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc i. Sensors shall be accurate to±0.5°F over minimum operating ranges. ii. Sensor, associated circuitry and readout shall have minimum resolution of 0.5°F. iii. Sensors shall withstand ambient temperatures of—30°F to 2407,but performance requirements must be met only for ranges specified. b. All sensors mounted in rooms shall be intrinsically safe for Class I, Division 1 environment. C. Provide thermistor(10,000 ohms or greater)or 1,000 ohm platinum resistance temperature device (RTD) sensors, and wall mounted space temperature sensors with 40°F to 100°F range. 2. Pressure Sensors and Transmitters: a. All pressure instruments shall conform to the following minimum standards. Additional specifications are given for specific applications below. i. Sensors shall be accurate to±1.0% of full scale and temperature effect shall contribute error less than±0.04% over the full scale of measurement. ii. Sensors shall withstand up to 150%of rated pressure,but performance requirements must be met only for ranges specified. iii. Sensor shall have separate zero and span adjustments for future field.calibration. Adjustments shall be non- interactive. 3. Electronic/Pneumatic Transducers: a. Input signal shall be either 4-20 mA or 0-10 vdc with an output pressure of 0-20 psig. b. Sensors shall be non-bleed type with no air consumption at steady state. C. Sensors shall be capable of field calibration. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 7 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc 1 2.2 SENSORS AND POINT HARDWARE A. General: 1. When providing instruments with 4-20 mA transmitters, conversion to voltage is required. Controls contractor shall provide 250 ohm 0.1% precision resistor. 2. Analog pneumatic outputs (3-15 psi) shall be produced by an analog output controlling a dedicated electronic to pneumatic transducer which is separately mounted in the field device section of the enclosure for ease of field replacement. The electronic to pneumatic transducer shall be a separate device which is not printed circuit card mounted. 3. Analog outputs should be linear variable outputs. If the Subcontractor uses the mode of operation for analog output which incorporates "pulse band width modulation" then the "pulse band width modulated" signal shall be converted through a "pulse band width to analog output transducer"which then provides output to the final control element to eliminate an inherent offset that can occur in mechanical electrical "floating control" type control loops. B. Alarms: 1. Alarm contacts shall be wired normally closed(NC). If equipment only has normally open(NO)contacts,provide an intervening relay that will have NC contacts which shall open via the NO relay. When in alarm condition or if wire to contact is opened(say wire cut in field), shall sense condition and generate alarm. 2. Common alarms shall be wired to alarm terminals on manufacturer's control panel. 3. Priority levels shall be provided for alarms, and alarm messages shall allow different levels for message outputs. C. Sensor Requirements: 1. Temperature Sensors and Transmitters: a. Temperature sensors shall conform to the following minimum standards. Additional specifications are given for specific applications below. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 6 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc inexperienced user. It shall describe in layman's language, the functions and procedures of"using"the system. 1.7 ACCEPTANCE TESTING A. At substantial completion of the work, this Subcontractor shall prepare a punch list of all items remaining to be completed or corrected. The failure to include any items on such list does not alter the responsibility of this Subcontractor to complete all work in accordance with the contract documents. This list shall be delivered to the Construction Manager prior to Subcontractor's request for formal acceptance testing. B. Acceptance Test Procedure: 1. This Subcontractor shall demonstrate in the presence of Engineer/Owner that all functions of the control systems are operating as specified in the contract documents, including any required change orders. The final checkout will include,but not be limited to, the following items: a. Provide hard copy of fully annotated program (PPLC)with comment lines for review and approval. b. Verification of the location, calibration and proper wiring/connection of all input and output devices. C. The proper operation and calibration of all ATC devices and actuators shall be verified individually. d. When system performance is deemed satisfactory, system parts shall be accepted for beneficial use. Warranty shall begin. All minor deficiencies found will be noted in writing by Construction Manager. All deficiencies so noted shall be corrected by this Subcontractor before the final acceptance will be issued. 2.0 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Andover Controls B. Johnson Controls C. Invensys REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 5 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc B. Codes and Standards: Meet requirements of all applicable standards and codes, except when more detailed or stringent requirements are indicated by the Contract Documents, including requirements of this Section. 1. Underwriters Laboratories: Products shall be UL-916-PAZX listed. 2. National Electrical Code--NFPA 70. 3. Federal Communications Commission--Part J. C.. All products used in this installation shall be new, currently under manufacture, and shall be applied in similar installations for a minimum of 2 years. This installation shall not be used as a test site for any new products unless explicitly approved by the Owner's representative in writing prior to bid date. Spare parts shall be available for at least 5 years after completion of this contract. D. All control devices shall be Y2K compliant. 1.8 EQUIPMENT OPERATION INSTRUCTION AND MAINTENANCE MANUALS A. On completion and acceptance of the work, furnish for approval three copies of written instructions on the proper operation and maintenance of all equipment and apparatus furnished under this section. B. Each manual shall be provided with an index sheet listing the contents in alphabetical order and shall contain but not be limited to the following material: 1. Updated copies of all submittal data and shop drawings as specified previously. 2. Manufacturer's instructions regarding the installation,maintenance and calibration of each component used in the ATC system installed by Subcontractor. 3. Copies of all warranties and guarantees issued by each equipment manufacturer. 4. "As-built" interconnecting wiring diagrams and wire lists of the field installed system with complete,properly identified numbering of each system component and device. 5. A set of"User's Manual"detailing the operation of the control systems. The manual shall describe the hardware operation as well as provide instructions in computer access and programming. This manual shall be submitted under separate cover. The User Manual shall be written for an REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 4 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc 1. Control drawing for each system, with detailed piping and wiring diagrams, including bills of materials and written description of operation. 2. System layout drawing showing controls. 3. Point List, listing every component to be sensed or controlled,including I/O device, signal type, control function, and associated alarms. 4. Valve and damper schedules showing sizes, configurations, capacities, pressure drops and locations of equipment, with calculations for valve coefficient(Cv) for each valve. 5. Data sheets and specifications for control system components, including sensors, transmitters, transducers, panels, controllers, and other devices. 6. Tabulated results of calculations for compressed air consumption and compressed air piping layout showing sizes and locations of compressed air mains and risers and locations and capacities of pressure reducing valves. 7. Complete commissioning plan with point-to point check out procedures to ensure that all physical points are consistently tested and verified for this project. 1.6 PROGRAMMED MAINTENANCE AND STARTUP A. Start system and perform necessary testing and debugging. Perform acceptance test in presence of Owners representative and Engineer. Provide 15 days notice before acceptance test. Notice shall certify that system is complete and operates as required by Contract Documents. When system performance is deemed satisfactory, system parts will be accepted for beneficial use warranty shall begin. 1.7 QUALITY ASSURANCE A. System Installer Qualifications 1. The Installer shall have an established working relationship with the Control System Manufacturer of not less than three years. 2. The Installer shall have successfully completed Control System Manufacturer's classes on the control system. The Installer shall present for review the certification of completed training, including the hours of instruction and course outlines upon request. 3. The,installer shall provide 24 hour response in the event of a customer call. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 3 SPE-16040-15900 J:\16040\Specs\Fina1\15900 Rev A.doc ' 1 J. Subcontractor shall furnish to the mechanical contractor all control valves as shown on the drawings and described in these specifications. K. Subcontractor shall assist testing and balancing contractor as required to complete balancing work. L. Subcontractor shall provide commissioning services as required to meet requirements of this specification. 1.2 RELATED SECTIONS A. The General Conditions of the Contract, Supplementary Conditions and General Requirements are a part of these Specifications and shall be used in conjunction with this Section as a part of the Contract Documents. Consult them for further instructions pertaining to this work. This Subcontractor is bound by the provisions of Division 0 and Division 1. 1.3 RELATED WORK BY OTHERS A. Control valves, and separable wells for immersion elements furnished by this Subcontractor shall be installed by the Mechanical Subcontractor under this Subcontractor's supervision. B. All cutting,patching and painting is by others. 1.4 WARRANTY OF SYSTEM A. Provide controls supplier's warranty of performance of entire system, including pneumatic components, as required by Contract documents. Performance and components requirements are established by control sequences and diagrams on Drawings and by this Paragraph. B. The Subcontractor shall guarantee the controls to be free from defects in material and workmanship and guarantee performance of systems as required by Contract Documents for one year of normal use and service beginning on date Owner begins to receive beneficial use of system. 1.5 SUBMITTALS A. This Paragraph supplements the provisions of the Submittals Paragraph of Section 15000 and Division 1 requirements B. Submit the following shop drawings and device documentation for approval: REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 2 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doc CONTROL SYSTEMS SECTION 15900 1.0 GENERAL REQUIREMENTS 1.1 SCOPE OF WORK A. Provide complete controls for building equipment control. All systems shall be provided directly by the manufacturer, or by a dealer licensed by the manufacturer. The manufacturer must provide full support to the licensed dealer throughout the guarantee period. Systems to be controlled include but not limited to air handling units,boilers, chillers, cooling tower and pumps. AHD's and chillers are provided with unit mounted controls. There are no provisions for a building management system as part of this scope. B. The DDC controls shall perform all sequences of operation which may be listed on control drawings or attached to this specification. The controls shall be capable of proportional-integral-derivative(PID)control. Pneumatic components shall be fully proportioning unless otherwise noted. Controls supplier shall provide all devices necessary to completely perform sequences whether such devices are explicitly shown on the drawings, specified, or not shown or specified. C. This Subcontractor shall provide panel enclosures to house all controllers,relays and control devices necessary for a fully functioning control system. D. This Subcontractor shall provide all pneumatic air piping for all control valve actuators and differential pressure sensors. E. This Subcontractor shall coordinate with mechanical and balancing contractor to meet all start-up and commissioning requirements. F. Certify maintenance of local office to job site, staffed with factory-trained engineers capable of providing instructions to Owner's personnel, and performing routine and emergency maintenance on all system components. G. Provide and install all control devices as indicated on the HVAC control diagrams located on the contract documents. H. Provide the services of control manufacturer's representative to be on site during installation and during the entire time that the startup,testing and balancing procedures detailed in other sections,take place. The representative shall be part of the manufacturer's service organization and shall be skilled in the adjustment and calibration of all control devices as well as being capable of modifying and checking system software. 1. Subcontractor shall furnish and install actuators for all control valves. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 1 SPE-16040-15900 JA16040\Specs\Fina1\15900 Rev A.doe TABLE OF CONTENTS 1.0 GENERAL REQUIREMENTS........................................................................................... 1 1.1 SCOPE OF WORK...................................,.......................................................................... 1 1.2 RELATED SECTIONS......................................................................................................2 1.3 RELATED WORK BY OTHERS......................................................................................2 1.4 WARRANTY OF SYSTEM...............................................................................................2 1.5 SUBMITTALS ...................................................................................................................2 1.6 PROGRAMMED MAINTENANCE AND STARTUP..................................................... 3 1.7 QUALITY ASSURANCE.................................................................................................. 3 1.8 EQUIPMENT OPERATION INSTRUCTION AND MAINTENANCE MANUALS .....4 1.7 ACCEPTANCE TESTING................................................................................................. 5 2.0 PRODUCTS........................................................................................................................ 5 2.1 ACCEPTABLE MANUFACTURERS .............................................................................. 5 2.2 SENSORS AND POINT HARDWARE ............................................................................ 6 2.3 APPLICATION SPECIFIC CONTROLLERS .................................................................. 9 2.4 CONTROL ACTUATORS............................................................................................... 10 2.5 CONTROL VALVES....................................................................................................... 10 2.6 BACK PRESSURE REGULATORS............................................................................... 10 2.7 COMPRESSED AIR SUPPLY ......................................................................................... 11 2.8 COMPRESSED AIR PIPING .......................................................................................... 11 3.0 EXECUTION.................................................................................................................... 11 3.1 SEQUENCE OF OPERATIONS....................................................................................... 11 3.2 ADDITIONAL FIELD SERVICES ................................................................................. 11 3.3 EXAMINATION.............................................................................................................. 12 3.4 GENERAL WORKMANSHIP......................................................................................... 12 3.5 WIRING............................................................................................................................ 12 3.6 INSTALLATION OF SENSORS..................................................................................... 14 3.7 ACTUATORS................................................................................................................... 14 3.8 IDENTIFICATION OF HARDWARE AND WIRING................................................... 15 3.9 CONTROLLERS.............................................................................................................. 15 3.10 PROGRAMMING............................................................................................................ 15 3.11 CLEANING...................................................................................................................... 16 3.12 PROTECTION................................................................................................................... 16 3.13 TRAINING..............................................,......................................................................... 17 3.14 FIELD QUALITY CONTROL.......................................................................................... 17 REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. i SPE-16040-15900 J:\16040\specs\Final\15900 Rev A.doc NNW 1. .I 5 l PFI DESIGN, P.C. SPECIFICATION FOR CONTROL SYSTEMS SPE-16040-15900 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 Pa axed �he�k��d a, pF A 1/24/01 Issue for Bid KAB TAE M HM Client Approval: Client: Date: PH DESIGN, P.C. Vendor Data Commitment Form Inquiry No.: SPE-16040-15710 P.O.No.: Vendor Name: Date: 12/28/00 Client: The Minute Maid Company Project No.: 16040 Equip.No.: CT-1 Drawing Description No.of Copies When Approval When Scheduled Required Required Before (To be Completed (Weeks After Fabrication by Vendor) P.O. General Arrangement/Outline Drawing 1 R/6 P 2 Yes Foundation Requirements Including 1 R/6 P 2 Yes Equipment/Operating Weights Assembly Drawings/Detail Cross- 1 R/6 P 4 Yes Section w/Parts List and Bill of Material Fabrication Drawings 1R/6P 6 Yes Wiring Diagrams 1 R/6 P 6 Yes Certified Drawings 1 R/6 P 4 weeks before shipping Fabrication Schedule 6 copies 4 Instrument Data Including Manufacturer 6 copies 6 Yes and Catalogue No. Installation Instructions,Operating and 6 copies each 4 weeks before Maintenance Manuals shipping Manufacturer's Data Sheets 6 copies 4 weeks before shipping Recommended Spare Parts for One 6 copies 4 Year's Operation with Prices, Availability and Part Nos.for Ordering Inspection,Test Procedures and Test 6 copies 6 Reports/Results Certified Performance Data 6 prints 4 weeks before shipping Sequence of Operation 6 copies 6 Yes I have completed the following and confirm I will comply with the dates/time period specified. Vendor Signature: s 3.5 DELIVERY A. Ship cooling tower as a single piece. B. Notify the Owner five (5) days in advance with the scheduled shipping date and location. The Owner reserves the right to inspect the cooling tower prior to unloading. C. Acceptance on Site: If the cooling tower is damaged upon arrival it will be rejected. ++END OF SECTION 15710++ REV. 0 PFI DESIGN, P.C. DECEMBER 28, 2000 Pg. 13 SPE-16040-15710 JAI 6040\Specs\Fina1\15710-Rev O.doc • B. All equipment and materials shall be suitably crated,boxed, equipped with handling fixtures, or otherwise prepared for shipment to prevent damage or contamination during handling and shipping. All parts which may be exposed to the weather due to physical size or arrangement shall be adequately protected by suitable weatherproofing. It shall be the responsibility of the Vendor to take any other precautions required to reasonably ensure jobsite arrival of the equipment in an undamaged and satisfactory working condition. C. All pipe ends shall be sealed, using plastic caps for flanged ends, and metal thread protectors or cap plugs for threaded ends to exclude entry of foreign matter. D. All parts shall be identified in an appropriate manner. When parts are crated or boxed, detailed packing lists shall be provided with each crate or box. E. Component weights shall be plainly marked on all equipment requiring rigging so that field construction forces can suitably handle the equipment. F. Vendor shall notify Purchaser ten(10)working days prior to shipment. 3.4 START-UP ASSISTANCE A. Vendor shall provide startup assistance at Owner's facility in Northampton, Massachusetts. Startup assistance shall consist of: 1. Commissioning and startup of equipment. 2. Operator Training. 3. The Manufacturer shall provide on-site services of a factory authorized service representative to completely check the mechanical and electrical installation of each unit, and to start up and test each unit in cooperation with the installing contractor and the water balance contractor. The Vendor shall provide per diem costs for additional services if required. 4. The Manufacturer shall provide a checklist for completion by the Contractor and approval by the Owner after installation of the units, to ensure that they are ready for start up. The Manufacturer shall schedule the start up service within two weeks of request given by the Owner. 5. The commissioning and start up service shall include full testing of the cooling tower. 6. The service representative shall submit three (3) copies of the start up report to the Owner within two weeks of start up. B. Vendor to provide an estimate of the startup duration. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 1.2 SPE-16040-15710 JAI 6040\Specs\Fina1\15710-Rev O.doc 12. All motors shall be designed for continuous duty and shall not exceed the temperature rises indicated for each insulation class, in NEMA Standards Publication MG1-1998. 13. Copper conductors shall be used for windings. 14. To provide resistance to chemical corrosion, no aluminum parts of the motor shall be exposed to the atmosphere. 15. For motors 10 HP and larger, the locked rotor kVA/HP shall not exceed locked rotor code letter"G" (5.6—6.29 kVA/HP). 16. A spring-loaded cap shall be installed on the outlet of each bearing grease chamber discharge port. Grease fittings shall be supplied on inlet grease connections. 17. Motors operating with VFDs shall be UL rated for Inverter Duty and shall meet all requirements Part 31 of NEMA standard MG1-1998 for Inverter- Fed Polyphase Motors. 18. The motor shall be suitable for operation in the environment indicated in the data sheet(s). 19. Motors for use in areas subject to washdown shall be suitable for wet or washdown locations. 3.0 EXECUTION 3.1 TESTS A. The Vendor shall make all shop tests necessary to insure that his material and workmanship are of the required quality and that the equipment furnished will perform as specified and guaranteed. 3.2 CLEANUP A. All oil, grease, and dirt shall be removed by scrubbing with soap, alkali cleaners or suitable solvents. All welding flux shall be brushed or blasted free. After cleaning,the vendor shall protect the equipment from intrusion of dirt, debris, or foreign material. 3.3 PREPARATION FOR SHIPMENT A. Vendor shall make final check for completeness of equipment prior to shipment. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 11 SPE-16040-15710 J:\16040\Specs\Fina1\15710-Rev O.doc • d. Range of motor frame sizes and mounting sizes easily adapted for each drive. e. Motor voltage 2. Motors greater than %i BP shall be 480 volts, 3-phase, 60 hertz. Motors %z BP or smaller shall be 120 volt, single phase, 60 hertz. 3. All motors will be designed and manufactured such as to conform to all applicable requirements of the latest editions of standards published by NEC, ANSI,IEEE,NFPA, and NEMA MG-1 standard. 4. All motors shall be premium efficiency. When the motor is operating at rated voltage and frequency, the minimum full load efficiency shall equal or exceed the nominal values in NEMA Standards Publications#MG1- 1998 and efficiencies list in this specification. 5. Motors shall be of the squirrel cage, induction type and shall be capable of starting and accelerating their load to normal operating speeds under the most severe conditions likely to be encountered without exceeding the horsepower rating indicated on the nameplate; and without usurping any portion of any specified service. 6. Speed and torque characteristics shall conform to NEMA Design B requirements. When speed and torque characteristics other than NEMA Design B are required,the bidder's proposal shall clearly indicate such requirements, and the motor shall have speed and torque characteristics, which will satisfy the requirements. Unless otherwise specified or required,motors shall have a Service Factor of 1.15,except inverter duty motors shall have a service factor of 1.0. 7. TEFC & ODP motors shall be rated for"mill and chemical duty". 8. Motors shall have NEMA Class F insulation minimum. 9. Motor nameplates shall be of stainless steel and shall be permanently fastened with stainless steel fasteners. 10. Seals shall be used to retain grease and to protect bearings from dust. 11. Motors shall have grease lubricated ball or roller bearings capable of in service lubrication. Bearings shall be of such design to provide extra long life. Permanently lubricated bearings will not be acceptable. Grease fittings shall be easily accessible and not interfere with machine operation. REV. 0 PFI DESIGN, P.C. DECEMBER 28, 2000 Pg. 10 SPE-16040-15710 JAI 6040\Specs\Fina1\15710-Rev O.doc B. Scope 1. All electrical work shall meet the standards of the latest issue of the NEC, and shall comply with applicable state and municipal laws, and local plant safety regulations covering each class of work. 2. All electrical controls and control panels shall be located where accessible and,preferably, at grade. 3. Cables and conductors shall be sized in accordance with the National Electrical Code (NEC),based on the current-carrying capacity, voltage- drop considerations, short circuit rating, and derating due to heating effects. 4. Electrical power will be supplied at 480 Volt AC +10%, 3 phase, 3 wire, 60 hertz. C. General Requirements 1. All motors, electrical equipment and control devices shall be designed and manufactured to conform to all applicable requirements of the latest editions of the code and standards as specified in the attached process specification. 2. Unless specifically noted, all electrical and electronic accessories supplied by the Vendor shall have suitable enclosures and connection boxes for the unit's electrical classification. They must also be listed and labeled with a minimum of one of the electrical listing agencies in the attached process specification. 3. All electrical equipment shall be UL listed for its application and shall be stamped with this approval. 4. Where conflicts occur among the codes, ordinances, standards, and specifications, more restrictive requirements shall govern. D. Motors 1. The Vendor shall provide with their quotation the motor design requirements necessary to provide adequate operation as required by this specification. The motor design requirements shall include at a minimum the following: a. Motor horsepower. b. Motor speed. C. Motor torque. REV. 0 PH DESIGN, P.C. DECEMBER 28, 2000 Pg. 9 SPE-16040-15710 J:\16040\Specs\Fina1\15710-Rev O.doe B. Ladder and platform shall be fully supported by tower. 2.4 SOUND LEVEL A. Unless clearly stated otherwise in the proposal and purchase agreement,no systems furnished under these specifications shall produce sound levels in excess of 85 dBA, as measured by OSHA standard methodology. 2.5 PAINTING A. All non-galvanized or non-stainless steel components shall be painted by the Vendor with two coats of epoxy paint. A copy of the Vendor's standard painting materials and procedures shall be forwarded to the Purchaser's Engineers for approval. A copy of the paint specifications shall be provided with the quotation. B. No blasted surfaces shall be allowed to remain un-coated overnight in humid areas. All paint is to be applied to a surface free from moisture, oil, dust, grit, or any other contaminants and discoloration. 2.6 MARKING A. Each piece of equipment shall be provided with a stainless steel nameplate, permanently attached to the exterior of the equipment, in an accessible location external to any insulated surface, and observable while the equipment is in operation. The nameplate shall include the following information: 1. Manufacturer's name,model, and serial number. 2. Year built. 3. Nominal capacity. 4. Purchaser's equipment identification number(CT-1.). 5. Weight of equipment. 6. Design(pressure/temperature). 2.7 ELECTRICAL REQUIREMENTS, MOTORS A. Introduction 1. This specification contains general electrical requirements for equipment and should be considered as an integral part of the specification that it accompanies. Should any discrepancies occur between this specification and the accompanying equipment specification, the purchaser shall be the sole party responsible for clarifying the discrepancies. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 8 SPE-16040-15710 JAI 6040\Specs\Fina1\15710-Rev O.doc 4. Fan bearings shall be heavy duty, self-aligning, grease lubricated ball bearings with moisture proof seals and integral slinger rings. All bearings shall be capable of in service lubrication. Permanently lubricated bearings are not acceptable. 5. Cooling tower fans to have 3-phase motors in accordance with section 2.6. Fan motors will be single-winding continuous duty motors, especially designed to for cooling tower duty. Motors shall be designed for 460 volt 3-phase 60 cycle power. Motors shall be non-overloading at all points on the fan curve at both speeds. 6. Motors shall be furnished with special moisture protection on the windings, shafts and bearings. Provide space heaters for wintertime operation. 7. Lifting eyes or lugs shall be provided for all motors. E. Options 1. Bottom floor outlet for a remote sump application. 2. Flanged inlet and outlet connections. 3. All assembly hardware and internal steel components shall be stainless steel. F. Piping and Fittings 1. Manufacturer's standard for industrial use. Vendor shall supply details of their piping, fittings and valve standards,with quote, for purchaser's review. G. Instrumentation 1. Vendor shall supply any required instrumentation noted in this specification as a minimum. Blowdown will be controlled automatically by Purchaser. H. Controls 1. All controls shall be provided by others. 2.3 UNIT ACCESS A. Provide ladder and platform as required to access tower motor and maintain tower. No external ladders or scaffolding shall be required to access tower. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 7 SPE-16040-15710 JA16040\Specs\Fina1\15710-Rev O.doc Removable and replaceable polypropylene nozzles installed in the floor of the basin shall provide full coverage of the fill by gravity flow. Nozzles must all have the same orifice size and be space symmetrically in both longitudinal and transverse directions. Removable fiberglass covers for the distribution basins are required. 2. Cold Water Basin and Accessories. a. The cold water basin shall be a single piece,joined to the tower structure at the factory. Provide bottom outlet with a debris screen and anti-cavitation device. The overflow shall consist of a 1.25" diameter PVC standpipe. When unscrewed from its fitting, this shall serve as a flush-out drain. C. Fill, Louvers and Drift Eliminators 1. Fill shall be film type,thermoformed PVC with louvers and drift eliminators formed as part of each fill sheet. It shall be suspended from structural tubing supported from the upper tower structure and elevated sufficiently above the floor of the cold water basin to allow cleaning. 2. Louvers shall be constructed of corrosion-resistant and non-combustible materials. The louvers shall be stiff enough to resist sagging, spaced to minimize air resistance and prevent water splash out, and shall be slip fitted into notched frames to allow rapid replacement without tools. 3. Vendor shall furnish a drift eliminator to limit drift loss to 0.005% or less of the water circulation rate. Drift eliminator shall be non-combustible and rot,rust, and mildew-proof. D. Fans, Drives and Motors 1. A single fan design shall be provided. The fan shall be single-speed. 2. Fan(s) shall be fixed pitch propeller type. Fan(s) shall be driven through V-belt(s)with a minimum service factor of 1.50 based on full motor HP. A fiberglass guard shall cover the motor pulley and belts. The fan and fan pulley will be mounted on a bearing housing with stainless steel shaft. A hot dip galvanized steel hoop fan guard shall be provided on all models. 3. The fan drive and motor assembly shall operate at all speeds without vibration. Vendor shall provide vibration switches with manual reset to shut down each fan in case of excessive vibration. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 6 SPE-16040-15710 JAI 6040\Specs\Fina1\15710-Rev O.doc ITEM DESCRIPTION Minimum Motor Efficiency 90% Number of Motor Speeds One Maximum Operating Weight 4,000 lbs. Make-up Valve Required No Remote Sump Application Yes Note: Tower to be selected based on the current 100 ton load. Selection of tower shall have the ability to upgrade to 125 tons by changing the motor to 7-1/2 HP. 2.0 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Marley- Series 3800, Model#3861. B. Baltimore Air Coil -Ultralite 100 Series, Model#XL-36-4-P2. C. Delta- 100 I 2.2 UNIT CONSTRUCTION A. Structural Requirements 1. Vendor to provide standard support arrangement design for approval. The design for the seismic zone corresponding to Northampton, MA. 2. Structural components of the tower, including the cold water basin, framework, casing, hot water basin and fan cylinder shall be fabricated of fiberglass reinforced polyester,manufactured by the spray lay-up method. Steel components, including the mechanical equipment support members, shall be heavy gauge steel protected against corrosion by G-210 galvanizing. All components subjected to factory welding shall be hot dip galvanized after completion of fabrication to a zinc thickness equivalent of G-210. Cold galvanizing is not acceptable. B. Basins And Water Distribution System 1. Hot Water Distribution System: a. An open basin above the fill bank shall receive hot water piped to each cell of the tower. This basin shall be an integral portion of the top section of the tower,precluding the need for installation and sealing. Water shall enter the basin through a removable wave suppressor splash box. The basin shall be no less than 6-1/2" deep to provide adequate freeboard against overflow and splash out. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 5 SPE-16040-15710 J:\16040\Specs\Fina1\15710-Rev O.doc NEC National Electric Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Agency NIST National Institute of Standards and Technology OSHA Occupational Safety and Health Administration UL Underwriter's Laboratories 1.7 MECHANICAL PARTS A. All mechanical parts subject to periodic maintenance,removal, or replacement, and all parts intended to be connected to Purchaser supplied equipment or piping shall conform to the standards set up for such parts by the pertinent governing code, insurance regulations, and engineering or manufacturing society. 1.8 QUALITY ASSURANCE A. Manufacturer's Certification: Certify cooling tower's thermal performance according to CTI Standard 201. B. NEMA Compliance: Provide electric motors and electrical components required as part of factory fabricated cooling towers that comply with applicable NEMA standards. C. NEC Compliance: Install cooling towers according to NFPA 70 "National Electrical Code". 1.9 SELECTION CRITERIA A. The cooling tower selected shall meet or exceed the design data listed below: ITEM DESCRIPTION Unit Tag CT-1 Entering Water Temperature 110°F Leaving Water Temperature 80°F GPM Flow Rate 100 Design Wet Bulb 75°F Maximum Wet Bulb 77°F Nominal Tonnage 100 Minimum Horsepower 5.0 Motor RPM 1,800 REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 4 SPE-16040-15710 JAI 6040\Specs\Fina1\15710-Rev O.doc 1.4 SAFETY AND HEALTH A. All equipment shall comply with the latest edition of EPA, OSHA,NFPA,UL, ANSI,ASHRAE, ASTM, and CTI standards, and other national, state, and local codes and regulations applicable at the Purchaser's plant location in Northampton, MA. 1.5 DEFINITIONS A. Owner: The Minute Maid Company 45 Industrial Drive Northampton,MA 01060 B. Architect/Engineer: Process Facilities Inc. 160 Federal Street Boston, MA 02110-1700 (617) 946-9400 C. Contractor: PFI Construction Corp. 160 Federal Street Boston, MA 02110-1700 (617) 946-9400 1.6 CODES AND STANDARDS A. Various codes, standards, or other documents that are mentioned by short-form name elsewhere in this Specification are fully identified below. To the extent that these documents apply,the version of the document that is applicable at the time the purchase order is placed shall apply. Short Name Complete Identification of the Document AGMA American Gear Manufacturer's Association ANSI American National Standards Institute ASHRAE American Society of Heating,Refrigerating, and Air- Conditioning Engineers ASTM American Society for Testing and Materials CTI Cooling Tower Institute EPA Environmental Protection Agency IEEE Institute of Electrical &Electronics Engineers REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 3 SPE-16040-15710 JA16040\Specs\Fina1\15710-Rev O.doc 1.2 SUBMITTALS A. General: Submit each item in this Article according to the conditions of the Contract requirements. Obtain approval from PFID before proceeding with fabrication and work. Six (6)copies shall be submitted to the Construction Manager. B. Product data including the following: 1. Certified cooling tower performance curves and data sheets with system operating conditions indicated. 2. System summary sheet. 3. Motor ratings and electrical characteristics. 4. Material gages and finishes. 5. All accessories being provided. C. Shop drawings from manufacturer detailing equipment assemblies and indicating dimensions, weights, loadings,required clearances,method of field assembly, components, and location size of each field connection. D. Wiring diagrams detailing wiring for power and control systems and differentiating between manufacturer-installed and field-installed wiring. E. Spare parts list with part numbers and pricing for ordering and recommended locations to purchase parts. F. Installation, Operation, and Maintenance manuals. G. Assembly drawings for field fabrication of items shipped loose. 1.3 GUARANTEE A. The Fabricator shall provide a thermal performance warranty, certified by the Cooling Tower Institute,that the system will operate satisfactorily, in clean and fouled conditions, over the entire range of operating conditions defined in the Purchaser's equipment specification. This performance must be accomplished using equal or less power than specified. The purchaser reserves the right to conduct an on-site thermal performance test to confirm conformance to the design. B. The entire cooling tower assembly shall have a(one) 1 year parts and labor warranty beginning on the date of startup and/or acceptance by the Owner. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 2 SPE-16040-15710 JA16040\.Specs\Fina1115710-Rev O.doc COOLING TOWER SECTION 15710 1.0 GENERAL REQUIREMENTS 1.1 SCOPE OF WORK A. This specification establishes the minimum requirements for the mechanical design, materials of construction, fabrication, testing, and delivery of one(1) Induced Draft Crossflow or Counterflow Cooling Tower to Northampton, Massachusetts. Tower shall be a remote sump application. B. The Vendor shall furnish all equipment,materials, and services required for satisfactory operation within the intent of this specification,which shall include, but not necessarily be limited to, the following: 1. The equipment as indicated in this specification. 2. Performance and mechanical guarantee for the unit. 3. Compliance with all requirements set forth on the Purchase Order. 4. Shop tests as required. 5. Lifting eyes and any special tools required for maintenance. 6. All instrument components, including enclosures and connection boxes. 7. All design information requested in this specification. 8. Table or curve of system capacity as a function of inlet temperature. C. The Vendor shall furnish pricing for the items indicated on the enclosed specification as a base case. The cost and delivery impact of non-standard items and requested options shall be listed separately. D. The following equipment,materials, utilities, and services shall be supplied by the Purchaser: 1. Labor and equipment for unloading and erection of all equipment at the job site. 2. Structural steel platform. 3. Cooling water treatment chemicals and equipment. 4. Cooling water filtration equipment. 5. Motor starters and 480 volt, 3 phase, 60 Hz power supply, starters and disconnects. E. Provide lead time for delivery of cooling tower to the site. F. The Vendor shall furnish all documentation as indicated in this specification and comply with all the requirements on the Purchase Order. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. I SPE-16040-15710 JAI 6040\Specs\Fina1115710-Rev O.doc TABLE OF CONTENTS 1.0 GENERAL REQUIREMENTS...............................................................................................1 1.1 SCOPE OF WORK..................................................................................................................1 1.2 SUBMITTALS ........................................................................................................................2 1.3 GUARANTEE.........................................................................................................................2 1.4 SAFETY AND HEALTH........................................................................................................3 1.5 DEFINITIONS.........................................................................................................................3 1.6 CODES AND STANDARDS..................................................................................................3 1.7 MECHANICAL PARTS .........................................................................................................4 1.8 QUALITY ASSURANCE.......................................................................................................4 1.9 SELECTION CRITERIA........................................................................................................4 2.0 PRODUCTS.............................................................................................................................5 2.1 ACCEPTABLE MANUFACTURERS ...................................................................................5 2.2 UNIT CONSTRUCTION........................................................................................................5 2.3 UNIT ACCESS........................................................................................................................7 2.4 SOUND LEVEL......................................................................................................................8 2.5 PAINTING............................................................................................... ..............................8 2.6 MARKING ..............................................................................................................................8 2.7 ELECTRICAL REQUIREMENTS,MOTORS.......................................................................8 3.0 EXECUTION.........................................................................................................................11 3.1 TESTS....................................................................................................................................11 3.2 CLEANUP.............................................................................................................................11 3.3 PREPARATION FOR SHIPMENT......................................................................................11 3.4 START-UP ASSISTANCE...................................................................................................12 3.5 DELIVERY.......................................................:.....................................................................13 REV. 0 PFI DESIGN, P.C. DECEMBER 28, 2000 Pg. i SPE-16040-15710 JAI 6040\Specs\Final\15710-Rev O.doc - g PFI DESIGN, P.C. SPECIFICATION FOR COOLING TOWER SPE-16040-15710 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 Re*: Date Description Admin Pre ared . ' :Checked ` °Approved A 11/17/00 Issue for Bid KAB TAE MJH HM 0 12/28/00 Issue for Construction KAB T HM Client Approval: Client: Date: PH DESIGN, P.C. Vendor Data Commitment Form Inquiry No.: SPE-16040-15780 P.O.No.: Vendor Name: Date: 12/28/00 Client: The Minute Maid Company Project No.: 16040 Equip.No.: MAU-5&MAU-6 Drawing Description No.of Copies When Approval When Scheduled Required Required Before (To be Completed (Weeks After Fabrication by Vendor) P.O. General Arrangement/Outline Drawing 1 R/6 P 2 Yes Foundation Requirements Including 1 R/6 P 2 Yes Equipment/Operating Weights Assembly Drawings/Detail Cross- 1 R/6 P 4 Yes Section w/Parts List and Bill of Material Fabrication Drawings 1 R/6 P 6 Yes Wiring Diagrams 1 R/6 P 6 Yes Certified Drawings 1R/6P 4 weeks before shipping Fabrication Schedule 6 copies 4 Instrument Data Including Manufacturer 6 copies 6 Yes and Catalogue No. Installation Instructions,Operating and 6 copies each 4 weeks before Maintenance Manuals shipping Recommended Spare Parts for One 6 copies 4 Year's Operation with Prices, Availability and Part Nos. for Ordering Inspection,Test Procedures and Test 6 copies 6 Reports/Results Certified Performance Data 6 prints 4 weeks before shipping Sequence of Operation 6 copies 6 Yes I have completed the following and confirm I will comply with the dates/time period specified. Vendor Signature: 3. The Manufacturer shall provide on-site services of a factory authorized service representative to completely check the mechanical and electrical installation of each unit, and to start up and test each unit in cooperation with the installing contractor and the water balance contractor. The Vendor shall provide per diem costs for additional services if required. 4. The Manufacturer shall provide a checklist for completion by the contractor and approval by the Owner after installation of the units, to ensure that they are ready for start up. The Manufacturer shall schedule the start up service within two weeks of request given by the Owner. 5. The commissioning and start up service shall include full testing of the make-up air units. 6. The service representative shall submit three (3) copies of the start up report to the Owner within two weeks of start up. B. Vendor to provide an estimate of the startup duration. 3.5 DELIVERY A. Ship make-up air units as a single piece. Individual sections shall be shrink wrapped as specified below. B. Ship unit sections with protective covers over all openings. Individually shrink wrap each section prior to loading onto truck. Shrink wrap starter, unit control panel and all other sections that will be adversely impacted by snow, ice,road salt, etc. After loading, secure tarps over boiler. Trucks arriving at site without protective packaging will not be allowed to unload. C. Notify the Owner five (5) days in advance with the scheduled shipping date and location. The Owner reserves the right to inspect the boiler prior to unloading. D. Notify the Owner of any components that may suffer damage if stored outside while remaining shrink wrapped. E. Acceptance on Site: If the make-up air units are damaged upon arrival it will be rej ected. ++END OF SECTION 15780 ++ REV. 0 PFI DESIGN, P.C. DECEMBER 28, 2000 Pg. 14 SPE-16040-15780 JA16040\Specs\Fina1\15780_Rev O.doc 3.0 EXECUTION 3.1 TESTS A. Tests: The Vendor shall make all shop tests necessary to insure that his material and workmanship are of the required quality and that the equipment furnished will perform as specified and guaranteed. 3.2 CLEANUP A. All oil, grease, and dirt shall be removed by scrubbing with soap, alkali cleaners or suitable solvents. All welding flux shall be brushed or blasted free. After cleaning,the Vendor shall protect the equipment from intrusion of dirt, debris, or foreign material. 3.3 PREPARATION FOR SHIPMENT A. Vendor shall make final check for completeness of equipment prior to shipment. B. All equipment and materials shall be suitably crated,boxed, equipped with handling fixtures, or otherwise.prepared for shipment to prevent damage or contamination during handling and shipping. All parts which may be exposed to the weather due to physical size or arrangement shall be adequately protected by suitable weatherproofing. It shall be the responsibility of the Vendor to take any other precautions required to reasonably ensure jobsite arrival of the equipment in an undamaged and satisfactory working condition. C. All pipe ends shall be sealed,using plastic caps*for flanged ends, and metal thread protectors or cap plugs for threaded ends to exclude entry of foreign matter. D. All parts shall be identified in an appropriate manner. When parts are crated or boxed, detailed packing lists shall be provided with each crate or box. E. Component weights shall be plainly marked on all equipment requiring rigging so that field construction forces can suitably handle the equipment. F. Vendor shall notify Purchaser ten(10)working days prior to shipment. 3.4 START-UP ASSISTANCE A. Vendor shall provide startup assistance at Owner's facility in Northampton, Massachusetts. Startup assistance shall consist of: 1. Commissioning and startup of equipment. 2. Operator Training. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 13 SPE-16040-15780 JA16040\Specs\Fina1\15780_Rev O.doc 7. TEFC & ODP motors shall be rated for"mill and chemical duty". 8. Motors shall have NEMA Class F insulation minimum. 9. Motor nameplates shall be of stainless steel and shall be permanently fastened with stainless steel fasteners. 10. Seals shall be used to retain grease and to protect bearings from dust. 11. Motors shall have grease lubricated ball or roller bearings capable of in service lubrication. Bearings shall be of such design to provide extra long life. Permanently lubricated bearings will not be acceptable. Grease fittings shall be easily accessible and not interfere with machine operation. 12. All motors shall be designed for continuous duty and shall not exceed the temperature rises indicated for each insulation class, in NEMA Standards Publication MG1-1998. 13. Copper conductors shall be used for windings. 14. To provide resistance to chemical corrosion,no aluminum parts of the motor shall be exposed to the atmosphere. 15. For motors 10 BP and larger, the locked rotor kVA/BP shall not exceed locked rotor code letter"G"(5.6—6.29 kVA/BP). 16. A spring-loaded cap shall be installed on the outlet of each bearing grease chamber discharge port. Grease fittings shall be supplied on inlet grease connections. 17. Motors operating with VFDs shall be UL rated for Inverter Duty and shall meet all requirements Part 31 of NEMA standard MG1-1998 for Inverter- Fed Polyphase Motors. 18. The motor shall be suitable for operation in the environment indicated in the data sheet(s). 19. Motors for use in areas subject to washdown shall be suitable for wet or washdown locations. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 12 SPE-16040-15780 JA16040\Specs\Fina1\15780_Rev O.doc 3. All electrical equipment shall be UL listed for its application and shall be stamped with this approval. 4. Where conflicts occur among the codes, ordinances, standards, and specifications,more restrictive requirements shall govern. D. Motors 1. The Vendor shall provide with their quotation the motor design requirements necessary to provide adequate operation as required by this specification. The motor design requirements shall include at a minimum the following: a. Motor horsepower. b. Motor speed. C. Motor torque. d. Range of motor frame sizes and mounting sizes easily adapted for each drive. e. Motor voltage 2. Motors greater than %2 HP shall be 480 volts, 3-phase, 60 hertz. Motors HP or smaller shall be 120 volt, single phase, 60 hertz. 3. All motors will be designed and manufactured such as to conform to all applicable requirements of the latest editions of standards published by NEC,ANSI, IEEE,NFPA, and NEMA MG-1 standard. 4. All motors shall be premium efficiency. When the motor is operating at rated voltage and frequency,the minimum full load efficiency shall equal or exceed the nominal values in NEMA Standards Publications#MG1- 1998 and efficiencies list in this specification. 5. Motors shall be of the squirrel cage, induction type and shall be capable of starting and accelerating their load to normal operating speeds under the most severe conditions likely to be encountered without exceeding the horsepower rating indicated on the nameplate; and without usurping any portion of any specified service. 6: Speed and torque characteristics shall conform to NEMA Design B requirements. When speed and torque characteristics other than NEMA Design B are required,the bidder's proposal shall clearly indicate such requirements, and the motor shall have speed and torque characteristics, which will satisfy the requirements. Unless otherwise specified or required, motors shall have a Service Factor of 1.1.5, except inverter duty motors shall have a service factor of 1.0. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 11 SPE-16040-15780 JA16040\Specs\Fina1\15780_Rev O.doc H. Extended grease lines. I. UV flame sensor. J. Bird screening on outside air intake opening. 2.10 ELECTRICAL REQUIREMENTS,MOTORS A. Introduction 1. This specification contains general electrical requirements for equipment and should be considered as an integral part of the specification that it accompanies. Should any discrepancies occur between this specification and the accompanying equipment specification,the purchaser shall be the sole party responsible for clarifying the discrepancies. B. Scope 1. All electrical work shall meet the standards of the latest issue of the NEC, and shall comply with applicable state and municipal laws, and local plant safety regulations covering each class of work. 2. All electrical controls and control panels shall be located where accessible and,preferably, at grade. 3. Cables and conductors shall be sized in accordance with the National 'Electrical Code (NEC),based on the current-carrying capacity, voltage- drop considerations, short circuit rating, and derating due to heating effects. 4. Electrical power will be supplied at 480 Volt AC +10%, 3 phase, 3 wire, 60 hertz. C. General Requirements 1. All motors, electrical equipment and control devices shall be designed and manufactured to conform to all applicable requirements of the latest editions of the code and standards as specified in the attached process specification. 2. Unless specifically noted, all electrical and electronic accessories supplied by the Vendor shall have suitable enclosures and connection boxes for the unit's electrical classification. They must also be listed and labeled with a minimum of one of the electrical listing agencies in the attached process specification. REV. 0 PFI DESIGN, P.C. DECEMBER 28, 2000 Pg. 10 SPE-16040-15780 1:\16040\Specs\Fina1\15780_Rev O.doc B. Units shall be provided with a(weathertight-NEMA 3R) control compartment. All controls mounted within this compartment are to be wired to a numbered terminal strip. All wiring is to be color coded and in accordance with NEC. A circuit diagram of the approved electrical drawing shall be provided with the unit. All electrical components shall bear the UL label. C. Each unit shall be provided with the space temperature control package. This system shall consist of a modulating gas system, which includes a discharge air sensor(55 to 90 °F range)mounted in the blower discharge, a modulator regulator valve mounted in the gas piping manifold, an amplifier installed in the electric control panel, a 115 to 24 volt transformer and a remote control station mounted in the space. The remote control station shall have the following mounted on the face: 1. Fan Switch On/Off. 2. Heat Switch On/Off. 3. Burner on light. 4. Flame failure light. 5. Clogged filter switch field adjustable from 0.250-2.00 in w.c. D. Each unit shall be setup to be interlocked with(2)boilers. If one boiler is firing, unit shall operate on low speed(8,500 cfin); if two boilers are firing, unit shall operate at high speed(17,000 cfin). Space temperature of 60°F shall be maintained at all times. E. Field interlocking of the boilers and mounting of the control panel shall be by others. 2.9 UNIT ACCESSORIES A. IRI gas train with high gas pressure regulator(over 10 psig). B. Internal blower/motor isolation. C. Remote control station(See Section 2.8) D. Time freeze protection consisting of an on/off discharge ductstat and timer factory pre-set at 45°F. E. Motorized inlet damper with damper motor and built in end switch and linkage. Provide additional end switches as required to interlock with fan motor. F. Premium efficiency two speed, two winding motor. G. 1-1/2" fiberglass insulation pin spotted to casing. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 9 SPE-16040-15780 JA16040\Specs\Fina1\15780_Rev O.doc 2.5 DIRECT GAS HEATING SECTION A. The burner section shall contain a Maxon NP burner constructed of rust-resistant cast iron bodies (which serve as the gas manifold)drilled to discharge the fuel between diverging#321 stainless steel mixing plates. The entire burner assembly is mounted directly in the airstream being heated. The fresh air stream passes through the mixing plates and mixes with the fuel as combustion air; thus, all available heat from the gaseous fuel is release directly into the airstream. Air velocities across the burner assemblies are established by the use of profile plates. B. The manifold is located outside of the airstream and shielded from atmospheric conditions by means of a protective compartment with hinged access. An observation port shall be located to provide view of the pilot and main flame. C. Units shall be supplied with a wide range burner with a modulating turndown ratio of 25 to 1. Adjustable profile plates shall be provided and sized to maintain the required velocity across the line burner. The operation of the burner shall be programmed through the flame safeguard with timed prepurge and flame sensing. 2.6 GAS TRAIN A. The Industrial Risk Insurers (IRI) gas train consists of a manual main gas shutoff valve, a motorized electric main gas valve, the Maxitrol modulating gas valve, a manual pilot gas shutoff valve, a manual pilot gas pressure regulator, a pilot gas valve, an orificed needle valve, a high/low gas pressure switch, a manual auxiliary gas shutoff valve, a normally open vent valve and an auxiliary gas valve. 2.7 FILTERS A. Provide V-bank filter rack of galvanized steel with filter guides and blockoffs as required to prevent air bypass. Access to filters shall be side access for easy filter service. B. Do not operate fan system until filters (temporary or permanent) are in place. Replace temporary filters used during construction. C. Provide 2" Farr 3 0/3 0 final replaceable filters and 1" thick permanent pre-filters. Final filters shall have an average efficiency of 25-30% and an average arrestance of 90-92%in accordance with ASHME Test Standard 52.1.92. 2.8 UNIT CONTROLS A Unit controls shall consist of a spark ignition system with a flame rod sensing the flame, a high temperature limit switch set at 185°F, a flame safeguard with alarm contacts, ignition.transformer, air proving differential switch and timed freeze protection. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 8 SPE-16040-15780 J:\16040\Specs\Fina1\15780_Rev O.doc r 1. Backward Inclined: Steel or aluminum construction with curved inlet flange,back plate,backward-curved blades, and cast-iron or cast-steel hub. 2. Airfoil Wheel: Steel; with smooth, curved inlet flange; back plate; die- formed,hollow , airfoil blades; and cast-iron or cast-steel hub. 3. Forward Curved: Black steel with enamel or galvanized finish, and having an inlet flange,back plate, shallow blades with inlet and tip curved forward in direction of airflow, and steel hub. E. Fan performance shall be certified as complying with ARI Standard 430-89. 2.4 MOTOR AND DRIVE A. Fan motor(s) shall be two speed, two winding premium efficiency, operable at 460 Volts, 60 Hz, 3-phase. B. V-Belt Drive: Cast iron or steel sheaves, dynamically balanced, bored to fit shafts and keyed. C. Supply fan drive shall be constant pitch. D. Drives shall be selected by the manufacturer to operate at 1.5 times nameplate rating of the motor. E. Shafts: Solid hot rolled steel, ground and polished, with key-way, and protectively coated with lubricating oil. F. Belts shall be enclosed as required by OSHA Standard 29 CFR 1910 to protect worker from accidental contact with the belts and sheaves. G. Belts shall be oil resistant,non-sparking and non-static; matched for multiple belt drives. H. Drives shall be factory mounted,with final alignment wheel balancing and belt adjustments made after installation in the field. I. The motor shall meet the efficiencies listed in the following schedule. 1200 RPM 1800 RPM Motor HP Minimum Efficiency % Minimum Efficiency 15 92.4 93.0 20 92.4 93.0 25 93.0 93.6 REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 7 SPE-16040-15780 JA16040\Specs\Fina1\15780_Rev O.doc 2.0 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Manufacturers: Subject to compliance with requirements,provide products by one of the following: 1. Trane Company 2. York International Corporation 3. Hastings 4. Jackson Church 2.2 UNIT CASING A. Basic unit casings shall be fabricated of die-formed galvanized steel. All casing shall be 18 gauge except for the walls,which shall be 16 gauge. B. Access doors are hinge mounted with industrial type hardware for easy access to service compartments. C. All casings shall be airtight and weatherproof. Complete access shall be provided to all components through gasketed access doors or panels. This includes the motor,blower,burner, electrical components and manifold sections. 2.3 FANS A. Fans used shall not decrease motor size, or increase tip speed by more than 10 percent, or increase inlet air velocity by more than 20 percent, from specified criteria. Fans shall be capable of accommodating static pressure variations of plus or minus 10 percent. Housings shall be adequately braced, and designed to minimize turbulence with spun inlet bell and shaped cut-off. B. Provide self-aligning, grease lubricated,ball or roller bearings with lubrication fittings extended to drive side of fan with plastic tube and grease fitting rigidly attached to fan supporting members. Bearing shall be rated for L-50 life of 200,000 hours. C. Fan and motor shall be internally mounted on common base. Provide access to motor, drive, and bearings through hinged access doors. Mount base on vibration isolators. V spring isolators shall be supplied for the supply fans. Isolators shall be rated for 1 inch static deflection,with side snubbers. D. Fan Assemblies: Statically and dynamically balanced and designed for continuous operation at maximum rated fan speed and motor power. Fan wheel shall be double-width, double-inlet type with forward or backward-curved airfoil blades as indicated on schedule. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 6 SPE-16040-15780 JA16040\Specs\Fina1\15780_Rev O.doc NEC National Electric Code IEEE Institute of Electrical & Electronics Engineers NIST National Institute of Standards and Technology NEMA-MGI National Electrical Manufacturers Association- Motors and Generators OSHA Occupational Safety and Health Administration 1.7 EXTRA MATERIALS A. Furnish extra materials described below that match products installed, are packaged with protective covering for storage, and are identified with labels describing contents. B. Filters: Furnish 2 sets (pre-filter and final) for each central-station air-handling unit. C. Fan Belts: Furnish 1 set for each central-station air-handling unit fan. 1.8 GUARANTEE A. The Make-up Air Unit Supplier shall guarantee that the equipment supplied meets the specifications, and that it will achieve the performance requirements. The guarantee shall cover parts and labor including motors, controls, and other items specified by the Vendor, whether or not manufactured by him. Equipment which fails to meet the performance guarantee, and equipment, materials,parts, and appurtenances which become defective under normal and proper use and maintenance before the end of the guarantee period shall be replaced or repaired to the Owner's satisfaction. Repair or replacement shall be initiated promptly upon receipt by the Vendor of notice from the Owner of the defect, and shall be completed as expeditiously as possible. Work under the guarantee shall be performed by qualified service personnel. B. The guarantee shall be in effect for a one-year period,beginning on the date of the air handling unit start-up and Owner acceptance. Formal acceptance is required. 1.9 ATTACHMENTS A. The following attachments are hereby made a part of this specification: SK-01 Make-up Air Unit Schedule SK-02 Make-up Air Unit Section&Plan View REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 5 SPE-16040-15780 JAI 6040\SpecsTinahl5780_Rev 0-doc 1.5 DEFINITIONS A. Owner: The Minute Maid Company 45 Industrial Drive Northampton, MA 01060 B. Architect/Engineer: Process Facilities Inc. 160 Federal Street Boston, MA 02110-1700 (617) 946-9400 C. Contractor: PFI Construction Corp. 160 Federal Street Boston,MA 02110-1700 (617) 946-9400 1.6 CODES AND STANDARDS Various codes, standards, or other documents that are mentioned by short-form name elsewhere in this Specification are fully identified below. To the extent that these documents apply, the version of the document that is applicable at the time the purchase order is placed shall apply. Short Name Complete Identification of the Document ASME American Society of Mechanical Engineers Boiler and Pressure vessels Code, Section 1,Power Boilers ANSI American National Standards Institute B31.3 Code for Piping, Chemical Plant and Petroleum Refinery Piping. B16.5 Code for Steel Pipe Flanges,Flanged Valves and Fittings. ASHRAE American Society of Heating, Refrigerating, and Air-Conditioning Engineers ASTM American Society for Testing and Materials BOCA Buildings Officials and Code Administrators International FM Factory Mutual IRI Industrial Risk Insurers ISA Instrument Society of America REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 4 SPE-16040-15780 JA16040\Specs\Fina1115780 Rev O.doc D. Wiring diagrams detailing wiring for power and control systems and differentiating between manufacturer-installed and field-installed wiring. E. Maintenance data for make-up air units shall be included in the operation and maintenance manuals. F. Operation and Maintenance manuals. 1.3 QUALITY ASSURANCE A. NFPA Compliance: Make-up air units and components shall be designed, fabricated, and installed in compliance with NFPA 90A, "Installation of Air Conditioning and Ventilating Systems." B. UL Compliance: Gas furnaces, along with complete make-up air unit, shall be listed and labeled by UL. C. ARI Certification: Make-up air units and their components shall be factory tested according to the applicable portions of ARI 430, "Central-Station Air-Handling Units," and shall be listed and bear the label of the Air-Conditioning and Refrigeration Institute (ARI). D. UL and NEMA Compliance: Provide motors required as part of make-up air units that are listed and labeled by UL and comply with applicable NEMA standards. E. Comply with NFPA 70 for components and installation. F. Listing and Labeling: Provide electrically operated components specified in this Section that are listed and labeled. 1. The Terms "Listed" and"Labeled": As defined in the National electrical Code,Article 100. 2. Listing and Labeling Agency Qualifications: A"Nationally Recognized . Testing Laboratory" (NRTL) as defined'in OSHA Regulation 1910.7. 1.4 SAFETY AND HEALTH A. All equipment shall comply with the latest edition of EPA, OSHA,NFPA,UL, ANSI, ASHRAE, ASTM,NFPA standards, and other National, state, and local codes and regulations applicable at the Owner's plant location in Northampton, Massachusetts. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 3 SPE-16040-15780 JA16040\Specs\Fina1\15780_Rev O.doc between wiring that is factory installed and wiring that is field installed. Submit load calculations indicating Electrical Load. E. Provide lead time for delivery of units to the site. F. Furnished by Purchaser The following equipment, materials, utilities and services will be supplied by the Purchaser: 1. Labor and equipment for unloading and erection of all equipment at the job site. 2. Insulation of Vendor equipment as specified herein. 3. Concrete foundations, anchor bolts and grouting as required. 4. 460 volt, 3 phase, 60 Hz power supply, motor starters and disconnects. 5. 10 psig natural gas. 1.2 SUBMITTALS A. General: Submit each item in this Article according to the conditions of the Contract. Obtain approval from PFID before proceeding with fabrication and work. Six(6) copies shall be submitted to the Construction Manager. B. Product data for each make-up air unit specified, including the following: 1. Certified fan-performance curves with system operating conditions indicated. 2. Certified fan-sound power ratings. 3. Certified coil-performance ratings with system operating conditions indicated. 4. Motor ratings and electrical characteristics plus motor and fan accessories. 5. Material gages and finishes. 6. Filters with performance characteristics. 6. Dampers, including housings, linkages, and operators. 7. Certified burner performance ratings with system operating conditions indicated. 8. All accessories being provided. C. Shop Drawings from manufacturer detailing equipment assemblies and indicating dimensions,weights, loadings, required clearances,method of field assembly, components, and location and size of each field connection. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 2 SPE-16040-15780 JA16040\Specs\Fina1\15780_Rev O.doc Y GAS FIRED MAKE-UP AIR UNITS (DIRECT-FIRED) SECTION 15780 1.0 GENERAL REQUIREMENTS 1.1 SCOPE OF WORK A. The Vendor shall provide and deliver two (2) direct fired vertical mount gas-fired make-up air units to Northampton, MA. B. The Vendor shall furnish all documentation as indicated in this specification and comply with all the requirements set forth on the Purchase Order. C. The Vendor shall submit with bid, three(3) copies of published catalog information indicating materials of construction and unit configuration with dimensioned record drawings for the make-up air units, along with all pertinent performance data, including but not limited to: 1. Product data indicating general assembly, components, safety controls, wiring diagrams, service connections, and service clearances for make-up air units. 2. Certified fan-performance curves with system operating conditions indicated. 3. Certified coil-performance ratings with system operating conditions indicated. 4. Motor ratings and electrical characteristics plus motor and fan accessories. 5. Material gages and finishes. 6. Filters with performance characteristics. 7. Dampers, including housings, linkages, and operators. 8. Certified burner performance ratings with system operating conditions indicated. 9. All accessories being provided. 10. Burner piping, valves, gas train, gas pressure requirements (minimum and maximum), etc., as described herein. D. Submit wiring diagrams for electrically operated equipment. Differentiate REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 1 SPE-16040-15780 JA16040\Specs\Fina1\15780_Rev O.doc TABLE OF CONTENTS 1.0 GENERAL REQUIREMENTS...........................................................................................1 1.1 SCOPE OF WORK..............................................................................................................1 1.2 SUBMITTALS ....................................................................................................................2 1.3 QUALITY ASSURANCE...................................................................................................3 1.4 SAFETY AND HEALTH....................................................................................................3 1.5 DEFINITIONS.....................................................................................................................4 1.6 CODES AND STANDARDS..............................................................................................4 1.7 EXTRA MATERIALS ........................................................................................................5 1.8 GUARANTEE.....................................................................................................................5 1.9 ATTACHMENTS................................................................................................................5 2.0 PRODUCTS.........................................................................................................................6 2.1 ACCEPTABLE MANUFACTURERS ...............................................................................6 2.2 UNIT CASING....................................................................................................................6 2.3 FANS ...................................................................................................................................6 2.4 MOTOR AND DRIVE........................................................................................................7 2.5 DIRECT GAS HEATING SECTION .................................................................................8 2.6 GAS TRAIN........................................................................................................................8 2.7 FILTERS..............................................................................................................................8 2.8 UNIT CONTROLS..............................................................................................................8 2.9 UNIT ACCESSORIES ........................................................................................................9 2.10 ELECTRICAL REQUIREMENTS, MOTORS.................................................................10 3.0 EXECUTION.....................................................................................................................13 3.1 TESTS................................................................................................................................13 3.2 CLEANUP............................................:............................................................................13 3.3 PREPARATION FOR SHIPMENT..................................................................................13 3.4 START-UP ASSISTANCE...............................................................................................13 3.5 DELIVERY........................................................................................................................14 REV. 0 PFI DESIGN, P.C. DECEMBER 28, 2000 Pg. i SPE-16040-15780 J:\16040\Specs\Final\15780_Rev O.doc e, C PFI DESIGN, P.C. SPECIFICATION FOR GAS FIRED MAKE-UP AIR UNITS (DIRECT-FIRED) SPE-16040-15780 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 Rev. Date Description Admin Prepared Checked Approved A 11/17/00 Issue for Bid KAB . TAE MJH H1VI 0 12/28/00 Issue for Construction KABtW T HM Client Approval: Client: Date: 3.2 CLEANUP All oil, grease, and dirt shall be removed by washing with soap, alkali cleaners or suitable solvents, and scrubbing as needed, followed by rinsing with potable or deionized water. Any remaining pockets of water shall be dried. The Vendor shall submit copies of the proposed cleaning methods including cleaning agents to the Owner/Engineer for approval. After cleaning, Vendor shall protect the equipment from intrusion of moisture, dirt, debris, or foreign material. 3.3 SUBSTITUTION OF MATERIALS OR EQUIPMENT A. Except in specific cases where words "Owner/Engineer-approved substitute" follow or refer to a maker's name and catalogue number or other identifying feature, only such items as are specified or shown on the drawings will be acceptable and no substitutions will be allowed. B. If the Fabricator wishes to use material or equipment other than those specifically designated herein as being equal to those so specifically designated, BEFORE PURCHASING OR FABRICATION,the proposed substitution shall be submitted to the Owner/Engineer for approval, and the decision of whether or not it is equal to that specified shall be that of the Owner/Engineer. C. If the apparatus or material substituted as equal for that specified necessitates changes or additional connections,piping supports, or construction, the same shall be provided and the Fabricator shall assume the cost. D. The Owner/Engineer's permission to make such substitution shall not relieve the Fabricator from full responsibility for the work. 3.4 SHIPMENT A. Unit shall be shipped to the site crated with all pipe ends protected. Shrink wrap tanks to prevent exposure to the weather. ++END OF SECTION 15600++ REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 10 SPE-16040-15600 J:\16040\Specs\Fina1\15600_Rev A.doc Tests shall include, as a minimum, those listed below. 1. Hydrostatic Tests a. All shop-fabricated equipment shall be hydrostatically tested in accordance with the ASME Code. Hydrostatic testing shall be done at 1.5 times the individual design pressures. The test pressure shall be held for not less than 60 minutes. The pressure specified shall be the pressure at the top of equipment in its test position. All vertical equipment,which is tested in the horizontal position,must have the test pressure adjusted to suit the additional pressure due to static b. Water used for the hydrotest shall be potable or clean raw water. C. Draining of the equipment shall be accomplished immediately after completion of the final hydrostatic test. Any remaining pockets of water shall be dried with air. d. Flanged joints which have been taken apart after a hydrotest(for whatever reason) shall be reassembled with unused gaskets. 2. Accessories The Vendor shall ensure that all accessories function in accordance with this specification. Vendor shall be responsible for any shop fit-ups'and installation of the accessories. B. Surveillance The Vendor shall fulfill the surveillance requirements listed below. 1. Dimensional Check and Check of Assembly The Vendor shall make a complete dimensional check and check of assembly of each piece of equipment,which will then be checked and accepted by the inspector for the Owner/Engineer prior to being released for shipment. 2. Weld Examination Weld examination procedures shall be in accordance with ASME Code and performed_by certified personnel. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 9 SPE-16040-15600 J:\16040\Specs\Fina1\15600_Rev A.doc slivers shall be ground smooth, and all oil,weld splatter, and flux shall be removed. C. Blasting media to be used shall be in accordance with SSPC-SP6. The surface profile shall meet the paint manufacturer's requirements. d. No blasted surfaces shall be allowed to remain uncoated overnight in humid areas. All paint is to be applied to a surface free from moisture, oil, dust, grit, or any other contaminants and discoloration. 2.6 MARKING A. Each piece of equipment shall be provided with a stainless steel nameplate, permanently attached to the exterior of the equipment, in an accessible location external to any insulated surface, and observable while the equipment is in operation. The nameplate shall include the following information: 1. Manufacturer's name,model, and serial number. 2. Year built. 3. Owner's purchase order number. 4. Owner's equipment identification number(Tag No.). 5. Nominal capacity(Gallons). 6. Weight of equipment. 7. Design pressure and temperature (vessel and jacket). a. Maximum allowable working pressure. b. Minimum design metal temperature. 8. Code Stamp and National Board number(where applicable). 9. Material of Construction. 3.0 EXECUTION 3.1 SURVEILLANCE AND TESTS A. Tests This Subcontractor shall make all shop inspections as necessary to insure that the material and workmanship are of the required quality and that the equipment furnished will perform as specified and guaranteed. A written test report and test data for all tests performed shall be submitted by the Subcontractor to the Owner and/or its representatives before shipment,whether or not tests are witnessed. Acceptance of shop tests shall not constitute a waiver of requirements to meet field test under specified operating conditions,nor does inspection relieve the manufacturer of his responsibilities in any way whatsoever. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 8 SPE-16040-15600 J:\16040\Specs\Fina1\15600_Rev A.doc 4 • b. Except for specified insulation supports and the name bracket which may be intermittently welded, all other attachments to the vessel shall be continuously welded with full penetration welds. C. All nozzle or manhole necks shall be attached with full penetration welds through the shell and any reinforcement plate. Permissible types of weld attachments shall be as shown in ASME Section VIII, Division 1,Part UW, Figures UW-16.1 (c), (d), (e), and(g). d. All attachments to shells and bonnets which require a back-up pad must be provided with '/a"max vent hole at the low point. 4. Preparation and Layout of Plates a. All surfaces which are exposed to vessel contents or its vapors shall be free of gouges, scratches,pits, cracks, or other surface defects. The Vendor shall minimize crevices,holes,pockets,weld craters, depressions, etc. b. The practice of using wide welds to overcome poor fit is not permissible. Accordingly,poor fitup shall be remedied by suitable means (regrooving, etc.). Except for small cavities, the Vendor shall not correct a plate edge deficiency unless approved by Owner/Engineer. . 5. Painting a. All interior and exterior carbon steel surfaces shall be painted with one coat of zinc rich primer. All tank interiors and the exterior of T-02 shall be painted with two coats of epoxy paint. All coatings shall be satisfactory for the design temperature. A copy of the paint manufacturer's specifications shall be forwarded to the Owner/Engineer for approval. b. Application shall be in strict accordance with the coating manufacturer's instructions and recommendations regarding surface and ambient temperatures,humidity, application equipment and methods, re-coat times, inspection procedures, etc. 6. Surface Preparation a. All steel surfaces and welds to be coated shall be abrasive blast cleaned to meet SSPC-SP6. b. Before surface blasting, all sharp edges, rough welds, and steel REV. A PFI DESIGN, P.C. JANUARY 24, 2001 Pg. 7 SPE-16040-15600 JA16040\Specs\Fina1\15600_Rev A.doc E. Gaskets, O-rings and seals which contact the process to be constructed of Teflon (all others shall be Manufacturer's standard). Corrosion resistance of gaskets shall be equal to or better than the part being joined. The hardness of the gaskets shall be less than either of the mating surfaces. Teflon- enveloped type, or Kalrez are acceptable where resiliency is necessary. F. Any clad components shall be clearly identified in the proposal (especially vessel walls or flanges). G. Asbestos or asbestos bearing materials are not permissible. 2.5 FABRICATION A. Fabrication shall be in accordance to ASME Code Section VIII, Division I. Vendor shall provide with his proposal all standard pre- and post-weld heat treatment procedures for fabrication of the equipment. Submittals shall clearly state which procedures, if any will be used. 1. Welding a. The Welding Procedure Specifications and welder's performance qualifications shall conform to the requirements of ASME Section IX and the additional requirements of this specification. b. Preheating requirements of ASME Section VIII, Division 1, Appendix R, shall be followed and be made a mandatory part of the weld procedure. C. Filler materials shall be selected from ASME Code, Section II, Part C, so that the principal elements in the deposited weld metal is the same P number as the nominal composition of the base metal. 2. Vessel Seams The Vendor shall locate the longitudinal weld seams and, insofar as it is practical, girth seams, so as not to interfere with welded attachments such as nozzles. Location of all welded seams shall be indicated on the Vendor's Vessel Drawing. 3. Attachments a. All attachments welded to the vessel shell, heads, or other pressure parts shall be welded in place before post weld heat treatment and/or shipment, insofar as possible. If attachments must be welded after post weld heat treatment, the Vendor shall follow the ASME Rules and preheat per Appendix "R" of the Code. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 6 SPE-16040-15600 J:\16040\Specs\Fina1\15600_Rev A.doc • E. Manway 1. When specified,manway shall be equipped with Vendor's standard spring assisted easy lift mechanism. F. Insulation 1. If specified,Tank Vendor shall supply one(1) continuously welded angled support ring at the top of the vessel and one (1)wire rod with stand-off support rings at the vessel tangent for the insulation as stated elsewhere in this specification. Material of construction of support rings shall be 304 SS. Insulation and insulation sheath will be provided and installed in the field by others. G. Combined Loads 1. The equipment (full) and its supports shall be designed to meet the seismic load requirements of section 1610 of the BOCA code corresponding to the Owner's site location,as well as any other local, state and federal requirements. H. Lifting Lugs 1. Lifting eyes or lugs shall be provided for all equipment and components weighing more than 50 pounds. I. Grounding Lugs 1. Tank Vendor to provide two (2) grounding lugs per vessel. Attachment shall be 3/8" flat steel with a 5/16"diameter hole. 2.4 MATERIALS A. All materials used in the vessels shall be carbon steel. B. Carbon steel materials shall be stored out of the weather or otherwise protected before, during, and after fabrication to minimize rust formation. C. Material substitutions,before or during tank fabrication, shall have the written concurrence of the Owner/Engineer before the materials are used in fabrication per Section 3.3 of this specification. D. It shall be the Fabricator's responsibility to select materials,which satisfy the requirements of this specification, the specified operating conditions,and the applicable codes (ASME or API). REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 5 SPE-16040-15600 J:\16040\Specs\Fina1\15600_Rev A.doe information on the tank drawings. Owner/Engineer will advise Vendor if this pressure is to be stamped on the nameplate and used in the code report. C. Nozzles and Handholes 1. Flange dimensions and ratings of nozzles,handholes and end enclosures shall be in accordance with the latest edition of ASME/ANSI B 16.5. Weld neck flanges nozzle design is preferred. Special flanges shall meet the design requirements of the ASME Code and Owner/Engineer's approval. 2. Base case flange material shall match the material of vessel wetted parts. 3. Unless internal projections are specified, all nozzles and handholes shall be cut off flush with the inside of the shell and the inside corner rounded to a radius of 1/3 the nozzle thickness or 3/8" whichever is smaller. 4. Bolt holes in any non-lap joint type flanges of nozzles located in the heads of vessels shall straddle the principal centerlines of the vessel or lines parallel to the centerlines. 5. Seating surfaces shall be standard finish. 6. All nozzles shall extend a minimum of six (6) inches beyond the vessel. D. Accessory Design All Tank Vendor supplied accessories including but not limited sightglasses shall be installed on the vessel and tested prior to shipment. The Vendor shall be responsible for any shop fit-ups of all accessories. 1. Sightglasses a. Sightglasses shall be provided as indicated on the contract documents. b. Sightglasses to be manufacturer's standard borosilicate glass design, suitable for the vessel design conditions and capable of easy replacement. C. All wetted materials shall be compatible with the vessel materials. d. Provide with optional gage cocks with threaded end connections for ease of replacement. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 4 SPE-16040-15600 J:\16040\Specs\Fina1\15600_Rev A.doc 2.0 PRODUCTS 2.1 DESIGN CRITERIA 2.2 GENERAL CONDITIONS A. All equipment shall be designed and fabricated in accordance with this specification and the contract documents. B. This specification shall supplement,but not supersede, all applicable legal requirements. The equipment constructed under this specification shall conform to all local, state, or federal codes or laws currently in effect at the plant location. 2.3 DESIGN REQUIREMENTS A. Tank Design 1. All equipment must be designed and fabricated in accordance to ASME or appropriate API standard. ASME Code stamps shall not be required. 2. Vessel tolerances shall be in accordance with ASME code. 3. Vessels nominal thickness shall be in accordance with ASME code. Alloy plate shall have a minimum thickness of 3/16"plus corrosion allowance. 4. The glycol surge tank(T-01) shall be insulated in the field with 2" of rigid insulation and aluminum jacketing. 5. The remote cooling tower sump (T-02) shall not be insulated. 6. Tanks shall be painted as described in Section 2.5 of this specification. 7. Refer to contract document drawing H-700 for tank connections and locations. 8. All materials of construction shall be as specified in Section 2.4. B. Design Pressure and Temperatures 1: Tank shall be designed for±15 in w.c. 2. Tank shall be designed for an operating temperature range of 0°F to 150°F. 3. Tank Vendor shall calculate actual pressure/vacuum rating of the vessel based on the material thickness used for fabrication, and shall furnish this REV. A PFI DESIGN, P.C. JANUARY 24, 2001 Pg. 3 SPE-16040-15600 JAI 6040\Specs\Fina1\15600_Rev A.doc Short Name Complete Identification of the Document ANSI American National Standards Institute ASME American Society of Mechanical Engineers Sect. VIII,Div. 1 Boiler and Pressure Vessel Code Pressure Vessels B31.3 Code for Piping, Chemical Plant and Petroleum Refinery Piping B16.5 Code for Steel Pipe Flanges,Flanged Valves and Fittings ASTM American Society For Testing and Materials BOCA Buildings Officials and Code Administrators International EPA Environmental Protection Agency FM Factory Mutual IEEE Institute of Electrical and Electronic Engineers ISA Instrument Society of America NEC National Electric Code NEMA National Electrical Manufacturers' Association NFPA National Fire Protection Association NIST National Institute of Standards and Technology OSHA Occupational Safety and Health Administration SSPC SP6 Steel Structures Painting Council, Systems and Specifications. Code of Commercial Blast Cleaning UL Underwriters Laboratory 1.5 MECHANICAL PARTS All mechanical parts subject to periodic maintenance, removal, or replacement, and all parts intended to be connected to Owner supplied equipment or piping shall conform to the standards set up for such parts by the pertinent governing code, insurance regulations, and engineering or manufacturing society. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 2 SPE-16040-15600 1:\16040\Specs\Fina1\15600_Rev A.doc CARBON STEEL VESSELS SECTION 15600 1.0 GENERAL 1.1 SCOPE OF WORK A. This specification including all attachments, establishes the minimum requirements for the mechanical design,materials, fabrication, testing and delivery to the Owner's site of one(1) glycol surge tank(T-01) and one (1) remote cooling tower sump (T-02): T-01 Glycol Surge Tank T-02 Cooling Tower Remote Sump B. This Subcontractor shall furnish all equipment,materials, and services required for satisfactory operation within the intent of this and shall include,but not necessarily be limited to,the following: 1. The equipment as described herein. 2. Performance guarantee. 3. Mechanical guarantee. 4. Lifting eyes and any special tools required for maintenance. 5. Vessel internals when specified. 1.2 PERFORMANCE GUARANTEE This Subcontractor shall guarantee that the system's performance will meet the criteria set forth in this specification. 1.3 SAFETY AND HEALTH All equipment shall comply with ASME, EPA, OSHA,NFPA, UL(and/or FM, etc.) and other national, state, and local codes and regulations applicable at the Owner's plant location in Northampton, MA. 1.4 CODES AND STANDARDS Various codes, standards, or other documents that are mentioned by short-form name elsewhere in this Specification are fully identified below. To the extent that these documents apply,the version of the document that is applicable at the time the purchase order is placed shall apply. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 1 SPE-16040-15600 JA16040\Specs\Fina1115600_Rev A.doc TABLE OF CONTENTS 1.0 GENERAL...............................................................................................................................1 1.1 SCOPE OF WORK..................................................................................................................1 1.2 PERFORMANCE GUARANTEE...........................................................................................1 1.3 SAFETY AND HEALTH........................................................................................................1 1.4 CODES AND STANDARDS..................................................................................................1 1.5 MECHANICAL PARTS .........................................................................................................2 2.0 PRODUCTS.............................................................................................................................3 2.1 DESIGN CRITERIA...............................................................................................................3 2.2 GENERAL CONDITIONS ..........................................................................:..........................3 2.3 DESIGN REQUIREMENTS...................................................................................................3 2.4 MATERIALS...........................................................................................................................5 2.5 FABRICATION.......................................................................................................................6 2.6 MARKING ..............................................................................................................................8 3.0 EXECUTION...........................................................................................................................8 3.1 SURVEILLANCE AND TESTS.............................................................................................8 3.2 CLEANUP.......................:.....................................................................................................10 3.3 SUBSTITUTION OF MATERIALS OR EQUIPMENT......................................................10 REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. i SPE-16040-15600 J:\16040\Specs\Final\15600_Rev A.doc A5/4 v PFI DESIGN, P.C. SPECIFICATION FOR CARBON STEEL VESSELS SPE-16040-15600 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 tee Date escr in Pry are h+e�ked , :A' ra A 1/24/01 Issue for Bid KAB T M HM Client Approval: Client: Date: PH DESIGN, P.C. Vendor Data Commitment Form Inquiry No.: SPE-16040-15685 P.O.No.: Vendor Name: Date: 12/28/00 Client: The Minute Maid Company Project No.: 16040 Equip.No.: CH-1 Drawing Description No.of Copies When Approval When Scheduled Required Required Before (To be Completed (Weeks After Fabrication by Vendor) P.O. General Arrangement/Outline Drawing 1 R/6 P 2 Yes Foundation Requirements Including 1 R/6 P 2 Yes Equipment/Operating Weights Assembly Drawings/Detail Cross- 1R/6P 4 Yes Section w/Parts List and Bill of Material Fabrication Drawings 1 R/6 P 4 Yes Wiring Diagrams 1 R/6 P 4 Yes Certified Drawings 1R/6P 4 weeks before shipping Fabrication Schedule 6 copies 3 Instrument Data Including Manufacturer 6 copies 6 Yes and Catalogue No. Installation Instructions,Operating and 6 copies each 4 weeks before Maintenance Manuals shipping Manufacturer's Data Sheets 6 copies 4 weeks before shipping Welding Procedures and Welder 6 copies 4 Yes Qualifications Recommended Spare Parts for One 6 copies 6 Year's Operation with Prices, Availability and Part Nos.for Ordering Inspection,Test Procedures and Test 6 copies 6 Reports/Results Code Certificates(if applicable) 6 copies 4 weeks before shipping Certified Performance Data 6 prints 4 weeks before shipping Sequence of Operation 6 copies 6 Yes Instrument/Electrical Panel Details 1R/6P 6 Yes I have completed the following and confirm I will comply with the dates/time period specified. Vendor Signature: { • C. Acceptance on Site: If the chiller is damaged upon arrival it will be rejected. ++END OF SECTION 15685 ++ REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 12 SPE-16040-15685 JA16040\Specs\Fina1\15685_REV O.doc C. All pipe ends shall be sealed, using plastic caps for flanged ends, and metal thread protectors or cap plugs for threaded ends to exclude entry of foreign matter. D. All parts shall be identified in an appropriate manner. When parts are crated or boxed, detailed packing lists shall be provided with each crate or box. E. Component weights shall be plainly marked on all equipment requiring rigging so that field construction forces can suitably handle the equipment. F. Vendor shall notify Purchaser ten(10)working days prior to shipment. 3.4 START-UP ASSISTANCE A. Vendor shall provide startup assistance at Owner's facility in Northampton, Massachusetts. Startup assistance shall consist of: 1. Commissioning and startup of equipment. 2. Operator Training. 3. The Manufacturer shall provide on-site services of a factory authorized service representative to completely check the mechanical and electrical installation of each unit, and to start up and test each unit in cooperation with the installing contractor and the water balance contractor. The Vendor shall provide per diem costs for additional services if required. .4. The Manufacturer shall provide a checklist for completion by the Contractor and approval by the Owner after installation of the units,to ensure that they are ready for start up. The Manufacturer shall schedule the start up service within two weeks of request given by the Owner. 5. The commissioning and start up service shall include full testing of the chiller and controls: 6. The service representative shall submit three (3) copies of the start up report to the Owner within two weeks of start up. B. Vendor to provide an estimate of the startup duration. 3.5 DELIVERY A. Ship chiller as a single piece. B. Notify the Owner five (5) days in advance with the scheduled shipping date and location. The Owner reserves the right to inspect the cooling tower prior to ' unloading. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 11 SPE-16040-15685 J:\16040\Specs\Fina1\15685_REV O.doc D. All electronic enclosures supplied by the Vendor shall be NEMA 3R. E. Provide a non-fused power disconnect switch. 2.11 MARKING A. Each piece of equipment shall be provided with a stainless steel nameplate, permanently attached to the exterior of the equipment, in an accessible location external to any insulated surface, and observable while the equipment is in operation. The nameplate shall include the following information: 1. Manufacturer's name,model, and serial number. 2. Year built. 3. Nominal capacity. 4. Purchaser's equipment identification number(CH-1.). 5. Weight of equipment. 6. Design(pressure/temperature). 3.0 EXECUTION 3.1 TESTS A. The Vendor shall make all shop tests necessary to insure that his material and workmanship are of the required quality and that the equipment furnished will perform as specified and guaranteed. 3.2 CLEANUP A. All oil, grease, and dirt shall be removed by scrubbing with soap, alkali cleaners or suitable solvents. All welding flux shall be brushed or blasted free. After cleaning,the Vendor shall protect the equipment from intrusion of dirt, debris, or foreign material. 3.3 PREPARATION FOR SHIPMENT A. Vendor shall make final check for completeness of equipment prior to shipment. B. All equipment and materials shall be suitably crated,boxed, equipped with handling fixtures, or otherwise prepared for shipment to prevent damage or contamination during handling and shipping. All parts which may be exposed to the weather due to physical size or arrangement shall be adequately protected by suitable weatherproofing. It shall be the responsibility of the Vendor to take any other precautions required to reasonably ensure jobsite arrival of the equipment in an undamaged and satisfactory working condition. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 10 SPE-16040-15685 JAI 6040\Specs\Fina1\15685_REV O.doc 9. Provide chiller with chilled water reset option including all control logic and field installed sensors for a load based (return water temperature) application. 10. Load limit thermostat to limit compressor loading on high return water temperature to prevent nuisance tripouts. 11. High ambient unloader pressure stat that unloads compressors to keep head pressure under control and help prevent high pressure nuisance tripouts on days when outside ambient is above design. 12. Compressor current sensation unloader unit that unloads compressors to help prevent current overload nuisance tripouts. 13. Low ambient lockout control with adjustable setpoint. 14. Provide pre-piped gauge board with pressure gauges for suction and discharge refrigerant pressures or digital display of pressure on microprocessor. 15. Provide ammeters for each compressor or digital display of%RLA on microprocessor. 16. Chiller manufacturer shall provide any controls not explicitly listed above, necessary for proper operation of the packaged system. 2.9 CHILLER OPTIONS A. Provide for each circuit refrigerant suction, discharge, and oil pressure gauges with isolation valves. B. Provide suction service valve option to isolate refrigerant charge(in evaporator or condenser) during servicing. C. Provide neoprene isolators shipped with chiller. 2.10 ELECTRICAL REQUIREMENTS A. The packaged chiller unit shall operate on 460v/3ph/60Hz power,with 115v/lph/60Hz controls,using its own control power transformer. B. All unit power wiring shall enter the casing at a single location. C. All power wiring shall be in conduit-no exposed wiring shall be permitted. All power or control wiring within the condenser section and any other wiring exposed to the elements shall be in vapor tight conduit. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 9 SPE-16040-15685 J:\16040\Specs\Fina1\15685_REV O.doc B. Safety controls shall include as a minimum: 1. Over-temperature and over-current motor protection,high and low refrigerant pressure cutout switches, low oil flow cutout, low water temperature cutout, and loss of water flow cutout;phase reversal/unbalance/single phasing,over/under voltage, failure of water temperature sensor and compressor status. 2. Compressor 5 minute solid state anti-recycle time delay, load limiting, and any additional safety controls recommended by manufacturer for proper operation, in addition to those listed above. C. The unit microprocessor shall provide the following operating controls as a stand- alone system: 1. Local and remote start/stop, setpoint adjustment,monitoring, diagnostics and alarms, all accessible via a unit mounted operator interface panel with keypad and screen, as well as capability for communication with a remote control panel. 2. Compressor staging and capacity control, utilizing a PID loop based on leaving water temperature, and modified as required by ambient conditions for optimum energy use. 3. Condenser fan cycling and fan speed control based on head pressure, for low ambient operation down to 0°F. 4. Compressor lead-lag control,based on number of starts and hours of operation,with capability for manual override. 5. Hot gas bypass control if required for low load operation. 6. Pumpdown control based on suction pressure or time interval,per the manufacturer's standard. 7. Refrigerant pressure monitoring (high and low), load limiting, low water temperature cutout, loss of water flow cutout, and other safety control functions. 8. Provide a remote chilled control panel capable of operating chiller via single data cables connecting to control panel. Remote control display panel shall have capability for start/stop and setpoint adjustments, remote starting of pumps and other related equipment, full diagnostics,parts failure, ambient temperature and alarm capabilities, chiller optimization programs and data logging. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 8 SPE-16040-15685 JA16040\Specs\Fina1\15685_REV O.doc balanced and fan assembly shall be either painted or zinc coated steel. Fan guard shall be either PVC, chrome or zinc coated. E. Provide fan motors with permanently lubricated ball bearings and built-in thermal overload protection. 2.7 REFRIGERANT CIRCUITS AND COMPONENTS A. Unit shall be equipped with dual refrigeration circuits each containing: Liquid line service valve, removable core filter drier, sight glass and moisture indicator, solenoid valve, thermal expansion valve and pressure relief provisions, charging valve, discharge oil line check valves, compressor suction and discharge service valves. The two circuits shall be completely isolated for independent operation. B. Provide electronic expansion valves if available as manufacturer's standard. C. For reciprocating compressor alternate only,provide hot gas bypass including piping, valves, and controls for each circuit for low load capacity control as specified in Section 2, above. D. High side pressure relief valve. E. Full operating charge of HCFC-22 and oil. F. Capacity Modulation: Provide capacity modulation by either slide valve or unloader valves. Unit shall be capable of operation down to 15%. In the event the manufacturer cannot provide a unit with modulation down to 15%,hot gas bypass must be provided. 2.8 AUTOMATIC CONTROLS A. Provide power devices, instrumentation, and refrigeration controls in a weather tight NEMA 3R enclosure. 1. The starter section shall contain the main unit power connection with across the line or Star(Wye)Delta closed transition starter for each compressor, control transformer, starting contactors, compressor overloads and oil pressure cutouts. The unit shall allow a single point power connection for all power and control functions. 2. The refrigeration controls section shall contain reset relays, compressor service switches,motor protector,high and low pressure controls and the control microprocessor. Refrigerant and oil pressure gauges with isolation valves shall be provided in this section as specified below. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 7 SPE-16040-15685 JA16040\Specs\Fina1\15685_REV O.doc speed shall be 3600 rpm. Forced oil circulation may be accomplished via refrigerant pressure differential. Compressor motor power factor shall be 0.90 or greater. If the compressor motor power factor is less than 0.90 power factor, correction capacities must be installed. 2. Reciprocating compressors shall be semi-hermetic, direct drive, and shall be equipped with cylinder unloading for a minimum of four(4) steps of capacity control for each chiller unit. Each circuit shall include factory prepiped hot gas bypass system to maintain control down to 10% of full load when either compressor is in the lead position. Maximum compressor operating speed shall be 1800 rpm. Provide positive displacement oil pump for each compressor. B. Compressors shall be mounted on spring type isolators with a minimum isolation efficiency of 95%. C. Each compressor shall be equipped with insert type crankcase heaters, discharge and oil line check valves, and suction and discharge service valves. 2.5 EVAPORATOR A. Evaporator shall be shell and tabe type with internally finned copper tubes expanded into tube sheets. The vessel shall be constructed and stamped in accordance with ASME Code for Unfired Pressure Vessels, for a minimum water side pressure of 215 psig. Refrigerant side pressure rating shall be 300 psig. B. Chilled water connections shall be 150#R.F. flanged. Provide vent and drain connection and wells for temperature and safety controls as required. C. Provide 3/4" closed cell urethane insulation, Armstrong"Armaflex" or equal, over entire surface of the evaporator;maximum insulation k factor shall be 0.28 Btu/in-hr-sf-°F. 2.6 CONDENSER AND FANS A. Low ambient controls for operation down to 0°F. B. Construct condenser coils of aluminum fins mechanically bonded to seamless copper tubing. Provide sub-cooling circuits. Air test under water to 506 psig. C. Provide factory mounted, 4" square,heavy wire mesh access guards that cover the service area beneath the condenser coils and coil protection shall be a heavy plastic covering that will prevent inadvertent damage to the coil prior to operation. D. Provide vertical discharge direct driven propeller type condenser fans with fan guard on discharge. Entire fan assembly shall be statically and dynamically REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 6 SPE-16040-15685 JA16040\Specs\Fina1\15685_REV O.doc 2.0 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Trane B. York C. McQuay 2.2 GENERAL A. The chiller unit must produce the full cooling temperature differential specified at the design water flow rate, at or below the design ambient air temperature using equal or less total power than specified. B. The discharge water temperature listed in the design data table must be maintained at setpoint,f '/2°F at actual loads from 20%to 100% of rated full load capacity. 2.3 UNIT CASING A. Unit casing shall be constructed of galvanized steel, and shall be protected against corrosion,using a suitable corrosion resistant finish of the Manufacturer's standard color. The casing shall be constructed of minimum 16 gauge panels on minimum 12 gauge unit structure,with entire unit supported by a structural steel base. B. Hinged, gasketed access doors,which are capable of being secured and locked in the open position, shall be provided to allow access to all power devices, controls, and instrumentation. It shall not be necessary to remove any bolts to open the access doors. The sections including electrical power and control devices shall be NEMA 3R(rainproof). All hinged panels shall be provided with suitable gasketing to prevent moisture leakage. C. Unit casing shall be equipped with lifting lugs to facilitate overhead rigging. 2.4 COMPRESSORS A. Compressors may be helical rotary screw type or reciprocating per the manufacturer's standard, and shall be located to facilitate servicing. I. Screw compressors shall be semi-hermetic, direct drive, and shall be equipped with slide valve unloading,providing modulating control down to 15% of full load capacity. Hot gas bypass shall not be required to maintain low load capacity control. Maximum compressor operating REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 5 SPE-16040-15685 JAI 6040\Specs\Fina1\15685_REV O.doc 1.6 GUARANTEE A. The Chiller Supplier shall guarantee that the equipment supplied meets the specifications, and that it will achieve the performance requirements. The guarantee shall cover parts and labor including motors, controls, and other items specified by the Vendor,whether or not manufactured by him. Equipment which fails to meet the performance guarantee, and equipment,materials,parts, and appurtenances which become defective under normal and proper use and maintenance before the end of the guarantee period shall be replaced or repaired to the Owner's satisfaction. Repair or replacement shall be initiated promptly upon receipt by the Vendor of notice from the Owner of the defect, and shall be completed as expeditiously as possible. Work under the guarantee shall be performed by qualified service personnel. B. The guarantee shall be in effect for a one-year period,beginning on the date of the chiller start-up and Owner acceptance. Formal acceptance is required. C. Provide five year parts and labor warranty on compressors. 1.7 SELECTION CRITERIA A. The air cooled chiller shall meet or exceed the design data listed below: ITEM DESCRIPTION Unit Tag CH-1 Entering Water Temperature 54°F Leaving Water Temperature 44°F GPM Flow Rate 60-360 Ambient Design Temperature j 4 95°F Evaporator Fouling Factor 0.0001 %Propylene glycol 35% Evaporator Pressure Drop 4-54 ft Compressor Quantity 2 Total Chiller Capacity nominal/actual 216 Maximum Unit Full Load Power Requirement 4:33 kW/ton Minimum Full Load EER W0 25%Load EER NPLV I4 4.4 Unit MCA 324 amps Maximum Fuse Size 458 amps Operating Weight 1-2,900 lbs. Unit Size 23'L x 7'-6"W x T-10"H REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 4 SPE-16040-15685 JA16040\Specs\Fina1\15685_REV O.doe B. Architect/Engineer: Process Facilities Inc. 160 Federal Street Boston,MA 02110-1700 (617) 946-9400 C. Contractor: PFI Construction Corp. 160 Federal Street Boston,MA 02110-1700 (617) 946-9400 1.4 QUALITY ASSURANCE A. Acceptable manufacturers include those companies specializing in the manufacture of the types of units specified herein,provided that they meet the construction and performance requirements of this Specification. B. Chiller shall be rated in accordance with the latest edition of ARI Standard 550/590-98. Unit shall be capable of starting and running at ambient outdoor temperatures from 0°F to 95°F. C. Unit shall be designed to conform to ANSI B9.1 Safety Code, ASME/ANSI B31.5 Refrigeration Piping Code, and ASHRAE Std. 15, Safety Code for Mechanical Refrigeration where applicable. Vessels shall be designed and stamped in accordance with ASME Section VIII, Code for Unfired Pressure Vessels. Control panels shall be UL Listed, and designed in accordance with the National Electrical Code. D. Unit casing shall be capable of withstanding ASTM A123 standard method of salt spray (fog)testing. E. Air cooled condenser coils shall be factory leak tested at minimum of 150 psig and pressure tested at 450 psig. Evaporator tubes and shells shall be factory pressure and leak tested at 1.5 times their respective working pressures as noted on required ASME stamps. F. Chiller shall be factory tested at full and part load conditions, and a full test report shall be provided to the Owner. The chiller shall be tested for refrigerant leaks and shipped with a full charge of R-22. 1.5 SAFETY AND HEALTH A. All equipment shall comply with the latest edition of EPA, OSHA,NFPA,UL, ANSI, ASHRAE, ASTM,NFPA standards, and other National, state, and local codes and regulations applicable at the Owner's plant location in Northampton, Massachusetts. REV. 0 PFI DESIGN, P.C. DECEMBER 28, 2000 Pg. 3 SPE-16040-15685 JA16040\Specs\Fina1\15685_REV O.doc H. Furnished by Purchaser The following equipment,materials, utilities and services will be supplied by the Purchaser: 1. Labor and equipment for unloading and erection of all equipment at the job site. 2. Structural support framing. 3. 460 volt, 3 phase, 60 Hz power supply. 1.2 SUBMITTALS A. General: Submit each item in this Article according to the conditions of the Contract. Obtain approval from PFID before proceeding with fabrication and work. Six (6) copies shall be submitted to the Construction Manager. B. Product data for each chiller specified, including the following: 1. Certified chiller performance curves with system operating conditions indicated. Provide computerized selection indicated part load efficiencies. 2. Electrical data. 3. Material gages and finishes. 4. All accessories being provided. C. Shop Drawings from manufacturer detailing equipment assemblies and indicating dimensions,weights, loadings,required clearances,method of field assembly, components, and location and size of each field connection. D. Wiring diagrams detailing wiring for power and control systems and differentiating between manufacturer-installed and field-installed wiring. E. Operation and Maintenance manuals. 1.3 DEFINITIONS A. Owner: The Minute Maid Company 45 Industrial Drive Northampton,MA 01060 REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 2 SPE-16040-15685 JA16040\Specs\Fina1\15685_REV O.doc AIR-COOLED CHILLER(CH-1) SECTION 15685 1.0 GENERAL 1.1 SCOPE OF WORK A. This Vendor shall quote firm price and delivery schedule to furnish and deliver, FOB Northampton, MA, one (1) industrial grade, air-cooled water chiller, as specified herein. The units shall utilize HCFC-22 as a refrigerant. B, The chiller unit shall be completely assembled,piped, wired and tested prior to shipment. Each unit shall have a full charge of refrigerant and compressor oil. C. Chiller unit shall meet or exceed the construction quality and performance data listed in Part 2,below. D. The Vendor shall submit with bid,three(3) copies of published catalog information indicating materials of construction and unit configuration with dimensioned record drawings for the air cooled chiller, along with all pertinent performance data, including but not limited to: 1. Product data indicating general assembly, components, safety controls, wiring diagrams, service connections, and service clearances. 2. Certified chiller performance curves with system operating conditions indicated. Provide computerized selection indicating part load efficiencies. 3. Electrical data. 4. Material gages and finishes. 5. Provide dimensional data unit weight and support requirements. 6. All accessories being provided. E. Submit wiring diagrams for electrically operated equipment. Differentiate between wiring that is factory installed and wiring that is field installed. Submit load calculations indicating Electrical Load. F. Provide estimated lead time for delivery of chiller to jobsite. G. Vendor shall furnish all documentation as indicated in this specification and comply with all the requirements set forth on the Purchase Order. REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. 1 SPE-16040-15685 JA16040\Specs\Fina1\15685_REV O.doc TABLE OF CONTENTS 1.0 GENERAL...........................................................................................................................l 1.1 SCOPE OF WORK..............................................................................................................1 1.2 SUBMITTALS ....................................................................................................................2 1.3 DEFINITIONS.....................................................................................................................2 1.4 QUALITY ASSURANCE...................................................................................................3 1.5 SAFETY AND HEALTH....................................................................................................3 1.6 GUARANTEE.....................................................................................................................4 1.7 SELECTION CRITERIA....................................................................................................4 2.0 PRODUCTS.........................................................................................................................5 2.1 ACCEPTABLE MANUFACTURERS ...............................................................................5 2.2 GENERAL...........................................................................................................................5 2.3 UNIT CASING....................................................................................................................5 2.4 COMPRESSORS.................................................................................................................5 2.5 EVAPORATOR...................................................................................................................6 2.6 CONDENSER AND FANS.................................................................................................6 2.7 REFRIGERANT CIRCUITS AND COMPONENTS.........................................................7 2.8 AUTOMATIC CONTROLS ...............................................................................................7 2.9 CHILLER OPTIONS...........................................................................................................9 2.10 ELECTRICAL REQUIREMENTS .....................................................................................9 2.11 MARKING ........................................................................................................................10 3.0 EXECUTION.....................................................................................................................10 3.1 TESTS................................................................................................................................10 3.2 CLEANUP.........................................................................................................................10 3.3 PREPARATION FOR SHIPMENT..................................................................................10 3.4 START-UP ASSISTANCE...............................................................................................11 3.5 DELIVERY........................................................................................................................11 REV. 0 PFI DESIGN,P.C. DECEMBER 28, 2000 Pg. i SPE-16040-15685 J:\16040\Specs\Final\15685_REV O.doc R PFI DESIGN, P.C. SPECIFICATION FOR AIR-COOLED CHILLER(CH-1) SPE-16040-15685 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 Rev:; late, Description Admn. Pre acedheced A raved A 11/17/00 Issue for Bid KAB TAE MJH HM 0 12/28/00 Issue for Construction KAB T MJH HM Client Approval: Client: Date: NOTES Initial drawings must show all information necessary for Owner's design of foundation, all connections to other equipment, space needed for access, disassembly, and maintenance. A reproducible is a master copy which can be legibly duplicated by either microproduction, diazo, or electrostatic process. A or B size drawings can be black on white. All prints and reproducibles larger than 11" x 17" are to be unfolded and rolled around a form adequately protected to prevent damage in transit. All drawings must show, adjacent to the title block, Owner's equipment title and number, manufacturer's serial number, and Purchase Order number. Final drawings must be certified. Vendor's drawings will be reviewed and approved only as to general arrangement and conformance to the specifications and related drawings. Approval shall not be construed to relieve or mitigate the Vendor's responsibility for accuracy or adequacy and suitability of materials and/or equipment represented thereon. During drawing review and approval stages of project all documents are to be delivered by overnight express mail except in the case where Owner allows a particular document to be transferred by telephone facsimile. ' Deliver installation instructions to PFICC at least one month prior to delivery of equipment to jobsite. The operation and maintenance manual will be needed in advance for preparing qualification/validation protocols. 2 All Vendor-supplied instruments and controls shall be provided with complete installation, operation, and maintenance manuals,parts list,protocols, and a list of required test/calibration equipment. 3 The parts list shall include actual ordering numbers for each item. 4 Bill of Materials shall include name, tag no. (if applicable),model no., serial no., and manufacturer. ++END OF SECTION 15690++ REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 28 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc 4.0 ATTACHMENTS 4.1 DOCUMENTATION REQUIREMENTS This multi-purpose form identifies the documents, drawings, and data required of the Vendor to satisfy the Purchase Order requirements. This schedule is to be fulfilled before rendering the final invoice. When Approval When Scheduled Drawing Description No.of Copies Required Before (To be Completed Required (Weeks After Fabrication by Vendor) P.O. General Arrangement/Outline Drawing 2 R/6 P* 4 Yes Foundation Requirements Including 2 R/6 P 4 Yes Equipment/Operating Weights Assembly Drawings/Detail Cross- 2 R/6 P°* 4 Yes Section w/Parts List and Bill of Material Fabrication Drawings 2 R/6 P* 6 Yes Wiring Diagrams 2 R/4 P* 6 Yes Electrical Outline Drawings 2 R/6 P* 6 Yes Motor Drawings 2 R/6 P* 6 Yes Certified Drawings 2 R/6 P* 4 weeks before shipping Nameplate Details 6 copies 6 Fabrication Schedule 6 copies 4 Instrument Data Including Manufacturer 6 copies 6 Yes and Catalogue No. Final Installation Instructions,Operating 6 copies 4 weeks before and Maintenance Manuals each',' shipping Manufacturer's Data Sheets 6 copies* 4 weeks before shipping Recommended Spare Parts for One 6 copies'* 4 Year's Operation with Prices, Availability and Part Nos.for Ordering Inspection,Test Procedures and Test and 6 copies 4 weeks before Cleaning Reports/Results shipping Code Certificates(if applicable) 1 orig/6 4 weeks before prints* shipping Certified Performance Data 6 prints* 4 weeks before shi in Sequence of Operation 6 copies* 6 Yes Instrument/Electrical Panel Details 2R/6P* 6 Yes R=Reproducible *As-Builts Required P=Print REV. A PFI DESIGN, P.C. JANUARY 10, 2001 Pg. 27 SPE-16040-15690 J:\16040\SpecsTinahl5690_Rev A.doc C. Failure to submit all documents on time can result in the Owner withholding all further payments. D. During the approval process,delivery of all documents shall be by overnight express mail except in the case where Owner allows use of electronic transfer of a particular document E. Vendor shall provide complete information on each lubricant to be used, including: 1. Type of material. 2. Brand name. 3. MSDS. 4. Recommended schedule for refilling and replacement. 3.4 SUBSTITUTION OF MATERIALS OR EQUIPMENT A. Except in specific cases where words "Owner approved substitute" follow or refer to a maker's name and catalogue number or other identifying feature,only such items as are specified or shown on the drawings will be acceptable and no substitutions will be allowed. B. If the Vendor wishes to use material or equipment other than those specifically designated herein as being equal to those so specifically designated, BEFORE PURCHASING OR FABRICATION,the proposed substitution shall be submitted to the Owner for approval, and the decision of whether or not it is equal to that specified shall be that of the Owner. C. If the apparatus or material substituted as equal for that specified necessitates changes or additional connections,piping supports, or construction, the same shall be provided and the Vendor shall assume the cost and entire responsibility thereof. D. The Owner's permission to make such substitution shall not relieve the Vendor from full responsibility for the work. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 26 SPE-16040-15690 JA16040\specs\Fina1\15690_Rev A.doc d. Draining of the system shall be accomplished immediately after completion of the final hydrostatic test. Any remaining pockets of water shall be dried with air. e. Flanged joints which have been taken apart after a hydrotest(for whatever reason) shall be reassembled with unused gaskets and then retested. 3. Pressure Test The assembled refrigeration system shall be pressure tested, vacuum tested, dehydrated and given a holding charge using dry nitrogen. 3.2 PREPARATION FOR SHIPMENT A. Vendor shall make final check for completeness of equipment prior to shipment. B. All equipment and materials shall be suitably crated,boxed, equipped with handling fixtures, or otherwise prepared for shipment to prevent damage or contamination during handling and shipping. All parts which may be exposed to the weather due to physical size or arrangement shall be adequately protected by suitable weatherproofing. It shall be the responsibility of the Vendor to take all precautions required to reasonably ensure job site arrival of the equipment in an undamaged and satisfactory working condition. The Vendor shall replace free of charge and in an expedient manner, any components damaged or broken during shipment. C. All pipe ends shall be sealed,using plastic caps for flanged ends, and metal thread protectors or cap plugs for threaded ends to exclude entry of foreign matter. D. All parts shall be identified in an appropriate manner. When parts are crated or boxed, detailed packing lists shall be provided with each crate or box. E. Component weights shall be plainly marked on all equipment requiring rigging so that field construction forces can suitably handle the equipment. F. Vendor shall notify Owner of shipment as set forth in the Purchase Agreement. 3.3 SUBMITTAL AND DOCUMENT REQUIREMENTS A. The Document Requirements, Section 4.1, indicates the number of each type of document which shall be submitted. B. Drawings which require approval by the Owner prior to fabrication shall be submitted by the Vendor within the.time period specified in Section 4.1. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 25 SPE-16040-15690 JA 16040\Specs\Fina1\15690_Rev A.doc 3.0 EXECUTION 3.1 TESTING AND PREPARATION FOR SHIPMENT A. Tests The Vendor shall make all shop tests necessary to insure that his material and workmanship are of the required quality and that the equipment furnished will perform as specified and guaranteed. Tests shall include, at a minimum, those listed below. Acceptance of shop tests shall not constitute a waiver of requirements to meet field tests under specified operating conditions,nor does inspection relieve the manufacturer of his responsibility in any way whatsoever. 1. Operational Test All Vendor supplied equipment,hardware and software, shall be shop tested. If possible, the unit should be run at full load, at 50%and at 10%, per ARI-550. Evaporator and condenser temp shall be adjusted at the test facility per ARI-550 to insure that the system will perform as specified and guaranteed. If the compressor oil filter(s) are used during the test, new elements shall be installed prior to shipment. If full load testing is not feasible,the Vendor shall check out all control circuits, stroke valves, bump motors, and verify the operability of the unit to the extent possible in the shop. Vendor shall provide a list of checks that have been performed and passed. 2. Hydrostatic Test a. All shop fabricated equipment shall be hydrostatically or pneumatically tested and documented in accordance with ASME code. Testing shall be done at 1.5 times the individual design pressures. The test pressure shall be held without decreasing for not less than 30 minutes. b. The pressure specified shall be the pressure at the tW of the equipment in its test position. All vertical equipment which is tested in the horizontal position must have the test pressure adjusted to suit the additional pressure due to the static head. C. Water used for the hydrotest shall be potable or clean raw water. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 24 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc 6. Unless otherwise specified or required, motors shall have a Service Factor of 1.15. 7. Motors shall be have NEMA Class F insulation. The motors shall be designed for continuous duty and shall not exceed Class B temperature rise when operating at a 1.15 service factor. 8. The cooling fans provided with fan cooled motors shall be made of a material which is not capable of producing sparks when struck by material of any description. 9. Nameplates shall be of stainless steel and shall be fastened with stainless steel screws. 10. Labyrinth seals and duct seals shall be used to retain grease and to protect bearings from dust. 11. Motors less than 250 BP shall have grease lubricated heavy duty roller bearings capable of in service lubrication. Bearings shall be of such design as to provide extra long life. Permanently lubricated bearings will not be acceptable. Grease fittings shall be easily accessible and not interfere with machine operation. A spring-loaded cap shall be installed on the outlet of each bearing grease chamber discharge port. Grease fittings shall be supplied on inlet grease connections. 12. Main compressor motors must have split sleeve bearings with oil rings, ample oil reservoirs, seals,pressure equalizing vents, and oil level indicators. A window shall be provided for visual inspection of the oil ring. Thomas Series 71 couplings shall be used. 13. Copper conductors shall be used for windings and motor loads. 14. When the motor is operating at rated voltage and ftequency, the minimum full load efficiency shall equal or exceed the nominal values in NEMA MG1-1993,Table 12-10. 15. Lifting eyes or lugs shall be provided for all motors weighing more than fifty(50)pounds. 16. All electrical equipment shall bear the UL stamp of approval. All wiring and wiring work shall be in accordance with the requirements of the latest issue of NEC, and all local codes. All factory wiring shall be run in conduit, and shall be color coded, numbered, and neatly arranged. Rigid galvanized steel conduit is preferred; flexible liquid tight steel conduit approved for the area may be used where vibration or relative motion prohibits rigid conduit. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 23 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc 3. All enclosures shall have a NEMA 3R rating. A 120 Vac 15 Amp convenience duplex receptacle shall be provided within the panel for the purpose of powering trouble lights, tools and test equipment. B. Motors 1. The Vendor shall provide with their quotation the motor design requirements necessary to provide adequate operation as required by this specification. The motor design requirements shall include at a minimum the following: a. Motor horsepower. b. Motor speed. C. Motor torque. d. Range of motor frame sizes and mounting sizes easily adapted for each drive. e. Motor voltage 2. All motors shall be designed and manufactured to conform to all applicable requirements of the latest editions of standards published by the following: ANSI American National Standards Institute IEEE Institute of Electrical and Electronics Engineers Standard 841- 1994 NEMA National Electrical Manufacturers Association(All MG Standards) NFPA National Fire Protection Association UL Underwriter's Laboratories 3. Motor mounting to be designed to maintain alignment of motor and compressor. Motor and compressor to be aligned in the factory. Motor and compressor to be joined by a flexible coupling, to accommodate misalignment. 4. As a minimum, motors shall be of the totally enclosed, fan-cooled type (TEFC). In no case will a motor less than one(1)horsepower be used. All motors shall be premium efficiency motors. 5. Motors shall be of the squirrel cage, induction type and shall be capable of starting and accelerating their load to normal operating speeds under the most severe conditions likely to be encountered without exceeding the horsepower rating indicated on the nameplate; and without usurping any portion of any specified service factor over 1.0. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 22 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc micrometers) deep and a maximum of 3 mils (75 micrometers) deep,with rogue peaks not exceeding 3.5 mils (85 micrometers). Blasting media shall be free of oil and moisture. 4. No blasted surfaces shall be allowed to remain uncoated overnight in humid areas. All paint is to be applied to a surface free from moisture, oil, dust, grit, or any other contaminants and discoloration. 2.11 MARKING Each piece of equipment shall be provided with a stainless steel nameplate,permanently attached to the exterior of the equipment, in an accessible location external to any insulated surface, and observable while the equipment is in operation. The nameplate shall include the following information: A. Manufacturer's name,model, and serial number. B. Year built. C. Design capacity. D. Owner's equipment identification number(Tag No.). E. Weight of equipment. F. Design pressure and temperature. G. Code symbol and national board number(where applicable). 2.12 ELECTRICAL A. Chiller Terminal Box 1. The chiller control panel shall contain all motor starters, step down transformers,power distribution, and controls required for chiller operation. The control panel will be powered from a 480 volt, 3 phase, 3 wire, 60 Hz dedicated feeder from a remote source. The control panel shall have service disconnecting means at the point of connection of the incoming line. The disconnect shall have provisions for lock-out. All interconnection wiring between the controller and the chiller equipment shall be provided by the chiller manufacturer. 2. Unless specifically noted, all electrical and electronic accessories supplied by the Vendor shall have suitable enclosures for the unit's electrical area classification. REV. A PFI DESIGN, P.C. JANUARY 10, 2001 Pg. 21 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc 4. The unit shall be pre-wired by the Vendor to a single point connection to a power source. 5. Vendor shall provide a local, hard-wired emergency stop pushbutton station, for emergency shutdown of the compressor motor. This pushbutton station shall be capable of being locked out in the"off' position, and hard-wired ahead of all other compressor motor start-stop control interlocks. I. Control and Protection Circuit design and wiring practice shall conform to the following standards: 1. National Electric Manufacturers Association. 2. ANSI Standards Institute. 3. American Institute of Electrical Engineers. J. Vendor to supply unit mounted motor starters. This includes any starters needed for the oil pump. The compressor starter shall be a solid-state, soft start type, mounted in a NEMA 3R enclosure. K. All control and power equipment shall be provided as part of the chiller control cabinet. L. Allowable number of restarts per hour shall be as per NEMA code. 2.10 FABRICATION A. Painting All carbon steel components shall be sand blasted and finished with the Vendor's standard paint system. A copy of the Vendor's standard painting materials and procedures shall be forwarded to the Owner's Engineers for approval. B. Surface Preparation 1. All steel surfaces and welds to be coated shall be blasted clean to meet SSPC-SP6-63. 2. Before blasting, all sharp edges,rough welds, and steel slivers shall be ground smooth and all oil, weld splatter, and flux shall be removed. 3. Blasting media to be used shall be either a 16-40 mesh nonmetallic abrasive, a SAEGL-40 steel grit, an 5-230 steel shot, or an equivalent abrasive that will give a minimum surface profile of one mil (25 REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 20 SPE-16040-15690 JAI 6040\Specs\Fina1\15690_Rev A.doc 2. High discharge pressure alarm & cutout. 3. High oil filter differential pressure alarm. 4. High discharge temperature alarm & cutout. 5. Low oil pressure alarm& cutout. 6. High oil temperature alarm&cutout. 7. Low oil temperature alarm and cutout. 8. Low oil level alarm. G. The Vendor supplied microprocessor based Control Panel and display shall be provided with the following features: 1. First out annunciator. 2. Graphical display of alarms, operating conditions, and setpoints. 3. Program and setpoints to be stored in nonvolatile memory, either in PROMS or in long-life battery backed-up RAM. Memory must be re- programmable in the field. 4. Real time clock/calendar to provide a local time/date stamp on alarms. 5. Self-check diagnostics and internal failure alarm, for conditions such as low AC line voltage,parameter range error, sensor calibration error, or memory error. 6. Automatic calibration of analog sensors. H. Control and Protection Circuits 1. Vendor shall assume full control and protection circuit design responsibility and shall furnish schematic diagrams showing all components and interconnecting wiring diagrams for connections to local and remote located equipment. 2. Control Circuits shall be fused(115 volts) and pre-wired to terminals. Control Power to be supplied by the Owner. 3. Compressor and sub-circuits shall be fused. REV. A PFI DESIGN, P.C. JANUARY 10, 2001 Pg. 19 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc have a chilled fluid temperature sensor in its outlet. The chiller shall be capable of performing temperature control on either of these measurements, selectable by the local control panel operator. 10. Vendor shall supply a fan control scheme to control air flow through the condenser during part load and low ambient temperature conditions. E. Control Panel 1. The Vendor shall provide a complete standalone,microprocessor based control system factory installed, wired,programmed, and tested located in a Vendor supplied local control panel. Vendor's control'panel shall be in a NEMA 3R enclosure. 2. All controls and lockouts necessary to protect the chiller, and for safe operation of the chiller shall be provided by the Vendor and shall operate locally. 3. Vendor shall provide a local microprocessor based display which shall indicate:' a. Panel Mounted Suction Pressure b. Panel Mounted Discharge Pressure C. Oil Pressure & Temperature d. Oil Filter Pressure Differential e. Step solenoid Valve Position and Mode f. % of Full Load Motor Amps g. Compressor Operating Mode h. Alarm Indication,with local buzzer i. Evaporator inlet and outlet temperature F. In addition, through the local microprocessor based display, the following control and alarm set points shall be indicated(by both visual and audible) and capable of local adjustment. An additional push button for muting the audible alarm shall be provided. 1. Low suction pressure alarm& cutout. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 18 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc 2.9 CONTROL AND INSTRUMENTATION SYSTEM A. Each chiller system shall be designed to allow unloaded startup, and shall be non- overloading throughout its operating range. A load control system, including a step solenoid valve for each compressor and a"hot gas bypass", shall be provided to allow operation within the full design range of 0-100%of load and enable the compressors to operate stably without overloading, choking or surging for extended periods of time. Control system shall maintain chilled fluid outlet temperature within f %°F of set point from 0-100% load. B. All electronic instruments and control system components with imbedded microprocessors must be year 2000 (Y2K) complaint. C. Vendor to provide the following Safety/Operating controls as a minimum: 1. Compressor Protection Module: Abnormal unbalance currents will de- energize the compressor. 2. High/Low Compressor Discharge Temperature Cutout: Provided with auto reset. 3. High Pressure Safety Control: De-energize circuit if high discharge pressure occurs, with manual reset. 4. Low Pressure Operating Control: Used for auto recycling pump-down of compressor(normal operating control); used for low pressure cutout with auto reset 5. Oil Failure Control: De-energize compressor on loss of oil pressure,high oil temperature, including built-in time circuit to prevent nuisance tripping on compressor start-up,with manual reset. 6. Freeze Control: De-energize circuit if suction pressure drops below pre- set point. 7. Chilled Fluid Low Flow Switch: The switch shall be a differential pressure type. The function of the switch is to sense decrease or stoppage of chilled fluid and to pump down and de-energize compressor on failure with manual reset. This shall be interlocked to break the control circuit and cause time-delayed circuit restart when flow is re-established. 8. Manual Pump Down. 9. Temperature Control: A glycol storage reservoir temperature sensor shall be provided. This temperature sensor shall provide a 4-20 mA signal to the Vendor's temperature control system. In addition,the chiller shall REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 17 SPE-16040-15690 JAI 6040\Specs\Fina1\15690_Rev A.doc 4. Triple Duty Check Valve a. Discharge side of each pump shall be fitted with a combination calibration balancing valve,non-slam vertical lift check valve and shut-off valve. Valve connections 2 inches and above shall be standard 125 psig ANSI flanges and rated for a maximum working pressure of 175 psig at 250°F. Valve connections of 1% inches. shall be threaded. The valve shall be constructed of heavy-duty cast iron. The valve shall be fitted with a bronze seat,replaceable bronze disc, stainless steel stem and chatter-preventing spring. The valve design shall permit re-packing under full system pressure. 5. Automatic Air Vents a. Automatic air vents shall be mounted at high points to provide for immediate removal of contained air or other non-condensable gases in liquid piping systems. They shall be of the float type design,having cast iron(brass or stainless steel)bodies with threaded connections. Valve head shall be EPDM material to provide positive shut-off. All other internals to be stainless steel. Air vent shall have minimum venting capacity of 4.8 SCFM at 100 psig. Provide isolation ball valve at inlet of air vent for removal. 2.8 PROCESS SURGE TANK A. The process surge tank shall be designed per ASME or appropriate API standard. 'B. The tank shall be 304 SS welded tank,insulated with 3" urethane foam, covered by an aluminum jacket. C. All flange dimensions,ratings of nozzles, handholes and end enclosures shall be in accordance with the latest edition of ASME/ANSI B 16.5. D. Provide (1) external level gauge for visual indication of tank level. Gauge piping shall have isolation ball valves and unions for ease of removal. E. Provide (1)tank level indicator and transmitter for alarm of high and low levels within the tank. F. Provide connections on tank for venting, draining and filling along with inlets and outlets. G. Provide (2) additional 1-1/2" I.P.T. connections with plugs for extra use by Owner. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 16 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc position lever handle. Valves shall be as manufactured by Worcester, Jamesbury or Stockham. C. Valves and Piping Specialties 1. "Y" Type Strainer a. Strainers shall be full size of entering pipe size and have a maximum clean pressure drop of one psi. Strainers shall be as manufactured by Sarco, Mueller, Watts or Armstrong. b. Provide blow-off valve on each strainer with plug. C. Strainers shall be threaded, stainless fitted bronze Y-type with 1/16" mesh screen for sizes 2" and below. Use flanged end, stainless-fitted iron body Y-type strainer for sizes 2-1/2" and above. 2. Provide unions for threaded end valves to facilitate removal from pipe. 3. Safety Relief Valves a. Steam safety relief valves shall be set to open at 85% of the maximum working pressure of the equipment or vessel being protected. b. Valves shall be sized to relieve at a rate equal to the maximum possible flowrate from fully-open pressure reducing control valve upstream. C. Valves shall be bonnet type with open operating lever. d. Valves shall be sealed after testing and ASME code stamped to indicate compliance with the ANSFASME Boiler and Pressure Vessel Code, Section VIII,Division 1. e. Valve body shall be carbon steel, cast iron or bronze,with internals of brass or stainless steel. f. Valves shall be threaded for pipe smaller than 1 inch in size, and flanged for pipe 1 inch and larger. g. Approved Models- Lonergan D series,Farris 2600 Series, Consolidated 1990 Series, Kunkle 5000 Series, or Spirax/Sarco 252 Series or.6000 Series. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 15 SPE-16040-15690 JAI 6040\Specs\Fina1\15690_Rev A.doc B. Piping and Skid Design: 1. Piping shall be 150# flanged or screwed construction; carbon steel. All chilled water piping shall be insulated with 2" of urethane foam, covered with aluminum jacketing. 2. Unit to be constructed for 125 psig (862 KPa) design pressure and shall include a manual vent tube for establishing the proper air volume in the compression tank on initial fill. 3. All pressure vessels (expansion tank) shall be ASME constructed for a 125 psig design pressure and bear ASME stamp. The heat exchanger shall be ASME constructed for a 150 psig design pressure and bear ASME stamp. A manufacturer's Data Report for pressure vessels, Form U-1 as required by the provisions of the ASME Boiler and Pressure Vessel Code, shall be furnished. 4. System to include necessary valves for shut-off,throttling and prevention of backflow. 5. The frame shall be heavy duty channel and angle iron construction. The frame material shall be galvanized structural steel. The inter-connecting piping shall be all ferrous schedule 40 black pipe. All welding for the frame and piping shall be performed by ASME Section IX certified welders with certificates provided upon request. 6. Heat exchanger shall be secured to the frame by means of a saddle. Fastening the heat exchanger with a simple welded stop will not be acceptable. Piping shall be arranged to permit easy removal of heat exchanger tube bundle. 7. The equipment(full) and its supports shall be designed for seismic forces in accordance with local building codes. The design for the seismic zone corresponding to Northampton,Massachusetts shall apply. Vendor to provide standard support arrangement design for approval. 8. Pump suction trim shall consist of a shut-off valve for pump isolation and, as specified elsewhere, a diffuser type strainer. Ball valves will be provided through 2". Valves shall be Class 125 psi swp, 600 psi wog; three-piece; full port;bronze body; reinforced Teflon seat and seal; hard face chromium plated ball; threaded ends. Valves 3" and larger shall be butterfly valve with lever operator. Butterfly valves shall be full lug wafer type with cast iron body, 150 psi pressure rating,bronze or aluminum bronze disc,type 316 stainless steel or coated steel stem, and EPDM liner suitable for 150 prig dead-end service. Valves shall be complete with 10 REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 14 SPE-16040-15690 JAI 6040\Specs\Fina1\15690_Rev A.doc 2.7 PUMPS AND PIPING ACCESSORIES A. Pumps: 1. Pumps shall be based-mounted, 304 stainless steel close coupled type with TEFC motor, single-stage, end suction design with an integrally cast, foot mounted volute, capable of the impeller and bearing assembly being serviced without disturbing piping connections,pump volute or motor. 2. Pumps volute shall be 304 stainless steel, suitable for 175 psi working pressure. The pump volute shall be supplied with plugged vent, drain, and gauge tappings. 3. The impeller shall be 304 stainless steel, enclosed, single suction type, dynamically balanced,keyed to the shaft and secured by a locking cap screw. The allowable residual unbalance in the impeller rotating assembly shall conform to ANSI Grade G6.3. 4. Pump bearing housing assembly shall have heavy-duty re-greaseable ball bearings,replaceable without disturbing piping connections and have support at coupling end. 5. Base plate shall be of structural steel or fabricated steel channel configuration fully enclosed at sides and ends,with securely welded cross members and fully open grouting area. A flexible-type spacer design coupler, capable of absorbing torsional vibration, shall be employed between the pump and motor. Coupler shall be shielded by a suitable coupler guard securely fastened to the base. 6. Motor shall meet EPACT 92 requirements and NEMA specifications. Pump and motor shall be factory aligned. 7. Each pump shall be factory tested per Hydraulic Institute standards. It shall then be thoroughly cleaned and painted with at least one coat of high grade machinery enamel prior to shipment. 8. All pumps shall have a pressure gauge installed with valving to pump suction and discharge to either suction, discharge or differential pressures may be read directly to determine pump operating TDH. Gage shall be case-drawn steel with glass window,brass movement,bourdon tube- phosphorous bronze, 1/4" NTT bottom connection, stem,mount, 4-1/2" diameter dial with a range of 30" vac-0-150 psi. Valving shall consist of petcocks rated for 300#WOG tested at 250 psi. 9. Pump Motor- see Electrical Section 2.11. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 13 SPE-16040-15690 J:\16040\Specs\Fina1\15690_Rev A.doc 2.6 REFRIGERANT CIRCUITS AND COMPONENTS A. Piping and fittings Manufacturer's standard for industrial use. Vendor shall supply details of their piping, fittings and valve standards,with quote, for Engineer's review. Vendor shall also supply any required instrumentation to be installed in off-skid piping, including reliefs. Chiller system piping shall be in accordance with ASHRAE Standard 15-1994 and ANSI B31.5. B. Refrigerant Receiver The receiver shall be mounted within the skid and piped and sized to hold the complete operating charge of refrigerant when 80% full. Receiver shall include an ASME code stamp with National Board No., level gauge, low level switch, dual relief valve and isolation valve. C. Refrigerant Circuit Vendor to provide: 1. Industrial grade,renewable core, refrigerant filter dryer. 2. Liquid line sight glass and moisture indicator. 3. Solenoid valve with step capacity control and hot gas bypass. 4. Compressor suction and discharge service valves. 5. Oil cooler. 6. Refrigerant shall be at a positive pressure throughout the refrigeration circuit. A purge system is not required for this design. 7. The low temperature surfaces (evaporator and connecting piping) shall be insulated with the Vendor's standard insulating materials by Armstrong. Insulation jacket shall be UV-light resistant. Insulation shall be vapor tight, weatherproof, and thick enough to prevent condensation during summer design conditions of 90°F dry bulb with 74°F wet bulb. 8. Full operating charge of HCFC-22 and oil. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 12 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc 2.4 EVAPORATOR A. Evaporator shall be shell and tube type having 304 stainless steel brazed plates. The vessel shall be constructed and stamped in accordance with ASME Code for Unfired Pressure Vessels, for a minimum water side pressure of 215 psig. Refrigerant side pressure rating shall be 300 psig. B. Chilled water connections shall be 150#R.F. flanged. Provide vent and drain connection and wells for temperature and safety controls as required. C. Provide 3/4" closed cell urethane insulation, Armstrong "Armaflex" or equal, over entire surface of the evaporator; maximum insulation k factor shall be 0.28 Btu/in-hr-sf-°F. D. All heat exchangers shall be fully cleanable shell and tube design. Each tube shall be individually replaceable. Vent and drain plugs shall be provided in each head. Exchanger head design shall permit full access for cleaning and replacement of tubes. E. All exchangers shall be designed and constructed in accordance with ASME Code Section VIII, Div.l and TEMA C standards. All exchangers to include ASME code stamp with National Board number on both shell and tube sides. F. All exchangers shall be equipped with refrigerant and oil safety relief devices per ASME code. 2.5 CONDENSER AND FANS A. Low ambient controls for operation down to 0°F. B. Construct condenser coils of aluminum fins mechanically bonded to seamless copper tubing. Provide sub-cooling circuits. Air test under water to 300 psig. C. Provide vertical discharge direct driven propeller type condenser fans with fan guard on discharge. Entire fan assembly shall be statically and dynamically balanced and fan assembly shall be either painted or zinc coated steel. Fan guard shall be either PVC, chrome or zinc coated. D. Provide fan motors with permanently lubricated ball bearings and built-in thermal overload protection. E. The condensing unit shall rest above all the other chiller components. The unit shall have a galvanized steel frame and casing,heavy gauge galvanized steel legs and base rail. The end panels, center support and partitions shall have collared tube holes to increase tube life. Its_coil shall have 18 gauge galvanized steel' casing and 18 inch aluminum plate type tube sheets. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 11 SPE-16040-15690 J:\16040\Specs\Fina1\15690_Rev A.doc I. Flow rate through the chiller will be held essentially constant; inlet temperature will normally vary from ambient at startup to the design outlet temperature at no load. J. A set of refrigerant shut-off valves shall be factory installed to hold the entire refrigerant charge within the chiller and condenser. K. The unit shall be capable of operating with lower ambient temperatures during partial load operation. L. Average dry bulb temperature during the coldest month in year is 5°F. Minimum winter dry bulb temperature is 0°F. Vendor shall provide any heaters, insulation and/or heat tracing needed on the oil system to ensure proper compressor operation during winter conditions. 2.3 COMPRESSORS A. Compressors may be helical rotary screw type or reciprocating per the manufacturer's standard, and shall be located to facilitate servicing. 1. Screw compressors shall be semi-hermetic, direct drive, and shall be equipped with slide vavle unloading,providing modulating control down to 15%of full load capacity. Maximum compressor operating speed shall be 3600 rpm. Forced oil circulation may be accomplished via refrigerant pressure differential. Compressor motor power factor shall be 0.90 or greater. If the compressor motor power factor is less than 0.90 power factor, correction capacities must be installed. 2. Reciprocating compressors shall be semi-hermetic, direct drive, and shall be equipped with cylinder unloading for a minimum of four(4) steps of capacity control for each chiller unit. Each circuit shall include factory prepiped hot gas bypass system to maintain control down to 10%of full load when either compressor is in the lead position. Maximum compressor operating speed shall be 1800 rpm. Provide positive displacement oil pump for each compressor. Acceptable manufacturers shall be Copeland Discus or a Bitzer compressor. B. Compressors shall be mounted on spring type isolators with a minimum isolation efficiency of 95%. C. Each compressor shall be equipped with insert type crankcase heaters, discharge and oil line check valves, and suction and discharge service valves. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 10 SPE-16040-15690 J:\16040\Specs\Fina1\15690_Rev A.doc 2.0 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Cooling Technology, Inc. B. FES C. Edwards 2.2 DESIGN CONDITIONS A. All equipment shall be designed and fabricated in accordance with this specification. The equipment shall be tested and inspected in accordance with the applicable code(s) and standard(s). B. This specification shall supplement,but not supersede, all applicable legal requirements. The equipment constructed under this specification shall conform to all local, state, or federal codes or laws currently in effect at the plant location. In case of conflict, the Vendor shall obtain a decision from the Owner as to which requirement shall govern. C. The chiller skid(s) shall be designed for installation outdoors in a non-hazardous area classification. D. The unit shall be a self-contained packaged chiller system having all components mounted on a welded structural steel frame, including rigging point lugs. The unit exterior shall be finished with the Vendor's standard paint system. The entire unit shall be mounted on a single skid which shall be furnished pre-piped and pre- wired. E. Hinged, gasketed access doors,which are capable of being secured and locked in the open position, shall be provided to allow access to all power devices, controls and instrumentation. It shall not be necessary to remove any bolts to open the access doors. The sections including electrical power and control devices shall be NEMA 3R(rainproof). All hinged panels shall be provided with suitable gasketing to prevent moisture leakage. F. The maximum temperature of propylene glycol solution at static or operating conditions,which can be circulated through the chiller,without damaging the chiller is 100°F. G. All components, including isolators and other hardware,must be protected from corrosion, either by galvanizing, cadmium plating, or other approved coating. H. All relief valve discharges shall be piped to grade. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 9 SPE-16040-15690 JAI 6040\Specs\Final\15690_Rev A.doc chiller flow requirements and pressures. The process pumps shall be selected based on the process flow and pressure requirements as indicated below in paragraph"B". both pumping systems shall draw fluid from a common surge tank. 3. System redundancy shall include a dedicated standby pump for each loop. The standby pump will automatically energize if the lead pump fails. An automatic switchover between lead and lag shall be provided such that each pump has the same amount of run time. 4. The surge tank shall be sized for 3 times the total gpm flow rate of the combined pumping systems. 5. System controls shall be provided to maintain the leaving water from the surge tank to the process system at 16°F ± 2°F. 6. The complete skids design shall fit within an envelope that is 8'-6" L x T-0" W x 10'-0" H. The envelope listed shall include all areas required for servicing components. B. System Selection Criteria 1. The air cooled chiller shall meet or exceed the design data listed below: ITEM DESCRIPTION Unit Tag CH-2 Ambient Design Temperature 100°F Supply Water Temperature to Process 16°F Return Water Temperature from Process 17°F Process Pumps GPM Flow Rate 190 Process Pumps Discharge Pressure 60 psig %Propylene glycol 50% Process Surge Tank Minimum Capacity 600 gallons Chilled Water Pumps GPM Flow Rate Vendor to determine Chilled Water Pumps Discharge Pressure Vendor to determine Unit Voltage 460 v, 3 0 REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 8 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc 1.9 STARTUP ASSISTANCE A. Vendor shall provide pricing for startup assistance at Owner's facility in Northampton, MA. Startup assistance shall consist of the following: 1. The Manufacturer shall provide on-site services of a factory authorized service representative to completely check the mechanical and electrical installation of each unit,purge and charge refrigerant, and to start up and test the unit in cooperation with the installing contractor. The Vendor shall provide per diem costs for additional services if required. 2. The Manufacturer shall provide a checklist for completion by the contractor and approval by the Owner after installation of the units,to ensure that they are ready for start up. The Manufacturer shall schedule the start up service within two weeks of request given by the Owner. 3. The commissioning and start up service shall include full testing of the chilled fluid side equipment, refrigeration system, and controls. The Vendor's representative shall be capable of programming the entire unit and of making any necessary changes. The service representative shall submit three (3) copies of the start up report to the Owner within two weeks of start up. 4. Operator Training: Vendor to quote has quoted a cost adder for providing operation and maintenance training assistance at Owner's facility in Northampton, MA. The training shall take place during normal weekday business hours. B. The Vendor shall provide an estimate of the startup duration. 1.10 SYSTEM DESCRIPTION& SELECTION CRITERIA A. System Description 1. The process chilled water system is being installed to maintain frozen juice concentrate at 17°F. As the product is delivered to the site,transfer piping moves the concentrate from the tank to a 20,000 gallon bulk storage tank located outside. 16°F chilled water will circulate through tracer lines wrapped around this transfer piping to maintain product temperature. The 16°F water will also circulate through jacketed piping located in the bulk storage tank walls. Both the tank and transfer lines will be insulated with 3" of insulation. 2. The packaged chiller system shall be an open tank design utilizing separate pumps for the chiller loop and separate pumps for the process loop. The chiller loop gpm shall be selected by the Vendor based on REV. A PFI DESIGN,P.C. JANUARY 10,2001 Pg. 7 SPE-16040-15690 JA16040\Specs\Fina1\15690 Rev A.doc B. Architect/Engineer: Process Facilities Inc. 160 Federal Street Boston,MA 02110-1700 (617) 946-9400 C. Contractor: PFI Construction Corp. 160 Federal Street Boston,MA 02110-1700 (617) 946-9400 1.7 QUALITY ASSURANCE A. Acceptable manufacturers include those companies specializing in the manufacture of the types of units specified herein,provided that they meet the construction and performance requirements of this Specification. B. Chiller shall be rated in accordance with the latest edition of ARI Standard 550/590-98. Unit shall be capable of starting and running at ambient outdoor temperatures from 0°F to 95°F. C. Unit shall be designed to conform to ANSI B9.1 Safety Code, ASME/ANSI B31.5 Refrigeration Piping Code, and ASHRAE Std. 15, Safety Code for Mechanical Refrigeration where applicable. Vessels shall be designed and stamped in accordance with ASME Section VIII, Code for Unfired Pressure Vessels. Control panels shall be UL Listed, and designed in accordance with the National Electrical Code. D. Unit casing shall be capable of withstanding ASTM A123 standard method of salt spray(fog) testing. E. Air cooled condenser coils shall be factory leak tested at minimum of 150 psig and pressure tested at 450 psig. Evaporator tubes and shells shall be factory pressure and leak tested at 1.5 times their respective working pressures as noted on required ASME stamps. F. Chiller shall be factory tested at full and part load conditions, and a full test report shall be provided to the Owner. The chiller shall be tested for refrigerant leaks and shipped with a full charge of R-22. 1.8 MECHANICAL PARTS All mechanical parts subject to periodic maintenance,removal, or replacement, and all parts intended to be connected to Owner supplied equipment or piping shall conform to the standards set up for such parts by the pertinent governing code, insurance regulations, and engineering or manufacturing society. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 6 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc 1.5 SUBMITTALS A. General: Submit each item in this Article according to the conditions of the Contract. Obtain approval from PFID before proceeding with fabrication and work. Six (6) copies shall be submitted to the Construction Manager. B. Product data for each chiller specified, including the following: 1. Certified chiller performance curves with system operating conditions indicated. Provide computerized selection indicated part load efficiencies. 2. Electrical data. 3. Material gages and finishes. 4. All accessories being provided. 5. Motor ratings and electrical characteristics. 6. Certified pump performance curves and data sheets with system operating conditions indicated. 7. Spare parts list with part numbers and pricing for ordering and recommended locations to purchase parts. 8. Utility diagram including all components and instrumentation being supplied. 9. Control diagrams with sequence of operation. C. Shop Drawings from manufacturer detailing equipment assemblies and indicating dimensions,weights, loadings,required clearances,method of field assembly, components, and location and size of each field connection. D. Wiring diagrams detailing wiring for power and control systems and differentiating between manufacturer-installed and field-installed wiring. E. Operation and Maintenance manuals. 1.6 DEFINITIONS A. Owner: The Minute Maid Company 45 Industrial Drive Northampton,MA 01060 REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 5 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc Short Name Complete Identification of the Document AGMA American Gear Manufacturer's Association ARI Air Conditioning and Refrigeration Institute ASME VIII American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section VIII, Division 1 for Pressure Vessels. ANSI American National Standards Institute B31.5 - Code for Refrigerant Piping. B16.5 - Code for Steel Pipe Flanges, Flanged Valves and Fittings. ASHRAE American Society of Heating, Refrigerating, and Air-Conditioning Engineers ASTM American Society for Testing and Materials BOCA Building Officials and Code Administrators FM Factory Mutual ISA Instrument Society of America CEC California Electric Code IEEE Institute of Electrical &Electronics Engineers NIST National Institute of Standards and Technology NEMA National Electrical Manufacturers Association OSHA Occupational Safety and Health Administration SSPC SP6 Steel Structures Painting Council, Systems and Specifications. Code of Commercial Blast Cleaning. TEMA Tubular Exchanger Manufacturers Association UBC 1997 Uniform Building Code 1997 UL Underwriters' Laboratories REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 4 SPE-16040-15690 JA16040\Specs\Fina1\15690 Rev A.doc 1.2 GUARANTEE A. The Vendor shall provide a thermal performance warranty, that the system will operate satisfactorily, in clean and fouled conditions, over the entire range of operating conditions defined in the Owner's equipment specification. This performance must be accomplished using power equal to or less than that quoted. B. The Vendor shall also guarantee that the furnished packaged system, including all mechanical equipment, instrumentation and control devices,piping,wiring, and the structural integrity of the frame, are mechanically sound, free of defects, and are constructed of new equipment, designed for the service intended. C. Optional extended warranty. Manufacturer shall quote a price for an option to extend the warranty to five (5)years on the entire machine. This includes parts and labor required to maintain the machine, assuming that the Owner's personnel only monitor the machine and clean tubes. D. The Manufacturer shall warrant the performance of the packaged chiller unit to meet or exceed the certified performance data provided with the submittal, including: 1. The chiller unit must produce the full cooling temperature differential specified at the design fluid flow rate, at or below the design air temperature using total power equal to or less than that specified. 2. The discharge fluid temperature listed in the selection criteria in Section 1.10 must be maintained within± 2°F at actual loads from 10%to 100% of rated full load capacity. E. System efficiency level must meet the requirements of latest edition of ANSFASHRAE Standards. 1.3 SAFETY AND HEALTH All equipment shall comply with the latest edition of ASME, EPA, OSHA,NFPA, ANSI, ASHRAE, ARI, ASTM,UL, (and/or FM, etc.) standards, and other national, state, and local codes. 1.4 CODES AND STANDARDS Various codes, standards, or other documents that are mentioned by short-form name elsewhere in this Specification are fully identified below. To the extent that these documents apply,the Vendor, and his subsuppliers and contractors, shall adhere to the version of the document that is applicable at the time the purchase order is placed shall apply. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 3 SPE-16040-15690 JAI 6040\SpecsWinal\15690_Rev A.doe 2. Compressor data, including quantity, manufacturer, size and type of compressors, capacity, motor characteristics, and method and limits of load control. 3. Evaporator data, including tube type and material, number of passes, minimum/maximum chilled fluid flow rates, and chilled fluid pressure drop. 4. Condenser data, including tube type,material, and fan information. 5. Pump(s) data including model no.,manufacturer, horsepower, gpm, head pressure and construction features. 6. Control system description, including all safety and operating controls, diagnostic functions, alarms, user setpoints and data logging capabilities. 7. Predicted noise data for unit at full load, is 85 dba at three feet distance. 8. Equipment dimensions, shipping weight and liquid full weight. 9. Material gauges and finishes. 10. Electrical data. 11. Product data indicating general assembly, components, safety controls, wiring diagrams, service connections and service clearances. T. Submit wiring diagrams for electrically operated equipment. Differentiate between wiring that is factory installed and wiring that is field installed. Submit load calculations indicating Electrical Load. G. Vendor shall furnish all documentation as indicated in this specification and comply with all the requirements set forth on the Purchase Order. H. Furnished by Purchaser The following equipment,materials,utilities and services will be supplied by the Purchaser: 1. Labor and equipment for unloading and erection of all equipment at the job site. 2. Concrete housekeeping pad. 3. 460 volt, 3 phase, 60 Hz power supply. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 2 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doe AIR COOLED GLYCOL CHILLER SECTION 15690 1.0 GENERAL REQUIREMENTS 1.1 SCOPE OF WORK A. The Vendor shall quote a firm price and delivery schedule to furnish and deliver one (1) air cooled liquid chiller system, as specified herein to the Minute Maid site located in Northampton,MA. B. The unit shall be a skid mounted package chiller requiring only water and electrical connections. The chiller system shall be designed and constructed for outdoor installation. The units shall meet or exceed the construction quality and performance data listed below in Sections 2.0. The unit will consist of as a minimum: 1. Four recirculating centrifugal pumps. 2. One compressor. 3. Evaporator shell and tube heat exchanger. 4. Completely factory pre-piped refrigerant circuit. 5. Condenser fan section. 6. Completely factory pre-piped chilled water system with flanged inlet and outlet connections and piping accessories as specified herein. 7. Carbon steel epoxy coated chiller tank. 8. Instrumentation to include: - Pressure gauges. - Thermowells,temperature elements and transmitters. - Pump hand switches and emergency stops. - Control valves. 9. Conduit,wiring,motor starters and electrical enclosures. 10. Factory insulation as specified. C. The Vendor shall furnish all documentation as indicated in this specification. D. The Vendor shall furnish one(1) full charge of refrigerant and lube oil, shipped with the unit. E. The Vendor shall submit,three(3) copies of published catalog information indicating materials of construction and unit configuration with dimensioned drawings for the chiller unit, along with all pertinent performance data including but not limited to: 1. Overall unit performance data,including part load efficiency curve. REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. 1 SPE-16040-15690 JA16040\Specs\Fina1\15690_Rev A.doc TABLE OF CONTENTS 1.0 GENERAL REQUIREMENTS...........................................................................................1 1.1 SCOPE OF WORK..............................................................................................................1 1.2 GUARANTEE.....................................................................................................................3 1.3 SAFETY AND HEALTH....................................................................................................3 1.4 CODES AND STANDARDS..............................................................................................3 1.5 SUBMITTALS.....................................................................................................................5 1.6 DEFINITIONS.................:...................................................................................................5 1.7 QUALITY ASSURANCE...................................................................................................6 1.8 MECHANICAL PARTS......................................................................................................6 1.9 STARTUP ASSISTANCE...................................................................................................7 1.10 SYSTEM DESCRIPTION& SELECTION CRITERIA.....................................................7 2.0 PRODUCTS.........................................................................................................................9 2.1 ACCEPTABLE MANUFACTURERS................................................................................9 2.2 DESIGN CONDITIONS......................................................................................................9 2.3 COMPRESSORS...............................................................................................................10 2.4 EVAPORATOR.................................................................................................................11 2.5 CONDENSER AND FANS...............................................................................................11 2.6 REFRIGERANT CIRCUITS AND COMPONENTS .......................................................12 2.7 PUMPS AND PIPING ACCESSORIES ...........................................................................13 2.8 PROCESS SURGE TANK................................................................................................16 2.9 CONTROL AND INSTRUMENTATION SYSTEM.......................................................17 2.10 FABRICATION.................................................................................................................20 2.11 MARKING.........................................................................................................................21 2.12 ELECTRICAL...................................................................................................................21 3.0 EXECUTION.....................................................................................................................24 3.1 TESTING AND PREPARATION FOR SHIPMENT.......................................................24 3.2 PREPARATION FOR SHIPMENT ..................................................................................25 3.3 SUBMITTAL AND DOCUMENT REQUIREMENTS....................................................25 3.4 SUBSTITUTION OF MATERIALS OR EQUIPMENT...................................................26 4.0 ATTACHMENTS..............................................................................................................27 4.1 DOCUMENTATION REQUIREMENTS.........................................................................27 REV. A PFI DESIGN,P.C. JANUARY 10, 2001 Pg. i SPE-16040-15690 JA16040\Specs\Final\15690_Rev A.doc �5/1 1K5 PFI DESIGN, P.C. SPECIFICATION FOR AIR COOLED GLYCOL CHILLER SPE-16040-15690 Tag No.: CH-2 The Minute Maid Company Pouch Line Addition Northampton, MA Project No. 16040 Rev.. . Date': .Descrpon Admxn Prepax Cl�ec d Abp �ed,a A 1/10/01 Issue for Bid KAB TAW M Client Approval: Client: Date: 3.5 PRESSURE TESTING A. All piping systems shall be tested at a pressure of 150 psig for a period of two hours. B. Preparation for testing: 1. All joints shall be visually examined for proper installation. 2. All piping shall be left uninsulated. C. Testing Procedure 1. Piping shall be hydro tested for pressure and duration as specified. 2. Precautions shall be taken to keep non-essential personnel clear of the piping system undergoing test. 3. Where leaks occur they shall be marked and identified for repair after termination of test. Where major leaks or additions are made to the piping system after the pressure test, affected piping shall be retested. 4. Provide testing records for each pressure test. Records shall include: • Date of test • Identification of piping tested • Test medium • Test pressure and total time held at test pressure. • Signature of witness (Owner or Engineer). 3.6 DOCUMENTATION REOUIREMENTS A. This Contractor shall provide the as-built/certified documents in an indexed contractor turnover package with signatures from the Contractor's representative certifying the accuracy of the information and compliance with this Specification. ++END OF SECTION 15500++ REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 18 SPE-16040-15500 JA16040\Specs\Fina1\15500 REV A.doc 2. Valve tags shall be at least V in diameter with numerals at least 3/8": high ad attached by"S"hooks or chains. Equipment tags shall be at least 2" diameter securely attached to apparatus. 3. Provide manufacturers equipment nameplates, catalog numbers and rating identification securely attached to electrical and mechanical equipment with screws or rivets. Adhesives or cements will not be permitted. B. Pipe Identification: 1. Provide color-coded pipe identification markers on piping installed under this Section. Pipe markers shall be snap-on laminated plastic protected by clear acrylic coating. 2. Provide arrow marker with each pipe content marker to indicate direction of flow. If flow can be in either direction, use double-headed arrow marker. 3. Mains shall be labeled at points of entrance and exit from mechanical room, adjacent to each valve, on each riser, at each tee fitting, at least once in each room, and at intervals no longer than 20 ft. Where pipe penetrates a wall,markers shall be placed near each side of the wall. 4. Size of legend letters on markers and length of color field shall be per the_ latest edition of ANSI. 5. Markers shall be "Setmark"by Seton Name Plate Corp. or approved equal. 3.4 PIPE CLEANING A. All piping shall be cleaned and flushed prior to system connection by the following methods: 1. Representative from an approved chemical company shall supply chemicals and witness all pipe cleaning. 2. When water/chemical mixture is attained it shall be circulated for four(4) hours, minimum. 3. After cleaning, lines shall be flushed with water until clear. 4. Pipe cleaning shall be documented by this contractor and witnessed by the engineer. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 17 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doc 3. Space hangers for horizontal piping as follows: a i w € Up to 1-1/4" 3/8" 5 ft.-0" 1-1/2 and 2" 3/8" 8 ft.-0" 2-1/2 and up %2" 10 ft.-0" 4. Horizontal copper tubing shall have maximum hanger spacing of 5 ft. for tubing 1 1/4" dia. and smaller and 8' for tubing 1 %z " and larger. 5. Reduce spacing to a maximum of 10'-0" apart, regardless of pipe size, as necessary for fittings,valves and other concentrated loads. 6. Hangers for horizontal lines shall be vertically adjustable to obtain pitch requirements of Piping Paragraph. E. Pipe Sleeves and Penetrations 1. Bare Pipe: a. All steel pipe or copper tubing penetrating fire walls or floors shall be encircled by sheet metal sleeves sized for maximum one inch annular spacing between pipe and sleeve. Spacing shall be packed on each end with UL.rated ceramic fiber strip insulation. 2. Insulated Pipe: a. Sleeves for insulated pipe shall be the same as for bare pipe,but with the addition of a 360 degree cylinder of waterproofed calcium silicate insulation encasing the pipe and covered with galvanized sheet metal shielding, all sized to extend to a minimum of one inch beyond wall or floor. 3.3 PIPE AND VALVE IDENTIFICATION A. Upon completion of work, attach engraved laminated tags to all valves. Valve tags shall have black characters on white face, consecutively numbered and prefixed by letter"V". Equipment tags shall have black characters on white face, with labels corresponding to drawing schedule numbers. 1. Embossed or engraved aluminum or brass tags may be substituted if desired. Tags shall be at least 1/8" thick. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 16 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doc 4. Make screw joints tight with Teflon(Polytetrafluoroethylene)tape for water or ligharge-glycerin mixture for steam applied to male threads. Use tapered threads. C. Pipe Insulation 1. Fittings, valves and flanges shall be insulated with same material and to same thickness as adjoining pipe insulation. 2. Pipe fittings shall be pre-tested, clean and dry before insulation. 3. Installation of insulation on fittings shall be as follows, in order: a. Wrap insulation around fitting and tuck ends into fitting throat. b. Edges of adjacent insulation shall be tufted and tucked in, to fully insulate fitting to thickness of adjacent pipe insulation. Use tow or more thickness if necessary. C. If-two layers of insulation shall be covered with one piece, PVC, molded jacket cover. Secure cover with stainless steel tack fasteners inserted into jacket throat overlap seam. d. Tape joints with pressure-sensitive vapor barrier tape; tape shall extend 2" on either side of joint. 4. For strainers and other valves or fittings which need maintenance,provide preformed removable insulation section. D. Pipe Hangers and Supports 1. Provide pipe stands, supports,hangers and other supporting appliances as necessary to support work required by Contract Documents. 2. Secure vertical piping to building construction to prevent sagging or swinging. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 15 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doc 3. Unit shall be equal to Morr Control Glycol Feeder model GF-1 as manufactured by Pulsafeeder, Inc. 3.0 EXECUTION 3.1 GENERAL A. Refer to Division 1, General Requirements and Division 15, General Requirements for Mechanical systems for information on site restrictions, cleaning, etc. 3.2 PIPING AND PIPING ACCESSORIES A. General 1. Provide air vent at each high point and drain valve at each low point for complete system drainage. 2. Provide a shutoff/isolation valve in the following locations in the distribution system: a. To each supply and return riser serving two or more terminal units. b. To each supply and return riser branch off a main serving two or more terminal units. C. To each supply and return main take-off serving two or more terminal units. 3. Provide blow-off valve on each strainer. B. Connections: 1. Provide eccentric reducing couplings to bring pipes flush on top for water service. 2. Nipples shall be same material, make and thickness as pipe with which they are used. Close nipples shall not be used. 3. Make piping connections 2 "diameter and smaller to valves and equipment with 300 psi brass seat unions on steel piping and with heavy semi-flushed brass unions on copper tubing. No screw threads permitted on Steam Lines (BS). REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 14 SPE-16040-15500 JAI 6040\Specs\Fina1\15500_REV A.doc 2.10 STEAM UNIT HEATERS A. Provide steam unit heaters of vertical discharge as shown on Drawings and on schedules. 1. Casings shall be heavy gauge steel with welded seams and shall have threaded connections for vertical hanger rods. 2. Heaters shall have two way adjustable steel discharge louvers. 3. Electric motor shall have integral overload protection and shall be mounted away from coil and heated air stream. Motors shall be premium efficiency open drip proof. 4. Fan blades shall be aluminum or steel, statically and dynamically balanced at factory. 5. Coil shall have seamless copper serpentine tubes and aluminum or soldered copper fins bonded to tubes. Coils shall be tested at 300 psig air pressure without leaks. B. Hangers and supports shall incorporate vibration and noise isolators. Motor and fan shall be separated from heater by resilient vibration isolators. OSHA- approved fan guards shall be provided on heaters. C. Unit heaters shall be factory assembled for field installation,by Airtherm, Modine, Sterling, or Trane. D. Disconnect switches and motor starters shall be by the Electrical contractor. 2.11 GLYCOL FEEDER 1. Furnish and install Glycol Feeder unit to provide a consistent operating pressure in the chilled water/30%Ethylene glycol system. Unit shall automatically add glycol solution to the piping system. 2. Unit shall consist of a control unit for one closed loop, a 50 gallon polyethylene tank, a preplumbed flow assembly, a low level switch and one positive displacement pump. The feeder shall be mounted on a welded stand for easy shipment and installation. A controller employs solid state electronics and a pressure gauge to monitor closed loop operating pressure. Its NEMA type 1 steel enclosure is prewired for easy installation. A preplumbed flow assembly includes a pressure switch and pressure relief valve to prevent excessive pressure buildup. A low liquid level switch prevents the positive displacement pump from operating when solution is low. The glycol feeder is mounted on a primed and painted steel frame with a polyethylene tank. REV. A PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 13 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doc V B. Hangers (where applicable) shall be by Carpenter and Patterson, F&S, or Grinnell Co. Figure numbers of Carpenter and Patterson are specified to establish standards of quality for performance and materials. C. Pipe support for chilled water, steam supply, and steam condensate piping shall be pipe roll hangers with adjustable rod hangers, sized to accommodate insulation. Pipes shall be supported maximum of 10 ft. apart. 2.7 SLEEVES AND PENETRATIONS A. Pipe Sleeves: 1. Provide manufactured,pre-engineered, fire-rated pipe sleeve kits for all fire wall and floor penetrations. 2. Sleeve and packing shall have the same fire rating as the wall or floor construction in which they are installed. Sleeves shall have passed the ASTM E119 test,per UBC Chapter 43 for pipe penetrations. 2.8 WATER SPECIALTIES A. Automatic air vent valves with manual shut-off for each high point on supply and return mains with '/4" copper overflow run to nearest plumbing fixture for drainage. B. Air vent valve installed on each piece of equipment. Air vents shall be Spirax- Sarco Model# 13W9. C. Drain valve at each low point with 3/4" brass heads with hose connections. D. Expansion tank for chilled water system shall be floor mounted type with diaphragm with ASME rating. E. Air Separator shall have 6 inch connections. 2.9 PRESSURE GAUGES AND THERMOMETERS A. Pressure gauges shall be Ashcroft Duragage, Trerice 50OX series or U.S. Gauge, 4%Z inches in diameter, cast aluminum case, screw driver pointer adjustment, stainless steel movement,bronze bourbon tube. Provide fittings and ball valves at gauges. B. Thermometers shall be Weiss "Vari-Angle" 9 inches industrial type glass front, mercury tube,with separable wells equal to Trerice BX9 series, Weksler or Ashcroft. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 12 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doe Service Pipe Saes Insulation Thickness (inches) (inches) Chilled water and all 1 cooling coil condensate drain pipes High pressure steam and 1"thru 4" 2-1/2 steam condensate over 4" 3-1/2 Low pressure steam, Up thru 2" 1-1/2 steam condensate and 2-1/2"thru 6" 2 pumped condensate 2.5 EQUIPMENT INSULATION A. The HVAC Piping Contractor shall be responsible for all equipment insulation material and work performed. Any insulation materials damaged due to weather shall be replaced by the Contractor. B. The HVAC Piping Contractor shall be responsible for insulating equipment relating to piping such as chilled water pumps and chilled water expansion tank. C. Insulation chilled water pumps and chilled water return surge tank with 2 inch thick 3 pound per cubic foot density, mineral fiber board. Maximum thermal conductivity(k)to be 0.23 (BTU) (inch) (hour) (square foot) (°F) at 75°F. 1. Insulate bottom half of pump casing with mineral fiber board segments conforming to the general shape of the pump casing, and securely wire and skewer in place. Fill void spaces between pump casing and insulation with insulating cement. Seal and finish the outside surface with specified coating reinforced with polyester reinforcing cloth. 2. Insulate top half of pump casing by fabricating a box from No. 18 gauge galvanized steel sheet that conforms to the general shape of the pump. Fill box completely with fiberglass insulation so that it makes contact with the entire top half of the pump casing. Attach insulation to the inside of the box with adhesive. Construct box so that it can be removed without disturbing the permanent insulation on the lower half of the casing. Submit shop drawing of the box for approval before fabrication. 2.6 PIPE HANGERS AND SUPPORTS A. All piping shall be supported on structural steel racks of design to withstand all forces and stress exerted by the system. REV. A PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 11 SPE-16040-15500 J:\16040\Specs\Fina1\15500_REV A.doc 2. Valves shall be system-powered, pilot-operated, single seat, designed for dead-end service and guaranteed to control delivery pressure within f 1 psi. 3. Valve body shall be cast iron with 250 psig APSE flanges. Provide valves with stainless steel seat rings, trim and stem. 4. Valves shall be controlled by air loaders equipped with air filter regulator and pressure gauge. 5. Approved Models - Spence type ED, Class GPK or GPB by Leslie Company, Type 92B by Fisher Controls, Series 25 by Spriax/Sarco. 2.3 STEAM TRAPS A. Provide F&T steam traps for low pressure steam and inverted bucket traps for high pressure steam where required equal to Spirax Sarco Model FT, Spence Armstrong or approved equal. B. Float and thermostatic steam traps shall have stainless steel floats,bronze fittings and integral thermostatic air bypasses. Bodies and covers shall be cast iron. Working parts of each trap shall be accessible by removing cover without necessitating disconnection from pipe. C. Inverted bucket steam traps shall be provided for high pressure steam service. Traps shall have stainless steel bucket, linkage, valve and seats. Bodies and covers shall be cast iron. Working parts of each trap shall be accessible by removing cover without necessitating disconnection from pipe. 2.4 PIPE INSULATION A. The HVAC Piping Contractor shall be responsible for all piping insulation material and work performed. Any insulation materials that are damaged due to weather shall be replaced by the Contractor. B. Insulation on chilled water piping, steam and steam condensate shall be Owens- Corning Fiberglass preformed pipe insulation, minimum density 3.5 lb/cu ft,with ASJ factory applied jacket with self-sealing,pressure sensitive lap and a thermal conductivity"k" of 0.24 Btu/(hr) (sq ft) (°F/in)maximum at 75 °F mean temperature. Fittings shall be Manville Uni-Fit or as approved. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 10 SPE-16040-15500 J:\16040\Specs\Final\15500_REV A.doc E. Strainers: 1. For chilled water service and steam, strainers shall be full size of entering pipe size and have a maximum clean pressure drop of one psi. Strainer for chilled water system shall be duplex basket strainer. Strainers shall be as manufactured by Sarco, Mueller, Watts or Armstrong. 2. Provide blow-off valve on each strainer with plug. 3. Strainers shall be threaded, stainless fitted bronze Y-type with 1/16" mesh screen for sizes 2" and below. Use flanged end, stainless-fitted iron body Y-type strainer for sizes 2-1/2" and above. F. Provide unions for threaded end valves to facilitate removal from pipe. G. Safety Relief Valves 1. Steam safety relief valves shall be set to open at 85%of the maximum working pressure of the equipment or vessel being protected. 2. Valves shall be sized to relieve at a rate equal to the maximum possible flowrate from fully-open pressure reducing control valve upstream. 3. Valves shall be bonnet type with open operating lever. 4. Valves shall be sealed after testing and ASME code stamped to indicate compliance with the ANSI/ASME Boiler and Pressure Vessel Code, Section VIII, Division 1 5. Valve body shall be carbon steel, cast iron or bronze,with internals of brass or stainless steel. 6. Valves shall be threaded for pipe smaller than 1 inch in size, and flanged for pipe 1 inch and larger. 7. Approved Models -Lonergan D series, Farris 2600 Series, Consolidated 1990 Series,Kunkle 5000 Series, or Spirax/Sarco 252 Series or 6000 Series. H. Pressure-Reducing Valves 1. Provide pressure-reducing valves in sizes and quantities as shown on the contract drawings. Each valve shall be manually adjustable within the range shown on the contract drawings. REV. A PFI DESIGN, P.C. DECEMBER 20,2000 Pg. 9 SPE-16040-15500 JA16040\SpecsTina1\15500_REV A.doc 6. Vacuum breakers shall be spring loaded ball check type, specifically designed for low pressure steam service and shall be stainless steel fitted bronze body with threaded ends. D. Valves for High Pressure Steam Service: 1. Isolation Valves (2 inches and smaller) Gate type: a. Class 300 pound,bronze union bonnet, rising stem, OS &Y, threaded connections, Powell Figure 1155 2. Isolation Valves (2 %2 inches and up) Gate type: a. Class 250 pound, cast iron,bronze trim, solid wedge, OS &Y, flanged ends,Powell Figure 1797 3. Throttling Valves (2 inches and smaller) Globe type: a. Class 300 pound,bronze, renewable disc, union bonnet; threaded connections, Powell Figure 2612. 4. Throttling Valves (2 %2 inches and up) Globe type: a. Class 250 pound, cast iron,renewable seat and disc, OS &Y flanged ends, Powell Figure 256. 5. Check Valves (2 inches and smaller) a. Class 300 pound,bronze, swing check Y pattern,renewable discs and side plugs, screwed ends, Powell Figure 563Y. 6. Check Valves (2 %2 inches and up) a. Class 250 pound, cast iron, swing check, trimmed,bronze renewable seat, discs and side plugs, flanged ends,Powell Figure 576. 7. Gaskets a. Non-asbestos with synthetic fibers and SBR binder, Garlock Style 3200 (reference ASTM F 104-87). REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 8 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doc a. 175 psig cwp, ductile iron body, flanged, EPDM seats,bronze disc and Type 416 stainless steel trim as manufactured by DeZurik, Centerline, Hammond or Milwaukee. 3. Drain valves shall be ball valves with hose end, including cap secured with chain. 4. Check Valves (2 inches and smaller): a. Class 200 psi swp, 400 psi wog; non Y type, swing check with bronze body and disc regrinding; threaded end, Teflon seated as manufactured by Stockham, Crane or Powell. 5. Triple Duty Valves: a. Provide triple duty valves at the outlet of each pump. C. Valves for low pressure steam service: 1. Isolation Valves (2 inches and smaller) a. Class 125 psig gate type. Valves shall be provided with stem extensions of proper length for insulation. Valve as manufactured by Crane, Stockham or Smith. 2. Isolation Valves (2%2 inches and up) gate type. a. Class 125, cast iron body and wedge; bronze seat, OS&Y, flanged end as manufactured by Grinnell, Crane or Stockham. 3. Throttling Valves. a. Class 125, globe valve as manufactured by Crane, Stockham or Smith. 4. Check Valve (2 inches and smaller) a. Class 125 wsp,non Y type swing check valve,bronze body, threaded, Teflon seat as manufactured by Stockham, Crane or Powell. 5. Check Valve(2%2 inches and up) a. Class 125 wsp,non Y type swing check valve, iron body, flanged, iron seat as manufactured by Stockham, Crane or Powell. REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 7 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doc 5. Cooling Coil Condensation Item Type Size Class or Material Remarks Joint Pressure and/or Rating Specification Pipe Solder All Type L Type L Hard drawn Copper ASTM Fittings Solder All 250 psi ANSI Copper B 16.22-80 Joining 95/5 -- -- ASTM B32- Alloy grade Materials (tin/Antimony) 87 or 95TA solder or 15% ANSI/AWS silver solder A5.8-81 6. Natural Gas Train Relief Vent Piping a. ASTM A53 or A120, Schedule 40 black steel. Fittings: ANSI/ASE B 16.3, malleable type, or ASTM A234; forged steel welded type. Joints: ANSI/AWS D1.1, welded. 2.2 VALVES AND STRAINERS A. General 1. All valves and piping accessories, at a minimum, shall be equal to existing material and methods. 2 Valves shall have name of manufacturer and guaranteed working pressure cast or stamped on bodies. Valves of similar type shall be by single manufacturer. Provide chain operators for valves 3" and larger that are 7 feet higher above floor. B. Valves for chilled water service: 1. Isolation Valves (2 inches and smaller): a. Class 125 psi swp, 600 psi wog; three-piece; full port;bronze body; reinforced Teflon seat and seal; hard face chromium plated ball; threaded ends. Valves shall be provided with stem extensions of the proper length on insulated services. Valve shall be as manufactured by Worcester, Jamesbury or Stockham. 2. Isolation Valves (2%2 inches and up)butterfly type. REV. A PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 6 SPE-16040-15500 JA16040\Specs\Fina1115500_REV A.doc + 3. Low Pressure Steam: Item Type Size Class or Material Remarks Joint Pressure and/or Rating Specification up thru 2 Schedule ASTM A53 Seamless Pipe Threaded inches 40 or ANSI black steel B36.10 Grade B Pipe Weld 2Y2 Schedule ASTM A53 Seamless inches 40 or ANSI black steel and up B36.10 Grade B Fittings Threaded up thru 2 125 ASTM A234 Cast iron inches Pound Fittings Weld 2%2 butt weld ASTM A234 Steel inches Schedule and up 40 4. Steam Condensate: (high pressure, low pressure and pumped condensate) Item Type Size Class or Material Remarks Joint Pressure and/or Rating Specification Pipe Threaded up thru 2 Schedule ASTM A53 Seamless inches 80 or ANSI black steel B36.10 Grade B Pipe Weld 2%inches Schedule ASTM A53 Seamless and up 80 or ANSI black steel. B36.10 Grade B Fittings Threaded up thru 2 125 ASTM A234 Cast iron inches pound* Fittings Weld 2%inches butt weld ASTM A234 Steel and up Schedule 80 * high pressure steam condensate to be 3000 pound forged steel socket weld REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 5 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doc 2.0 PRODUCTS 2.1 PIPING AND FITTINGS A. General 1. Pipe materials and fitting materials shall be as indicated in Schedule of Pipe and Fitting Materials. Provide dielectric fittings to connect different piping materials. B. Schedule of Pipe and Fitting Materials 1. Chilled water(glycol): Item Type Size Class or Material Remarks Joint Pressure and/or Rating Specification Pipe Soldered up thru 2 Type L Type L inch Copper ASTM B88 Fittings Welded 2-1/2"and Schedule ASTM A53 UP 40 2. High Pressure Steam: Item Type Size Class or Material Remarks Joint Pressure and/or Rating Specification ASTM A53 Seamless up thru 2 Schedule Pipe Weld inches 80 or ANSI black steel B36.10 Grade B Pipe Weld 2Y2 Schedule ASTM A53 Seamless inches 40 or ANSI black steel and up 1336.10 Grade B Fittings Weld up thru 2 3000 ASTM A234 Cast iron inches Pound* Fittings Weld 2%2 butt weld ASTM A234 Steel inches Schedule and up 40 * high pressure steam fittings to be 3000 pound forged steel socket weld REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 4 SPE-16040-15500 JA1&A0\.Specs\Fina1115500_REV A.doc N. All installation activities will require coordination with other Contractors, including the General Contractor, Ductwork Contractor, Plumbing Contractor, Electrical Contractor and Process Equipment Contractors. 1.2 REFERENCE DOCUMENTS A. CODES AND STANDARDS 1. All piping systems shall meet the requirements of the latest applicable ASME, ANSI, and ASTM Codes. B. CONTRACT DRAWINGS 1. The Owner is responsible for the accuracy of supplied contract drawings and the Contractor is to install the piping systems to reflect the configuration, dimensions, elevations, slope requirements,pipe insulation and pipe supports as indicated on contract drawings. 2. It is the responsibility of the Contractor to, upon review of contract drawings and existing site conditions,notify the Owner or construction manager,prior to any relative fabrication or installation, of any problems or situations requiring modification to piping as indicated on contract drawings. 1.3 SUBMITTALS A. The Contractor shall submit shop drawings for all equipment,piping systems, and product data for all piping fittings, valves and specialties. B. All materials submitted should not be procured until reviewed and approved by the Engineer. C. The Contractor shall be responsible for including all piping information on the coordination drawing. D. Provide all pipe support details for all piping systems. E. All submittal procedures shall be as specified in Section 15000. REV. A PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 3 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doc not limited to (9) steam unit heaters; furnish and install pressure reducing stations; furnish and install piping to air conditioning units ACU-1, ACU- 2 and related duct steam coils; furnish and install steam piping to steam coils within prepurchased air handlers RTU-1, RTU-2 and RTU-3; furnish and install (2) condensate receiver pump sets; furnish and install all piping,piping components, traps, valves,hangers, supports, expansion compensators, expansion loops,pipe insulation, guide, anchors, miscellaneous support steel, etc. 3. Furnish and install all miscellaneous piping systems and related items including but not limited to air conditioning unit condensation drain piping to roof,natural gas train relief vent piping to prepurchased boiler B-1, (plumbing contractor to install natural gas main and pilot piping to new boiler). D. The Contractor is responsible for all shop and field fabrication, field erection, rigging, installation,pressure testing, and documentation of the HVAC piping systems. E. The Contractor is required to furnish and install all wall and ceiling penetrations, caulking, firestopping,pipe supports, pipe sleeves and piping insulation for all contract piping systems. F. The Contractor shall coordinate closely with the ATC Contractor and all other trades. G. All new HVAC control valves shall be supplied by the ATC Contractor and installed by this Contractor. H. The Contractor shall provide all start-up services required by the specifications. I. The Contractor shall flush, clean and test all piping as stated in this specification. J. All fabrication shall be in accordance with the applicable sections of the latest . edition of the applicable ANSFASME Codes.' K. The Contractor is responsible to provide to Minute Maid an orderly turnover documentation package for all HVAC piping systems. L. All piping systems installed under this contract are to be labeled with piping service codes. M. All valves and instruments installed under this contract are to be tagged. REV. A PFI DESIGN,P.C. DECEMBER 20,2000 Pg. 2 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doc HVAC PIPING SECTION 15500 1.0 GENERAL A. It is the intent of this Specification to provide the Contractor with the necessary information to enable him to provide the HVAC piping systems as noted herein. These items shall be the Contractor's standard design modified as required to meet the operation and design requirements given herein and in the attached Specifications and Contract Drawings. B. Compliance with the specification does not relieve the Contractor or manufacturer from the responsibility to furnish piping system of proper design and construction suitable for all operational conditions. 1.1 SCOPE OF WORK A. The Contractor shall furnish labor, supervision, tools, equipment and materials for the HVAC piping work as per this Specification SPE-16040-15500 and the Contract Drawings. B. The Contractor shall furnish and install all steam, steam condensate, condensate drain,pumped condensate, safety relief valve venting,natural gas train relief valve vent piping as described herein, and chilled water piping and piping accessories as shown on the drawings and as described in these specifications. C. This Contractor shall include the following work: 1. Furnish and install complete chilled water 30%propylene glycol piping system, including installation of prepurchased air cooled chiller ACCH-1, furnish and install(2)two based mounted pumps CHGP-1 and CHGP-2, along with all associated components including but not limited to return surge tank, automatic glycol solution fill tank with injection pump and tank, duplex basket strainer, suction diffusers, triple duty valves, isolation valves, air vents,piping,piping hangers and supports,vibration isolators, flexible connectors,unions,pipe and equipment insulation and miscellaneous support steel, etc. Furnish and install all 30%pre-mixed propylene glycol deionized water solution to completely fill entire chilled water piping system and glycol feeder drum. Glycol solution shall be equal to the Dow Chemical Co. product"dowfrost". 2. Furnish and install complete steam piping system including installation of prepurchased high pressure steam boiler B-1,prepurchased ASME deaerator,prepurchased 350 gallon blowdown tank,prepurchased chemical treatment system for new boiler and new deaerator,prepurchased breeching/stack; furnish and install all other related items including but REV. A PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 1 SPE-16040-15500 JA16040\Specs\Fina1\15500_REV A.doe w TA13LE OF CONTENTS 1.0 GENERAL.......................................................................................................................... 1 1.1 SCOPE OF WORK............................................................................................................. 1 1.2 REFERENCE DOCUMENTS............................................................................................ 3 1.3 SUBMITTALS ................................................................................................................... 3 2.0 PRODUCTS........................................................................................................................4 2.1 PIPING AND FITTINGS ...................................................................................................4 2.2 VALVES AND STRAINERS ............................................................................................ 6 2.3 STEAM TRAPS ............................................................................................................... 10 2.4 PIPE INSULATION......................................................................................................... 10 2.5 EQUIPMENT INSULATION.......................................................................................... 11 2.6 PIPE HANGERS AND SUPPORTS................................................................................ 11 2.7 SLEEVES AND PENETRATIONS................................................................................. 12 2.8 WATER SPECIALTIES................................................................................................... 12 2.9 PRESSURE GAUGES AND THERMOMETERS.......................................................... 12 2.10 STEAM UNIT HEATERS ............................................................................................... 13 2.11 GLYCOL FEEDER.......................................................................................................... 13 3.0 EXECUTION.................................................................................................................... 14 3.1 GENERAL......................................................................................................................... 14 3.2 PIPING AND PIPING ACCESSORIES .......................................................................... 14 3.3 PIPE AND VALVE IDENTIFICATION......................................................................... 16 3.4 PIPE CLEANING............................................................................................................. 17 3.5 PRESSURE TESTING..................................................................................................... 18 3.6 DOCUMENTATION REQUIREMENTS........................................................................ 18 REV. A PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. i SPE-16040-15500 J:\16040\Specs\Final\15500_REV A.doc PFI DESIGN, P.C. SPECIFICATION FOR HVAC PIPING SPE-16040-15500 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 Rev. Date Decriptian Admin Pr�par peke Appro vet A 12/20/00 Issue for Review KAB TABXk M HM Client Approval: Client: Date: � F � S 2. Close-Out Checklist Example. PROJECT: DIVISION NO.: CONTRACTOR: DATES OWNER'S ITEM' SIGN-OFF COMPLETED RECEIVED BY OWNER Permits City and County Inspection Manufacturers Warranties Contractors Warranties State Fire Rating Data Copy of Final Shop Drawings List and Possession of Spare Parts Pressure Tests Equipment Tests Required by Specs 0 &M Manuals Record Documents Coordination Drawings Sanitization Reports Commissioning Reports/Letters On Site Training Complete Protective Device Settings Valve Tags and Charts Final ATC Installation Drawings Insurance Underwriters Approvals Final Punch List(Initialed by contractor that items are complete) Building Certificate of Occupancy (CO) 'Provide separate line item for each specified item(do not group items). REV.A PFI DESIGN,P.C. JANUARY 19,2001 Pg. 19 SPE-16040-15000 JA16040\Specs\Fina1\15000_Rev A.doc authorized representative(s) signed receipt on all items requiring owner sign-off. B. Project Close-Out Checklist 1. Review requirements of each section of the specifications and submit for approval to Engineer the sign-off forms which shall become the project close-out checklist. These at a minimum shall include the following information shown in attached Project Closeout Checklist Example. The Owner may incorporate additional specific items to the following checklist which shall become part of the project requirements REV. A PFI DESIGN,P.C. JANUARY 24,2001 Pg. 18 SPE-16040-15000 JA16040\Specs\Fina1\15000_Rev A.doc T 6. Leaks, damage and defects discovered or resulting from startup and testing shall be repaired or replaced by this contract to like-new condition with acceptable materials. Tests shall be continued until system operates without adjustments or repairs. 7. For each piece of equipment, copy nameplate data and include in report. 3.8 INSTALLATION ONLY ITEMS A. Where this Subcontractor is required to install items purchased by others,he shall coordinate their delivery and be responsible for their unloading from delivery vehicles and for their safe handling and field storage up to the time of installation. This trade shall be responsible for: 1. Any necessary field assembly and internal connections, as well as mounting in place of the items, including the purchase and installation of all dunnage supporting members and fastenings necessary to adapt them to architectural and structural conditions. 2. Their connection to building systems including the purchase and installation of all terminating fittings necessary to adapt and connect them to the building systems. B. This Subcontractor shall carefully examine such items upon delivery, and shall advise the Owner of any damages or defects noted, as well as advising the shipper. C. All equipment shall be delivered to the project site and stored on-site or put into place on the date of delivery as determined by the Construction Manager. 3.9 MAINTENANCE A. Maintain equipment and systems until Final Acceptance. Ensure adequate protection of equipment and material during delivery, storage, installation and shutdown and during delays pending final test of systems and equipment because of seasonal conditions. 3.10 PROJECT CLOSEOUT A. General 1. The requirements of this section are in addition to and supplement the requirements outlined in Division 1. 2. It shall be each Subcontractor's responsibility to personally hand-deliver all of the required project close-out checklist items and to obtain owner's REV. A PFI DESIGN, P.C. JANUARY 24,2001 Pg. 17 SPE-16040-15000 JA16040\Specs\Fina1\15000_Rev A.doc 4. Single or multiple pipes passing through walls and floors shall have the annular space between pipes or between pipes and structure filled with silicone elastomer to provide a 3-hour rated firestop for floors and walls. B. Pipe and Ducts: The annulus between exposed pipe and ductwork and walls or floors in finished spaces shall be filled, sealed, and painted to match adjacent surfaces. C. Future Slots: Identify unused sleeves and slots for future use by permanently anchored brass nameplates identifying size and purpose of the covered slot. 3.7 COMMISSIONING OF EQUIPMENT AND SYSTEMS A. General 1. Completion of start up and commissioning is a prerequisite for substantial completion(refer to project closeout section). 2. Operate and maintain systems and equipment until final acceptance by the Owner. 3. All guarantees and warranties shall not begin until final acceptance of the systems and equipment by the Owner. Acceptance requires, at a minimum, complete systems commissioning. B. Comprehensive Work Plan 1. Provide detailed,methodical, scheduled start up, and commissioning procedures and execution of same for every system and piece of equipment provided. 2. Develop and submit for approval a specific start up check out and sign off form for each and every system. 3. Systems shall be operated under actual or stimulated full load conditions. Identify the operating conditions in the work plan. 4. After all components and every system have been completely commissioned,provide a 2-week, 24-hour per day fully functional automatic operation period of all systems simultaneously. This shall be successfully concluded before systems are accepted by the Owner. 5. Do not cover or conceal work before testing and inspection and obtaining approval. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 16 SPE-16040-15000 JA16040\Specs\Fina1\15000_Rev A.doc C. On completion of each day's work, remove all rubbish and debris resulting from this contract, and dispose of same. At any time should the construction manager be dissatisfied with the performance of clean-up responsibilities, he may elect, after proper notification,to undertake this operation and charge this Subcontractor accordingly. D. Air ducts shall be protected after fabrication and in shipment,prior to construction. Openings shall be suitably closed to prevent the admission of dust and construction debris. The protection shall be a minimum of 10 mil reinforced plastic and shall be removed only by the Subcontractor installing the ductwork system. 3.5 ADJUSTING TESTING AND BALANCING AIR SYSTEMS A. General: 1. Adjusting testing and balancing will be done under a separate contract,per Specification Section 15990. 2. All Subcontractors shall be responsible for cooperating with the balancing Subcontractor. 3.6 FIRESTOPPING A. Firestopping: Unused slots, sleeves and other penetrations in floors,walls or other general construction shall be closed and sealed with an approved firestopping material. 1. Firestopping material shall be UL listed and tested silicone elastomer specifically formulated for use in horizontal and vertical applications. The material shall possess intumescent characteristics; upon exposure to heat above 250°F shall expand to not less than five times its original volume to form a fireproof envelope UL rated for 2- and 3-hoar protection,when applied in accordance with the manufacturer's recommendation. 2. Floor slots and openings shall be closed with 16 gauge galvanized steel sheet supported on 1-inch by 1-inch by 1/8-inch structural angle drilled or supported with powder-driven studs into the building structure. Firestop with a layer of silicone elastomer not less than 1-inch thick which completely fills the opening. The top surface of the silicone elastomer shall be approximately 1-inch below the finished floor slab. 3. Openings in walls shall be closed with 16 gauge galvanized steel sheet securely attached at the midpoint of the wall thickness and firestopped on both sides of the steel sheet with not less than 1/8-inch thick layer.of non- sagging silicone elastomer to fully cover the opening. REV. A PFI DESIGN, P.C. JANUARY 24,2001 Pg. 15 SPE-16040-15000 JA16040\Specs\Fina1\15000_Rev A.doc D. Nameplates, catalog numbers and rating identifications shall be securely attached to equipment with screws or rivets. Adhesives or cements will not be permitted. E. This Subcontractor shall be responsible for the protection of the work from injury and shall protect all apparatus with suitable enclosures. 3.3 ERECTION AND INSTALLATION A. Installation and workmanship requirements are specified hereinafter. B. This Subcontractor shall be responsible for the famishing and installing of all support steel, hangers,rods, clamps, etc.,to provide adequate support of all mechanical equipment specified herein. C. Provide all transportation, freight, loading, and unloading, and provide all labor necessary for erecting in place all material and equipment shown, specified or required for completion of the HVAC work. D. The work shall be performed in a timely manner so as to cause no delay in job progress. Cooperate with the other phases of construction so that the work is installed in the most beneficial sequence for proper project completion. E. Install all work so that all parts required are readily accessible for inspections, operation,maintenance, and repair. Minor deviations from the drawings may be made for this purpose,but changes of magnitude shall not be made without prior written approval of the Engineer. F. Locate access panels for walls, ceilings and floors at locations indicated on drawings or as required to permit access for adjustment,removal and replacement, and servicing of all concealed HVAC equipment. G. All access panels shall be located in a workmanlike manner,generally in closets, storage rooms and other non-public areas,positioned so that the equipment can be easily reached, and the size shall be sufficient for this purpose (minimum 14" x 14"). When access panels are required in corridors, lobby or other habitable areas, they will be located as directed by the Architect/Engineer. 3.4 CLEANING OF SYSTEMS AND PREMISES A. Before the systems are tested and balanced, ducts,piping and equipment shall be thoroughly cleaned so that no dirt,.dust, or other foreign matter will be deposited in or carried through the systems. B. At all times,keep the premises clear of undue accumulation of rubbish. REV. A PFI DESIGN,P.C. JANUARY 24,2001 Pg. 14 SPE-16040-15000 J:\16040\Specs\Fina1\15000_Rev A.doc responsibility of these contractors. Any changes in the above requirements after letting and accepting the respective contract will be paid for by the Mechanical Subcontractor. Any additional costs incurred due to the information not being provided on time or in error will be paid for by the responsible Subcontractor. 2.0 PRODUCTS 2.1 MATERIALS A. All materials, except as otherwise specified, shall be new, of current production, first quality, and the best of each class specified. B. Required materials not covered by the detailed specifications shall be of a suitable class, grade, and type and shall be subject to the approval of the Engineer. Where two or more units of the same class of equipment are required, these units shall be the products of a single manufacturer. All equipment and materials shall be installed and constructed to operate safely, as designed,without leakage,undue wear,noise, vibration or corrosion. 3.0 EXECUTION 3.1 PREPARATION A. Arrangements shall be made to have the openings,inserts, sleeves and such other incidentals set in place ahead of the construction work, where practical, to eliminate the need of cutting and patching. If cutting becomes necessary for installation of the work, it shall be done under this Section. All holes shall be neatly patched and approved by the Engineer. All cutting shall be performed in a manner approved by the Engineer. All cutting shall be performed in a manner not to weaken the structural parts and in the manner and method, which shall meet the approval of the Engineer and code. 3.2 WORKMANSHIP A. All work shall be coordinated with the work to be performed or installed under other Sections of these Specifications. B. All work shall be executed in a workmanlike manner by workmen skilled in this type of work and shall present a neat appearance when completed. C. Where required to avoid interference with other work, to increase headroom, or to improve the appearance of duct runs, offsets shall be provided as required. All duct supports, structural members, hangers and other apparatus necessary to support firmly and substantially the various components of the systems shall be provided under this Section. . REV. A PFI DESIGN,P.C. JANUARY 24,2001 Pg. 13 SPE-16040-15000 JAI 6040\Specs\Fina1\15000_Rev A.doc B. Furnish three copies of manuals to Engineer for approval and distribution to Owner. Deliver manuals no less than 30 days prior to acceptance of equipment to permit Owner's personnel to become familiar with equipment and operation prior to acceptance. C. Operating instructions: Upon completion of installation or when Owner accepts portions of building and equipment for operational use, instruct Owner's operating personnel in any or all parts of various systems. Instructions shall be performed by factory-trained personnel. Owner shall determine which systems require additional instructions. Duration of instructions shall take equipment through complete cycle of operation. Make adjustments under operating conditions. D. Each Subcontractor shall be responsible for his work and equipment until finally inspected, tested, and accepted. Carefully store materials and equipment which are not immediately installed after delivery to site. Close open ends of work with temporary covers or plug during construction to prevent entry of obstructing material. E. Each separate Subcontractor shall protect the work and material of other trades that might be damaged by his work or workmen and make good all damage thus caused. 1.13 INSTRUCTION TO OWNER'S PERSONNEL A. After completion of work and tests, and at times designated by Engineer,the Subcontractor shall provide necessary skilled personnel to operate the entire installation for a total period of two 8 hour days. During the operating period the Subcontractor shall fully instruct the Owner's representative in the complete operation, adjustment, and maintenance of the entire installation. B. Manufacturer's representatives shall instruct the Owner's personnel in the operation and maintenance of each piece of equipment and system in which installed. 1. Submit a written report to the Engineer stating the date of instruction, number of hours of instruction provided for each piece of equipment and each system, each instructor's name,title, and company affiliation, and the name and title of each person instructed. Beneficial occupancy or substantial completion of HVAC systems will not be acknowledged until this report is received and acknowledged acceptable by the Engineer. 1.14 COORDINATION WITH THE BUILDING TRADES A. Structural members and building openings for ducts,piping, etc., for use by the Mechanical Subcontractor shown on the architectural plans are the coordination REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 12 SPE-16040-15000 JA16040\Specs\Fina1\15000_Rev A.doc E. Identify piping with stenciled signs and arrows showing piping system service and direction of flow. See SPE-16040-15500 for details. 1.11 RECORD DRAWINGS A. The Engineer will furnish the Subcontractor one set of reproducible drawings or AutoCAD Rev 14 drawing files of the mechanical drawings as issued for this contract. Change these drawings to indicate accurately and neatly, any deviation in the actual installation from the Drawings as issued. B. Record drawings shall show record condition of details, sections, riser diagrams, control changes and corrections to schedules. Schedules shall show actual manufacturer and make and model numbers of final equipment installation. C. At the completion'of the job, the Drawings shall be delivered to the Engineer for a permanent record of the exact location of all equipment, etc., described in Division 1 of these specifications. D. The Engineer will not certify the accuracy of the record drawings. This is the sole responsibility of the Subcontractor. 1.12 INSTALLATION,MANUALS, OPERATING INSTRUCTIONS,AND PROTECTION A. Obtain at time of purchase of equipment,three copies of operation, installation and maintenance manuals for all items. Assemble literature in coordinated manuals with additional information describing combined operation of field assembled units, including as-built wiring diagrams. Manual shall contain names and addresses of manufacturers and local representatives who stock or furnish repair parts for items or equipment. Divide manuals into three sections or books as follows: 1. Directions for and sequence of operation of each item or mechanical system, e.g. pumps, fans, etc. Sequence shall list valves, switches, and other devices used to start, stop and control system. Detail procedure to be followed in case of malfunctions. 2. Detailed maintenance and trouble shooting manuals containing data furnished by manufacturer for complete maintenance. Include copy of balancing report. 3. Lubrication instructions detailing type of lubricant, amount, and intervals recommended by manufacturer for each item of equipment. Include additional instructions necessary for implementation of first class lubrication program. Include approved summary of lubrication instructions in chart form,where appropriate. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 11 SPE-16040-15000 JA16040\Specs\Fina1\15000_Rev A.doc to fabrication processes or means,methods, techniques, sequences and procedures of construction; and for coordination of work of this and other Sections. Submittal review shall not diminish responsibility under this Contract for dimensional coordination, quantities, installation,wiring, supports and access for service, nor the shop drawing errors or deviations from requirements of Contract Documents. The Engineer's noting of some errors while overlooking others will not excuse the Subcontractor from proceeding in error. Contract Documents requirements are not limited, waived nor superseded in any way by review. 2. INFORM SUBCONTRACTORS,MANUFACTURERS, SUPPLIERS, ETC. OF SCOPE AND LIMITED NATURE OF REVIEW PROCESS AND ENFORCE COMPLIANCE WITH CONTRACT DOCUMENTS. 1.8 COORDINATION DRAWINGS A. Ductwork coordination drawings with a minimum scale of 1/4 inch per foot shall be made by the Subcontractor. The ductwork shall be drawn to scale and single line duct layout will not be acceptable. Ductwork shall be located by dimensions on the drawings both in plan and elevation. Section and elevation views shall be made for critical areas. All piping for steam and chilled water shall be shown on this drawing. B. Six (6)prints of coordination drawings are required to be submitted to the Engineer for review or approval. 1.9 FEES AND PERMITS A. Apply for, obtain and pay for all required permits and inspection certificates. 1.10 EQUIPMENT IDENTIFICATION A. Equipment and component parts thereof shall bear manufacturer's nameplates, giving manufacturer's name, size, type model number or serial number, and electrical characteristics, to facilitate maintenance and replacements. Nameplates of distributors or Subcontractors are not acceptable. Electrical equipment shall be UL listed as applicable. B. All labels and tags shall conform with ANSI/ASME A13.1. C. Plastic tags shall be laminated three-layer plastic with engraved black letters on light, contrasting background color. Tag size shall be 1-1/2" square or diameter minimum with V high text. D. Identify all HVAC equipment including, air handling units, fans,heating devices, etc. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 10 SPE-16040-15000 J:\16040\Specs\Fina1\15000_Rev A.doc within the available space-this determination is solely the responsibility of the Subcontractor. 4. For rooftop mounted equipment and for equipment mounted in areas where structural matters are a consideration, the products must have a weight no greater than the product listed in the schedules or specifications. 5. Products must adhere to all architectural considerations including but not limited to: being of the same color as the product scheduled or specified, fitting within architectural enclosures and details, and for diffusers, lighting and plumbing fixtures -being the same size and of the same physical appearance as scheduled or specified products. D. Deviations 1. Concerning deviations other than substitutions proposed deviations from Contract Documents shall be requested individually in writing whether deviations result from field conditions, standard shop practice, or other cause. Submit letter with transmittal of Shop Drawings,which flags the deviation to the attention of the Engineer. 2. Approval of proposed deviations, if any,will be made at discretion of Engineer. E. Schedule 1. Incorporate shop drawing review period into construction schedule so that work is not delayed. Subcontractor shall assume full responsibility for delays caused by not incorporating the following shop drawing review time requirements into his project schedule. Working days listed reference the time in the Engineer's office. It does not include transmittal or review time of Subcontractor or Architect. Allow at least 5 working days, exclusive of transmittal time, for review each time shop drawing is submitted or resubmitted. F. List of Proposed Equipment and Materials 1. Within four weeks after Award of Contract and before ordering materials or equipment, submit complete list of proposed materials and equipment and indicate manufacturer's names and addresses. G. Responsibility 1. Intent of Submittal review is to check for capacity, rating, and certain construction features. Subcontractor shall ensure that work meets requirements of Contract Documents regarding information that pertains REV. A PFI DESIGN, P.C. JANUARY 24, 2001 Pg. 9 SPE-16040-15000 JAI 6040\Specs\Fina1\15000_Rev A.doe 1.7 SHOP DRAWINGS AND SUBMITTALS A. General 1. Shop Drawings are information prepared by the Subcontractor to illustrate portions of the work in more detail than shown in the Contract Documents. B. Submittal Procedures and Format 1. Review submittal packages for compliance with Contract Documents and then submit to Engineer for review. Submit two blue-or black-line reproductions of each Shop Drawing larger than 8%x 11. Submit six sets of each smaller shop drawing. 2. Shop drawings showing manufacturer's product data shall contain detailed dimensional drawings, accurate and complete description of materials of construction,manufacturer's published performance characteristics and capacity ratings (performance data alone is not acceptable), electrical requirements and wiring diagrams. Drawings shall clearly indicate location(terminal block or wire number), voltage and function for all field terminations, and other information necessary to demonstrate compliance with all requirements of Contract Documents. 3. Ductwork shop drawings showing sheet metal layout shall contain sufficient information in the form of plan views, elevation sections and details to determine system completeness. See Section 1.9. C. Acceptable Manufacturers The Engineer's mechanical design for each product is based on the single manufacturer listed in the schedule or shown on the drawings. Alternate manufacturers are acceptable only if, as a minimum, they: 1. Meet all performance criteria listed in the schedules and outlined in the Specification. 2. Have identical operating characteristics to those called for in the Specification. 3. Fit within the available space it was designed for, including space for maintenance and component removal,with no modification to either the space or the product. Clearances to walls, ceilings and other equipment will be at least equal to those shown on the design drawings. The fact that a manufacturer's name appears as acceptable shall not be taken to mean that the Engineer has determined that the manufacturers products will fit REV. A PFI DESIGN, P.C. JANUARY 24, 2001 Pg. 8 SPE-16040-15000 JA16040\Specs\Fina1\15000_Rev A.doc H. The Subcontractor shall notify the Engineer of any deviations from the above referenced requirements pertaining to work indicated or specified before the installation of this work is affected. I. The Subcontractor is strongly urged to visit job site and review existing conditions which may affect Subcontractor's work,prior to submission of bid. Subcontractor shall be advised that no extra compensation will be provided for any additional work required to be done to provide complete functional systems, if a site review would have identified the necessity for the additional work. This condition will be strictly conformed to, even if all required work is not explicitly indicated on the Project Drawings. 1.6 GUARANTEE AND 24 HOUR SERVICE A. Guarantee the Work of this Section in writing for one year following the date of Substantial Completion. The guarantee shall repair or replace defective materials, equipment, workmanship and installation that develop within this period, promptly and to Owner's satisfaction and correct damage caused in making necessary repairs and replacements under guarantee within Contract Price. B. In addition to guarantee requirements of Division 1 and of Subparagraph A above, obtain written equipment and material warranties offered in manufacturer's published data without exclusion or limitation, in Owner's name. C. Provide 24 hour service beginning on the date of Substantial Completion and lasting until the termination of the guarantee period. Service shall be at no cost to the Owner. Service can be provided by this Subcontractor or a separate service organization. Choice of service organization shall be subject to Owner approval. Submit name and a phone number that will be answered on a 24 hour basis each day of the week, for the duration of the service. D. Submit copies of equipment and material warranties to Owner before final payment. E. At end of guarantee period, transfer manufacturers' equipment and material warranties still in force to Owner. F. This Paragraph shall not be interpreted to limit Owner's rights under applicable codes and laws and under this Contract. G. Use of systems provided under this section for temporary services and facilities shall not constitute Final Acceptance of work nor beneficial use by Owner, and shall not institute guarantee period. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 7 SPE-16040-15000 7:\16040\Specs\Fina1\15000_Rev A.doc MSS Manufacturer's Standardization Society of the Valve and Fittings Industry, Inc. NAPHCC National Association of Plumbing, Heating, Cooling Contractors NBS National Bureau of Standards NEBB National Environmental Balancing Bureau NEC National Electric Code NEMA National Electrical Manufacturers Association NFC National Fire Code NFPA National Fire Protection Association OSHA Occupational Safety and Health Association SMACNA Sheet Metal and Air Conditioning Contractors,National Association, Inc. UL Underwriters' Laboratories, Inc. C. Equipment and installation must comply with requirements set forth by Owner3s Insurance Underwriter. D. Equipment shall bear Underwriters'Laboratories labels where applicable. E. Installation shall comply with all local and state plumbing regulations. F. All materials furnished and all work installed shall comply with the rules and recommendations of the National Fire Protection Association with all requirements of local utility companies,with the recommendations of the Fire Insurance Rating Organization having jurisdiction and with the requirements of the State of Massachusetts and the city of Northampton. G. Any materials or workmanship called for in the above referenced requirements not specified or shown on the drawings shall be furnished and installed by the Subcontractors as though same had been specifically indicated or mentioned. Any work installed in conflict with these requirements shall be come the sole responsibility of the Subcontractor,who shall assume the expense to rectify the installation to the Engineer's satisfaction. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 6 SPE-16040-15000 J:\16040\Specs\Fina1\15000_Rev A.doc Drawings shall have precedence. In case of conflict between published requirements, the Owner's Representative or Engineer shall determine which is to be followed. B. Where standards or codes are mentioned in these specifications, the latest edition of the revision shall be followed. Where provisions of the contract documents conflict with any standards, codes, laws,rules or regulations,the latter shall govern. Where the contract requirements are in excess of applicable standards, codes, law,rules or regulations the former shall govern, unless otherwise directed. Extra payment will not be allowed for work or changes required by local code or enforcement authorities. C. Prior to commencement of work, notify applicable authorities as required and submit all of the required notifications for construction, operation and/or demolition. D. Abbreviation and the title of national, state and industry standards,technical societies, associations and institutes and other organizations used throughout this division lists as follows: (Abbreviation-Title of Organization) AABC Associated Air Balance Council ACGIH American Conference of Governmental Industrial Hygienists ADC Air Diffusion Council AMCA Air Moving and Conditioning Association ANSI American National Standards Institute ARI Air-Conditioning and Refrigeration Institute ASHRAE American Society of Heating,Refrigerating and Air-Conditioning Engineers, Inc. ASME American Society for Mechanical Engineers ASTM American Society for Testing and Materials BOCA Building Officials Conference of America FM Associated Factory Mutual Fire Insurance Companies MCAA Mechanical Contractors Association of America REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 5 SPE-16040-15000 JA16040\Specs\Fina1\15000 Rev A.doc 1.3 RELATED WORK IN OTHER SECTIONS (NOT IN CONTRACT) A. The following is a list of related work items that will be performed or furnished under other Sections of the Specifications as indicated: 1. Electric Power wiring to Heating, Ventilation,Air Conditioning Systems. Including starters and disconnects unless otherwise noted on drawings. 2. Cutting and patching of masonry, concrete,tile and other parts of structure,with the exception of drilling for hangers and providing holes and openings in metal decks. 3. Flashing of wall and roof penetrations. 4. Finish painting all piping, ductwork, insulation, equipment covering, supports, and equipment not having a factory finish,unless otherwise specified. 5. Temporary light,power,water, and heat for use during construction and testing. 6. Wall louvers necessary for outdoor air. 7. Structural steel platforms for the air cooled chiller and cooling tower. 8. Concrete pads for equipment. 9. Removal and/or installation of gas piping. 10. Installation of gas pressure regulators. 1.4 DISCREPANCIES IN DOCUMENTS A. Where drawings and specifications conflict or are unclear, advise Engineer in writing before proceeding with work. B. Where drawings and specifications do not coincide with manufacturer's recommendations, or with applicable codes and standards, alert Engineer in writing before installation. 1.5 CODES AND STANDARDS A. The latest published issue of Standards or Recommendations of the following listed Societies, Associations or Institutes in effect three months prior to the date of this contract are part of this Specification. These shall be considered as minimum requirements. Specific requirements of this Specification and/or REV. A PFI DESIGN, P.C. JANUARY 24, 2001 Pg. 4 SPE-16040-15000 JA16040\Specs\Fina1\15000_Rev A.doc 11. Provision and installation of all cooling tower water piping, insulation, valves,remote sump and pumps serving the new and existing water cooler air compressors. Subcontractor shall be responsible for connection to all air compressors and dryers as indicated on the contract documents. 12. Provision and installation of a new process chilled water surge tank, process chilled water pumps,process chilled water piping,pipe insulation, along with all required valves, strainers, control devices, etc as indicated on the contract documents. Process chilled water system shall include 35%premixed solution of propylene glycol; along with an automatic glycol feeder, including tank,pump, controls, etc.,mounted on a skid. Chilled water shall be furnished and installed along with required insulation to within 3 feet of the thermal processor skid,provided by others. 13. This Subcontractor shall provide all piping support for steam, steam condensate, chilled water supply and return, cooling tower water supply and return,piping. This includes all structural steel,hangers,pipe racks and accessories to fully carry all piping. 14. Removal of(3) existing gas fired unit heaters and gas vents. 15. Instruct the owner in the operation of all new HVAC systems to be installed as described herein, including the new boiler, steam system components, cooling tower system,process chiller,pumps, etc. 16. Provisions of all HVAC Controls as designated on drawings. 17. Provisions for the cleaning, start-up and commissioning of all HVAC systems. 18. Provisions of shop drawings, equipment submittals and as-built drawings. 19. Installation, operation, and maintenance manuals, and startup instructions. 20. All scaffolding as required for work. 21. Provisions for tags and identification of HVAC systems. 22. Removal of(4) existing 20 hp motors inside MAU-1 thru 4 and install(4) new premium efficiency(94.1%)40 hp motors inside MAU-1 thru MAU- 4. Scope of work shall include providing and installing new motor bases, fuses, fuse chips, controls, starters, sheaves,bushings and belts. REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 3 SPE-16040-15000 JM6040\Specs\Final\15000_Rev A.doe . coordinate the work with other trades, receive instructions from the Engineer, and make proper layout of the work to suit job conditions and to satisfy the general requirements of the contract. F. HVAC work, including but not limited to: 1. Hoisting and rigging required to complete the work. 2. Sleeves, inserts, supports and hangers, and vibration isolation equipment. 3. Provision and installation of all the new HVAC related equipment described on the contract drawings and specifications. 4. Installation of the following prepurchased items: a. 600 hp gas fired steam boiler. b. Boiler blowdown tank. C. Chemical feed tank. d. The following piping devices shipped loose with boiler. 1) Safety relief valves. 2) Feedwater control valve. 3) Boiler blowdown valves. 4) 8" non-return valve. 5) 8" stop valve. 6) 8" steam spool piece. 5. Installation of a new prepurchased 215 ton air cooled chiller. 6. Installation of new prepurchased 7 ton process air cooled chiller water skid package. 7. Installation of new prepurchased cooling tower. 8. Provision and installation of steam, steam condensate, valves and insulation as indicated on the contract drawings. Steam distribution piping shall be installed to within 10 feet of the Head Space Sterilizer and Thermal Processor Skid, furnished by others. 9. Provision and installation of all steam boiler feedwater, softened water, nonpotable water,boiler blowdown, chemical feed, relief and drain piping in the existing boiler room as indicated on the contract documents. 10. Provision and installation of all low temperature process chilled water piping, insulation and valves serving the jacketed piping located in both the 20,000 gallon bulk storage tank and transfer piping as indicated on the contract documents. REV. A PFI DESIGN,P.C. JANUARY 24,2001 Pg. 2 SPE-16040-15000 JA16040\Specs\Fina1\15000_Rev A.doc MECHANICAL REQUIREMENTS SECTION 15000 1.0 GENERAL 1.1 GENERAL CONDITIONS A. Division 1, General Conditions, is hereby made a part of this Section as fully as if repeated herein. Where paragraphs of this Section conflict with similar paragraphs of Division 1,requirements of this Section shall prevail. B. Section includes general mechanical requirements for work specified in all other sections of Division 15, the drawings and schedules. C. Subcontractor, unless otherwise qualified, shall mean the installer of the heating, ventilating and air conditioning work. 1.2 WORK INCLUDED A. The work covered by Section SPE-16040-15000 of the Specifications, consists of furnishing all materials, labor,equipment and appurtenances to perform, and leave in satisfactory operating condition, all heating, ventilating, air conditioning work, complete,including all tests and adjustments, in strict accordance with the Specifications and the applicable drawings. B. The work also includes provisions for steam generation and distribution to process equipment and chilled water generation and distribution to process equipment. C. The Drawings show the general arrangement, directions and sizes of equipment, piping and ducts. It is not intended to show every offset and fitting of every structural difficulty that may be encountered,but the Subcontractor shall furnish and install all materials and perform all labor necessary to make complete working systems ready for use,without extra charge to the Owner. All measurements shall be verified in the field. D. Give notices, file plans, obtain permits and licenses,pay fees and charges, and obtain necessary approvals from authorities that have jurisdiction as required to perform work in accordance with all legal requirements of the contract documents. E. Examine the site and all drawings before proceeding with the layout and installation of this work. Arrange the work essentially as shown, exact layout to be made on the job to suit actual conditions. Confer and cooperate with other trades on the job so all work will be installed in proper relationship. Precise location of parts to coordinate with other work is the responsibility of this Subcontractor. Provide a full time Superintendent who shall oversee and REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. 1 SPE-16040-15000 J:\16040\Specs\Fina1\15000_Rev A.doc TABLE OF CONTENTS 1.0 GENERAL............................................................................................................................1 1.1 GENERAL CONDITIONS .................................................................................................1 1.2 WORK INCLUDED............................................................................................................1 1.3 RELATED WORK IN OTHER SECTIONS (NOT IN CONTRACT)...............................4 1.4 DISCREPANCIES IN DOCUMENTS................................................................................4 1.5 CODES AND STANDARDS..............................................................................................4 1.6 GUARANTEE AND 24 HOUR SERVICE ........................................................................7 1.7 SHOP DRAWINGS AND SUBMITTALS.........................................................................8 1.8 COORDINATION DRAWINGS ......................................................................................10 1.9 FEES AND PERMITS.......................................................................................................10 1.10 EQUIPMENT IDENTIFICATION....................................................................................10 1.11 RECORD DRAWINGS.....................................................................................................11 1.12 INSTALLATION,MANUALS, OPERATING INSTRUCTIONS, ANDPROTECTION.........................................................................................................11 1.13 INSTRUCTION TO OWNER'S PERSONNEL................................................................12 1.14 COORDINATION WITH THE BUILDING TRADES....................................................12 2.0 PRODUCTS.......................................................................................................................13 2.1 MATERIALS.....................................................................................................................13 3.0 EXECUTION.....................................................................................................................13 3.1 PREPARATION................................................................................................................13 3.2 WORKMANSHIP .............................................................................................................13 3.3 ERECTION AND INSTALLATION................................................................................14 3.4 CLEANING OF SYSTEMS AND PREMISES................................................................14 3.5 ADJUSTING TESTING AND BALANCING AIR SYSTEMS.......................................15 3.6 FIRESTOPPING..........................................:.....................................................................15 3.7 COMMISSIONING OF EQUIPMENT AND SYSTEMS................................................16 3.8 INSTALLATION ONLY ITEMS .....................................................................................17 3.9 MAINTENANCE..............................................................................................................17 3.10 PROJECT CLOSE OUT....................................................................................................17 REV. A PFI DESIGN,P.C. JANUARY 24, 2001 Pg. i SPE-16040-15000 J:\16040\Specs\Final\15000_Rev A.doc PFI DESIGN, P. C. SPECIFICATION FOR MECHANICAL REQUIREMENTS SPE-16040-15000 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 Rev:, Date Descry tion Admin. Park are Checked; : A rQi�e A 1/24/01 Issue for Bid KAB TAE&A MRM HM tLVA Client Approval: Client: Date: 4. The installation is complete and tested and ready to be inspected by the Owner, and that all required test reports have been submitted. C. The Subcontractor shall arrange for an officer of this Contracting company or of the Owner's Representative to witness the listed tests, as well as to other test witnesses that may be required. At the conclusion of each such test, this Subcontractor shall submit a letter signed by the officer stating: 1. The individual is an officer of the company. 2. The individual has personally witnessed the tests (provide name). 3. Test dates. 4. Test results as compared to specified performance. 5. List the name, title and company affiliation of all those witnessing the test. D. All piping and systems testing require letters. 3.19 CHARTS AND SPARE SPRINKLERS A. Provide glass-mounted instruction charts on wall near valves,with description of operation of system and maintenance procedures. Provide supply of spare sprinklers in cabinets, in accordance with requirements of NFPA. Locate cabinets where directed. 3.20 IDENTIFICATION A. Identify and label all control,drain and test-alarm valves, and piping with identification tags and labels of the type approved by NFPA and The Minute Maid Company's facility standards, securely wire to valve stems. Install pipe markers in accordance with manufacturer's recommendations. ++END OF SECTION 15300++ REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 36 SPE-16040-15300 JAI 6040\SpecsWina1\15300-Rev-A.doc r 3.17 TESTING AND FLUSHING A. General: 1. All testing and flushing shall be performed in accordance with NFPA and applicable insurance company standards. 2. The Subcontractor shall make tests of his work as required by the Owner's Representative during the progress of work to demonstrate strength, durability and fitness of installation. 3. Sufficient notice shall be given to the Owner's Representative to allow his representative to be present during tests. Any leaks detected shall be fixed by replacing defective materials and the test shall be continued until systems are free of leaks and proven tight under test pressures. B. Hydrostatically test piping in accordance with requirements of NFPA. Remedy defects and repeat test. Maintain test pressure by means of a small pump, with main controlling gate shut to avoid serious water damage in the event of a break, while testing underground section. C. Thoroughly flush interior system in accordance with requirements of NFPA. Flush exterior system through blow-off prior to making connection to interior gate valve. Notify Owner's Representative of readiness for flushing. D. Submit evidence of approval by Factory Mutual for work under this section,prior to acceptance of work by owner. 3.18 COMMISSIONING OF SYSTEMS A. The Owner shall check the completed installation either sequentially as different parts are completed, or when the entire installation is complete, at the sole option of the Owner. B. Prior to the Owner's checking a part of this installation or the entire installation, this Subcontractor shall submit a letter signed by an officer of this Contracting company or an officer of the Owner's Representative stating: 1. The individual is an officer of the company. 2. The individual has personally inspected the installations. 3. Inspection dates. REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. 35 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc 3.13 EQUIPMENT INSTALLATION A. Install fire protection appurtenances in locations that are accessible for service. 3.14 WELDING A. Subcontractor shall visually inspect welding while welders are making welds and again after work is complete. After welding is complete, hand or power wire brush welds and clean before check inspection. Inspect welds under light for surface cracking,porosity, and slag inclusions, excessive roughness,unfilled craters, gas pockets, undercuts, overlaps, size and insufficient throat and concavity. Correct deficiencies until approved by the Owner's Representative. 3.15 WIRING A. Provide all controls,pull stations and interlock wiring (if applicable)in accordance with requirements of Division 16, except work specifically shown on the electrical drawings or described under the electrical specifications. Wiring shall conform to the National Electrical Code and local electrical codes. 3.16 HYDRAULIC CALCULATIONS A. Hydraulic calculations shall be prepared by this Subcontractor and stamped and signed by a registered professional engineer retained by said Subcontractor in accordance with NFPA No. 13 and the requirements of the local Fire Marshal with the following exceptions: 1. Pipe friction losses shall be calculated for all piping over one foot in length. Vertical lengths less than one foot shall be included for elevation purposes only. 2. Flows shall be calculated to the nearest whole gallon per minute. 3. Velocity pressure may be neglected. 4. Velocities in all piping shall not exceed 25 feet per second. B. The Subcontractor shall perform all hydrant flow tests to obtain a basis for his hydraulic calculations, and: 1. State and/or Local Fire Marshall shall witness and approval all tests. 2. Northampton,Massachusetts Water Department shall approve all tests. 3. Final calculations shall be based on flow data derived from flow tests performed by this Subcontractor at the hydrants installed on the site. REV. A PFI DESIGN, P.C. JANUARY 5, 2001 Pg. 34 SPE-16040-15300 J:\16040\Specs\Final\15300-Rev-A.doc C. Where approved, butterfly valves may be used instead of gate valves. D. Provide drain valves at main shut-off valves and at low points of piping. 3.8 INSERT INSTALLATION A. Install inserts for suspending hangers from reinforced concrete slabs and sides of reinforced concrete beams wherever practicable. B. Set inserts in position in advance of the concrete work. Provide reinforcement rods in the concrete for inserts carrying pipe over 4 inches in diameter. C. Where concrete slabs form a finished ceiling, finish inserts flush with the slab surface. D. Where inserts are omitted, drill through the concrete slab from below and provide a rod with a recessed 6 inch square steel plate and nut above the slab. 3.9 PIPE HANGERS AND SUPPORT INSTALLATION A. Support vertical piping at each floor. B. Where practical, support riser piping independently from connected horizontal piping. C. During hydrostatic test of lines supported by springs, counterweights, etc., temporary rigid,supports or blocking shall be installed to prevent excessive strain on piping and equipment and overloading of spring devices. 3.10 ESCUTCHEON PLATE INSTALLATION A. Install required escutcheons around exposed pipe passing through finished floors. B. The outer edge of the escutcheon plates shall completely cover the opening in the structure penetrated and any patchwork around the opening. 3.11 ANCHOR INSTALLATION A. Install anchors as necessary for attachment of piping system supports. 3.12 FLASHING INSTALLATION A. Flash and counter-flash where the plumbing piping systems pass through weather or water-proofed walls, floors, and roofs, in accordance with the requirements of Division L REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. 33 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doe compatible with the couplings. Mechanical couplings shall be by one manufacturer. S. Welded joints shall be shop welded by certified welders qualified for welding in accordance with the requirements of ASTM boiler and pressure vessel code Section IX, and welding methods shall be in accordance with ANSI B31.1.0- 1967, including agenda ANSI B31.LOS and B31.LOB. T. Flanged joints shall be made using proper gaskets and bolts according to latest NFPA regulations. U. Provide escutcheon plates for all sprinkler piping passing through floors, walls and ceilings of an approved one-piece or split-type. Plates shall be securely anchored in place with set screws or other approved means. V. Seal coring and sleeve penetration to achieve fire resistance equivalent to fire separation required. W. All sprinkler pipe and fittings shall be installed so that system can drain thoroughly. All piping shall be arranged, if possible, so that system drains to main drain valve. Pipe shall be straightened before installation to prevent pockets, which could interfere with proper drainage. 1. Sprinkler pipes may be installed level, unless otherwise indicated. Trapped piping shall be drained in accordance with NFPA standards. X. Install piping to conserve facility space and not interfere with use of space. Y. Install piping to allow for expansion and contraction without stressing pipe,joints, or connected equipment. Z. Piping shall not be installed below ceiling grid elevation unless otherwise noted. AA. Provide access where valves and fittings are not exposed. Coordinate size and location of access doors in accordance with the requirements of Division I. BB. Unless otherwise noted, field paint all exposed piping to comply with cGMP Guidelines or with The Minute Maid Company facility standards, whichever is more stringent. 3.7 VALVE INSTALLATION A. Provide shut-off valves in special hazard areas. B. Install valves with stems.horizontal, not inverted. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 32 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc F. Install piping in accordance with NFPA 13 for sprinkler systems. G. Do not penetrate building structural members unless approved by the Owner's Representative. H. Place pipe runs to minimize obstruction to other work. I. Place all sprinkler piping in concealed spaces (i.e. above finished ceilings,within soffits, etc.) completely acceptable to the Architect and the local Fire Marshal. J. Place sprinkler heads in ceilings with respect to other disciplines and provide piping offsets as required. K. Apply strippable tape or paper cover to ensure concealed sprinkler head cover plates do not receive field finishes. L. Install piping, hangers, sprinkler heads, fittings, drain connections and inspectors test stations in strict accordance with the requirements of NFPA 13. M. Furnish and install piping straight,plumb, and as direct as possible. Form right angles on parallel lines with building walls. N. Piping shall be accurately cut to measurements established in the field and worked into place without springing or forcing. O. All piping shall be reamed to be free of burrs after cutting. P. Keep piping free from scale and dirt: Protect open pipe ends whenever work is suspended during construction to prevent foreign bodies entering and lodging there. Use temporary plugs, or other approved material for protection. Q. Screwed Joints: 1. All pipe and fittings with screwed ends'shall have I.P.S. thread cut clean and true in conformance with ANSI Specifications B2.1 for taper threads. 2. Fittings shall be screwed up close to shoulders of male threads. Lampwich, cord, wool or any other similar materials shall not be used in making threaded joints. 3. All screwed pipe joints, except where specified otherwise, shall be made up with pipe dope joint compound, applied to male threads only. R. Pipe jointed with mechanical grooved couplings shall be joined by an approved combination of couplings, gaskets and grooves. Grooves shall be dimensionally REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 31 SPE-16040-15300 JA16040\Specs\Fina1\15300-Rev-A.doc B. Clean and remove scale, dirt,mud, gravel and other foreign material on inside and outside of pipe and/or fittings before assembly. C. Prepare all surfaces in accordance with manufacturer's installation instructions and the requirements of Division 1. D. De-grease and clean all surfaces which shall receive adhesive. E. Review fire protection millwork shop drawings. Confirm location and size of fixtures and openings before rough-in and installation. 3.5 PENETRATIONS A. Installation Testing, Listings and Approvals: 1. Installation shall meet material manufacturer's installation instructions exactly,particularly in regards to preparation of surfaces, removal of foreign materials, safety requirements, ventilation and other details of installation. Dam openings as recommended. Remove flammable materials used for damming and forming seals in fire-rated construction. 2. Core drill and sleeve seals shall be water- and gas-tight and shall meet the requirements of ASTM E-119 Standard Methods of Fire Tests of Building Construction and Materials. 3. Inspect sealant to ensure that installation achieves manufacturer's optimum structure. 3.6 PIPING AND FITTING INSTALLATION A. Screw joint steel piping up to and including 2-inch diameter. Weld piping 2-inch diameter and larger including branch connections. Provide jointing compound of polytetrafluoroethylene pipe tape for pipe threads. Apply tape to male threads only. B. Threaded or welded joints may be used instead of mechanical grooved joints. C. Die cut screw joints with full cut standard taper pipe threads with pipe dope joint compound applied to male threads only. D. Coat threaded ends with pipe lubricant compound. E. In steel piping,main sized saddle branch connections or direct connection of branch lines to mains is permitted if main is one pipe size larger than the branch for up to 6 inch mains. Do not project branch pipes inside the main pipe. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 30 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc C. The Subcontractor shall establish reference points to base his measurements,both horizontal and vertical, and be responsible for correctly laying out the work. D. In event of discrepancy between actual measurements and those indicated,notify Owner's Representative in writing and do not proceed with work until written instructions have been issued by Owner's Representative. E. The Subcontractor shall provide for the required equipment manufacturer's authorized factory personnel, on site, for final fire protection inspection and start- up and include costs in his bid. 3.2 MATERIALS AND WORKMANSHIP A. Work shall be neat and rectilinear. Install materials and equipment as recommended by manufacturer. Installation shall operate safely and without leakage, undue wear,noise,vibration, corrosion, or water hammer. Close pipe openings to prevent obstruction and damage prior to completion. B. Except as specified otherwise, material and equipment shall be new. Provide supplies, appliances and connections necessary for complete and operational installation. Provide components required or recommended by OSHA and NFPA. C. References to manufacturers and catalog designations are intended to establish standards of quality for performance and materials but imply no further limitation of competitive bidding. D. Finish of materials, components and equipment shall be approved by the Owner's Representative and shall be resistant to corrosion and weather as necessary. E. Owner shall not be responsible for materials and fixtures before final acceptance. 3.3 CONTINUITY OF SERVICES A. Do not interrupt existing services without Owner's approval. B. Schedule interruptions in advance, according to Owner's instructions. Submit request for interruption with methods proposed to minimum length of interruption in writing. C. Interruptions shall be scheduled at such times of day and work to minimize impact on Owner's operations. 3.4 PREPARATION A. Ream.pipe and tube ends. Remove burrs and sharp edges by peening or filling the edge. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 29 SPE-16040-15300 JAI 6040\SpecsTinahl5300-Rev-A.doc 4. In the exterior walls,the space between the pipe and the opening (the surface of the insulation and the opening for the insulated lines) shall be filled with as suitable non-combustible insulation, and the exterior face fully sealed against weather. The opening between the pipe and the wall shall be completely concealed, on both the inside and outside faces of the wall,by a neat cover or an escutcheon plate of non-corroding metal and shall be painted to match. The paint shall match as closely as possible in material, appearance, and durability of the finish on the walls. 5. Covers and escutcheon plates are not required where the pipe-wall joint shall not be visible in completed work, except as required to retain the insulation in the annular space between the pipe and the opening. 6. In interior partitions, walls, or floors, the space between the pipe and the opening shall be packed full with glass fiber insulation, held in place by a positive means, such as an escutcheon or a cover plate. 2.18 CATHODIC/ELECTROLYTIC PROTECTION A. Connections between dissimilar metals shall be made with dielectric connectors, equal to Victaulic "Clearflow"fittings. 2.19 GENERAL A. Provide all fire protection items of the same manufacturer throughout where possible. 2.20 SPARE PARTS AND SPECIAL TOOLS A. Provide in accordance with the requirements of Division I. 3.0 EXECUTION 3.1 SUBCONTRACTOR RESPONSIBILITIES A. Maintain systems until final acceptance. Ensure adequate protection of materials during delivery, storage, installation and shutdown, and during delays pending final test of systems and equipment because of seasonal conditions. B. Periodic observations by Owner, Architect or designated agent shall not be construed as supervision of actual construction, nor make either responsible for providing safe place for performance of work of various trades or suppliers, or for visitors or occupants, or make either responsible for omission of safety devices called for by codes, ordinances, or specifications of manufacturer of equipment supplied. REV. A PFI DESIGN, P.C. JANUARY 5, 2001 Pg. 28 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc E. For slab on grade construction,provide waterproofing membrane locking devices at floor penetrations. Where penetrations occur at foundation walls,provide 150 lb. slip-on welding flanges. F. Acceptable waterproof pipe penetrations (not for use for slotted concrete) shall include modular mechanical penetration seals shall be interlocking synthetic rubber links with galvanized carbon steel nuts,bolts, and pressure plates to expand the rubber seals to make an acceptable watertight seal for the annular space between the pipe and the concrete opening. The seal shall be completely watertight, equal to"Linkseal"modular mechanical type interlocking links. G. The cored opening in the floor shall have a tight-fitting 12 gauge galvanized sheet metal sleeve, adequately anchored and caulked to provide as watertight an instal- lation as a cast-in-place sleeve. The sheet metal sleeve shall extend above the finished floor. Refer to details on the drawings. H. For pipes which extend from a dry area through a wall, ceiling or roof into a wet area or where vibration suppression is required between the pipe and the concrete element through which it passes (not for use for slotted concrete), the pipe penetration shall be sealed with neoprene gaskets and compression flanges or similar approved devices, to ensure a watertight seal between the pipe and the wall, etc., surrounding the pipe. I. Penetrations through walls, floors, or ceilings to accommodate piping and appurtenances shall not increase the sound transmission class (STC) of construction. J. Sleeves at metal decking or flooring shall be welded to the decking or flooring as required to resist a 200 lb. horizontal force, applied in any direction at the top of the sleeve,without damage or permanent deformation of the sleeve,welds, deck or floor. K. All exposed lines,which pass through a floor, ceiling, wall, or partition shall have a chrome escutcheon cover plate. 1. Closures shall conform to all applicable codes and FM requirements. 2. The escutcheon plate at the insulated line shall be sized to fit over the insulation,which shall be adequately protected from chafing damage at the plate. Insulation shall be carried through the opening with no reduction in insulation thickness. 3. Each escutcheon plate at the floor shall cover the one-inch pipe extension above the finished floor. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 27 SPE-16040-15300 JAI 6040\,Specs\Fina1115300-Rev-A.doc 2.16 FIRE PROTECTION SYSTEM IDENTIFICATION MATERIALS A. Unless specified otherwise, colors shall conform with ANSUASME A13.1 and The Minute Maid Company facility standards. B. Conform to Division 1 for standard for tagging. C. Stencils shall have clean cut symbols and letters of the following size: OUTSIDE DIAMETER OF LENGTH OF SIZE OF INSULATION OR PIPE COLOR FIELD LETTERS 3/4 1 - 11/4" 81' V2„ 1 V211 -211 81f 3/4 1 2V211 - 611 12" 11/4" D. Stencil paint shall be in accordance with the requirements of Division I. E. Plastic pipe markers shall be factory fabricated, flexible, semi-rigid plastic, preformed to fit around the pipe or pipe covering with minimum information indicating flow direction arrow and the fluid being conveyed. F. Plastic tape pipe markers shall be flexible vinyl film tape with pressure sensitive adhesive backing and printed markings. 2.17 PENETRATIONS AND CORE DRILLING A. The Subcontractor shall not do any core drilling without the written consent and approval of the Owner's Representative and the Structural Engineer. The locations of the openings shall be laid out in advance and indicated with chalk. The sizes, locations and dimensions of the openings shall be checked and verified against the equipment and general arrangement plans by the Owner's Representative and the Structural Engineer prior to any core drilling. B. As permitted,the Subcontractor may then make neat, cored holes in the concrete and masonry. C. The Subcontractor shall thoroughly investigate the existing conditions in the vicinity of required opening prior to coring. The Subcontractor shall not disturb existing systems unless as specified. D. The Subcontractor shall be responsible for all damages to the facility and its systems from core drilling operations. REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. 26 SPE-16040-15300 J:\16040\Specs\Final\15300-Rev-A.doc 2.11 SPRINKLER HEADS A. Sprinkler system heads shall be UL listed,FM approved, large orifice, upright or pendent spray type with a minimum temperature rating of 165°F, except in areas of high temperatures, in accordance with NFPA 13, the local Fire Marshal, and the Owner's Insurance Underwriter. 1. Finished areas shall incorporate pendent type heads, clean, concealed type with gaskets for clean areas. 2. Unfinished areas shall incorporate upright heads. 2.12 INSERTS A. Inserts shall have a malleable iron case with a galvanized steel shell and expander plug for threaded connection with a lateral adjustment top slot for reinforcing rods. Lugs for attaching to forms; Figure No. 650 for i/4 inch through 5/8 inch rods and Figure No. 266 for 3/4 to 1-inch rods. B. Size inserts to suit the threaded hanger rods. 2.13 PIPE HANGERS AND SUPPORTS A. Pipe hanger supports shall be provided in accordance with the latest Massachusetts State Seismic Requirements. B. Seismic restraints shall be equal to Holdrite,Model#EB-010. 2.14 EXPANSION JOINTS A. Expansion joints shall be of the pack-less, corrugated type. Circumferential welded seams shall not be permitted in the bellows material except for seal welds which join bellows to end connections. Bellows shall be fabricated from stainless steel. B. Expansion joints shall be suitable for the temperatures,pressures and thermal movements required and shall be fitted with sleeves. 2.15 PIPE ANCHORS AND GUIDES A. Anchors shall be provided in accordance with the latest local seismic requirements and shall be secured to the building structural members only. Submit calculation showing forces imposed on the building structure with the anchor design details. B. Guides shall be equal to "Fabreeka", Figure No. 189. REV. A PFI DESIGN, P.C. JANUARY 5,2001 Pg. 25 SPE-16040-15300 JAI 6040\SpecsTina1115300-Rev-A.doc nuts, and washers; galvanized couplings for galvanized pipe, equal to Victaulic Firelock. Flexible couplings shall be used where seismic conditions exist. 2.6 PIPE AND VALVE SPECIALTIES A. Supervisory Switches: UL 753 for valves, electrical supervision type, SPDT (single-pole, double-throw),normally closed contacts, designed to signal controlled valve in other than full open position, equal to Potter Signal Model OSYSU-A. B. Waterflow switches for wet sprinkler system piping 1" to 1-1/2" in size shall be a vane type with retard,UL listed, in a cast aluminum enclosure with red enamel finish, equal to Potter Electric Signal#VSR-SF. C. Pressure Switches: UL 753 listed for valves, electrical-supervision type, SPDT (single-pole, double-throw),normally closed contacts, designed to signal controlled valve in other than full open position, equal to Potter Signal Model OSYSU-A. D. Electrically Operated Bell: E. Any electrical devices located in electrically classified rooms shall be explosion- proof as required. 2.7 GATE VALVES A. Iron body,bronze trim, rising stem, OS&Y, solid wedge, 175 psi working pressure,.with supervisory switch and UL label and FM listed. 2.8 DRAIN VALVES A. Brass ball valve with cap and chain. 2.9 BUTTERFLY VALVES A. Iron body,bronze disc and stem, resilient replaceable liner seat, 175 psi working pressure,with supervisory switch,UL listed or FM approved, equal to Kennedy Figure 911. Grooved-end valves shall be equal to Victaulic# 708-W with weatherproof gear operators. 2.10 VALVE CONNECTIONS A. Provide valve connections to match pipe joints. Use valves of same pipe size. REV. A PFI DESIGN, P.C. JANUARY 5,2001 Pg. 24 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc H: Items of the same function and performance shall be acceptable if submitted and approved in conformance with the requirements of Division I. All manufacturers shall be domestic and ISO 9000 certification is preferred. 2.3 PIPE AND FITTINGS A. Above ground wet system piping shall be ASTM A 53, Schedule 40 black steel pipe,with threaded black cast iron threaded fittings. Cast iron fitting shall be ANSI/ASME B 16.4, screwed. Pipe 2 %2" and larger may have welded outlets or mechanical tees (as defined in NFPA 13)with roll groove (min. 300 psi working pressure) fittings, equal to Victaulic Firelock @ 300 psi. B. Dry pipe system piping shall be galvanized steel pipe, with 175 psi galvanized fittings and screwed or grooved joints, listed for dry service. C. Roll grooved piping may be allowed utilizing Victaulic "Firelock"couplings and fittings. Gaskets shall be EPDM Type A. D. Provide flexible groove fittings and couplings furnished with projecting rib gaskets that fit between end of the pipe and prevent liquid from settling behind rolled ends of pipe. Provide gaskets such that inner walls of the pipe are without gasket protrusions or indentations to restrict a smooth flow of liquid. E. Malleable Iron Fittings shall be ANSI/ASME B 16.3, screwed type or ANSI/ASTM A47. F. Drain piping for inspector's test assembly and main drain shall be galvanized steel,ASTM A120,with galvanized malleable iron groove(min. 300 psi WP) fittings. 2.4 JOINT MATERIALS A. Solder: ANSI/ASTM B32, 95/5 alloy. B. Brazing: ANSI/AWS A5.8. C. Threaded Joint Compound: pipe dope joint sealer, 3 mil,DuPont No. 48, or equal. 2.5 UNIONS, FLANGES, COUPLINGS A. Unions: 150 psi malleable iron for threaded ferrous piping. B. Flanges: 150 psi forged steel slip-on flanges for ferrous piping. C. Mechanical Grooved Couplings shall be ductile iron housing clamps to engdge and lock, designed to be rigid; "C" shaped composition sealing gasket, steel bolts, REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 23 SPE-16040-15300 JAI 6040\Specs\Final\15300-Rev-A.doc C. All items shall be secure and in their final positions, and shall present a neat and professional appearance. D. All temporary bracing, cross ties and the like shall be removed. E. All items shall serve the purpose for which they are intended, i.e., to support, anchor, frame,block-out, etc. Finish items to present accurate,true,plumb, finished and completed appearances. F. All stains and/or damage done to the finish of the facility that is caused by faulty workmanship and/or improper handling of materials regarding to this installation shall be cleaned,removed and/or replaced. 2.0 PRODUCTS 2.1 MATERIALS A. All materials shall conform to the requirements of Factory Mutual,Underwriters Laboratories,NFPA, Local Codes, Federal Specification and/or standards listed such as Commercial Standards, ASTM, and requirements specifically stipulated herein. 2.2 ACCEPTABLE MANUFACTURERS A. Pressure Switches: Simplex, Gamewell,Potter Electric Signal, or approved substitute. B. Supervisory Switches: Notifier,Potter Electric Signal, or approved substitute. C. Detectors: Central, Gamewell, Potter Electric, Viking, Simplex, or approved substitute. D. Grooved Products: Victaulic, or approved substitute. E. Sprinklers: ASCOA Fire Systems, Central Sprinkler, Firematic Sprinkler Devices, Grinnell, Globe Fire Sprinkler,Reliable Automatic Sprinkler, Star Sprinkler, Viking, or approved substitute. F. Hangers, supplementary steel channels, supports, fasteners, and hangers: Carpenter&Paterson, Grinnel,Michigan Hanger Co. Except as otherwise noted, hanger and support figure numbers referred to are these of Carpenter&Paterson. G. Fire Protection System Identification: Seton, Brady, or approved substitute. REV. A PFI DESIGN, P.C. JANUARY 5, 2001 Pg. 22 SPE-16040-15300 JAI 6040\SpecsTinahl 5300-Rev-A.doc B. All materials, equipment and work furnished under this Section shall be guaranteed,by this Subcontractor, against all defects in materials and workmanship for a period of one (1)year commencing with the date of final acceptance. Any failure due to defective material, equipment or workmanship which may develop, shall be corrected at no expense to the Owner including all damage to areas,materials and other systems resulting from such failures. C. Upon receipt of notice from the Owner of failure of any part of the systems during the guarantee period, the affected parts shall be replaced at no cost to Owner. Any equipment requiring excessive service shall be considered defective and shall be replaced. D. If any part of a system should be stopped by foreign matter being placed in the systems, disconnect the system, clean, and reconnect wherever necessary to locate and remove obstructions. Repair or replace any work damaged in the course of removing obstructions. 1.47 MAINTENANCE MANUALS A. Provide three (3)bound manuals containing operating., installation, and maintenance instructions for all equipment. 1.48 POWER WIRING A. All power wiring shall conform to the requirements of Division 16 and as shown on electrical drawings. 1.49 ELECTRICAL WORK A. This Subcontractor shall provide appurtenances as specified for the fire protection systems in accordance with the manufacturer's requirements for a complete system. Wiring for interlocking,protective or signal devices for systems operation,control devices, circuit breakers, switches, control panels and enclosures shall be by the Electrical Subcontractor and shall conform to the requirements of Division 16. 1.50 CLEAN UP AND REMOVAL OF RUBBISH A. The Subcontractor shall keep the facility and site clean from the accumulation of rubbish and waste materials and, upon completion, leave the facility,the site and the installation in a clean condition, completely acceptable to the Architect and to the Owner's Representative. B. At the completion of the work, this Subcontractor shall remove all tools, scaffolding, debris and waste and unused materials from and about the premises. REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. 21 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc 1.42 PORTABLE OR DETACHABLE PARTS A. The Subcontractor shall retain in his possession and shall be responsible for all portable and detachable parts and portions of the installation and all other devices or materials that shall be relative to and necessary for the proper operation and maintenance of the fire protection systems until final completion of the work. B. The Subcontractor shall replace all stolen, lost, or damaged items relative to the installation and operation of the fire protection systems before the facility is accepted. 1.43 CATHODIC/ELECTROLYTIC PROTECTION A. Connections between dissimilar metals shall be cathodically protected by suitable methods acceptable to the Owner's Representative. 1.44 TESTING AND ADJUSTING A. The Owner shall supply single phase power for equipment,where locally available, and provide all utilities such as water, fuel, and electricity for all tests associated with or specified for the fire protection work. B. Test all work and systems and make all adjustments and corrections as required to provide a complete, first-class working system. C. Provide all labor, materials, and instruments necessary for completion of tests under observation of the local authorities and the designated inspectors. D. Make adjustments and place all piping systems in operation and demonstrate the proper functions of the piping systems, equipment, and controls. 1.45 CERTIFICATES OF APPROVAL A. Upon completion of all work and after the necessary periodic inspections by the, authorities having jurisdiction have been made,'copies of inspection reports and approvals shall be forwarded to the Owner's Representative. B. Refer to Division 1 for requirements pertaining to substantial completion and Final Acceptance, all of which shall be provided for under this Section. 1.46 GUARANTEE A. Manufacturers shall provide their standard warranties for materials and equipment furnished under this section. Such warranties shall be in addition to, and not in lieu of, all liabilities which the manufacturer and Subcontractor may have by law or by provisions of the Contract Documents. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 20 SPE-16040-15300 J:\16040\Specs\Final\15300-Rev-A.doc 1.40 SUPPLEMENTARY STEEL, CHANNELS AND SUPPORTS A. Furnish and install all supplementary steel and structural supports required for the proper installation,mounting and support of all piping and equipment. B. Supplementary steel and channels shall be firmly connected to building construction in a manner approved by the Contractor, as specified. C. The type and size of the supporting steel shall be determined by the installer and shall be of sufficient strength and size to allow only a minimum deflection in conformance with the manufacturer's requirements. D. All supplementary steel shall be installed in a neat and professional manner parallel to the walls, floor and ceiling construction. All turns shall be made with 90E and 45E fittings, as required to suit the construction and installation conditions. E. All supplementary steel supports and fittings shall be galvanized structural steel or roll formed steel as manufactured by Unistrut, Power-Strut, or accepted substitute. 1.41 FASTENERS AND HANGERS A. Necessary bolts, anchor bolts,nuts,washers, and plates for the fire protection work shall be included. Anchor bolts and threaded rods shall have suitable washers, lock washers, and hexagonal nuts on either side of the support materials. B. Bolts, threaded rods, anchor bolts,nuts,washers,plates, and bolt sleeves shall be galvanized,unless otherwise indicated or specified. Threaded items shall be galvanized after threading in accordance with ASTM A 123 or A 153, as appropriate. C. Expansion bolts shall have malleable iron and lead composition elements of required size. D. Stud, tap, and machine bolts shall be refined bar iron, unless otherwise specified, with hexagonal nuts of same quality metal as bolts. Threads shall be clean cut, conforming to ANSI B 1.1. E. Where specified,bolts, threaded rods, anchor bolts,nuts, and washers shall be Type 316 stainless steel. F. Suitable templates shall be provided for anchor bolts to be cast in concrete. REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. 19 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc 1.35 REMODELING A. Disconnecting, capping off, and re-connection of"live" ends of existing piping within the existing facility to portions of the new fire protection system shall be included as part of fire protection work to be accomplished by the Subcontractor. 1.36 TEMPORARY OPENINGS A. Arrange for the Owner's Representative to provide special temporary openings in the structure and in exterior walls as required for the admission of apparatus furnished as part of the fire protection work. B. Provide for temporary closings as work progresses. 1.37 ACCESSIBILITY A. Install all work so that all parts required shall be readily accessible for inspections, operation,maintenance, and repair. Minor deviations from the drawings may be made for this purpose,but changes of magnitude shall not be made without prior written approval of the Owner's Representative. 1.38 ACCESS PANELS A. Provide access panels for walls, ceilings and floors as required to permit access for adjustment, removal and replacement, and servicing of fire protection system appurtenances requiring access and all other items requiring maintenance and adjustment. B. All access panels shall be located in a professional manner in accordance with the requirements of Division I. C. All access panels shall have a fire rating equal to or better than the wall it serves. 1.39 FIREPROOFING A. All clips,hangers, clamps, supports and other attachments to the fireproofed structure shall be coordinated with other trades in order to avoid any damage to the fire proofing. B. All items which would interfere with the proper application of fireproofing shall be installed after the application of fireproofing work. This Subcontractor shall provide all patching of disturbed fireproofing. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 18 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc C. The Subcontractor shall give sufficient supervision to the work using his best skills and attention. He shall carefully study and compare all drawings, specifications and other instructions, and shall report at once to the Owner's Representative any error, inconsistency or omission which he may discover but he shall not be held responsible for the existence or discovery. D. Store, handle and protect products under provisions set fourth by the piping and equipment manufacturers and as specified. 1.32 EXTRA STOCK A. Provide extra sprinkler heads and special sprinkler wrenches for each type and temperature rating in accordance with NFPA 13, 2-2.8. B. Provide a metal storage cabinet for spare heads and locate per the Owners' direction. 1.33 CUTTING AND PATCHING A. All core drilling for the piping systems shall be done by this Subcontractor as specified herein. Any injury to the facility caused by this Subcontractor shall be repaired by him, leaving the work equal to the surrounding work. B. When finished materials of other trades are to be cut or fitted in the shop, this Subcontractor shall furnish the necessary drawings to the trades whose materials shall be cut or fitted. C. All concrete patching associated with the fire protection system installation shall be the responsibility of this Subcontractor. He shall repair all disturbed concrete including steel reinforcing to match existing conditions. D. Inserts, anchor bolts and similar items set into concrete or masonry or the work of other trades shall be furnished and installed by the Subcontractor. The Subcontractor shall be responsible for all such items necessary to hang or support his work. 1.34 UTILITIES A. Provide all utilities such as water, fuel, and electricity for all tests associated with or specified for the fire protection work. B. The owner shall supply single phase power for equipment where locally available. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 17 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A,doc Representative and relocate as directed. Do not prevent or disturb operation of active services that are to remain. B. Inactive Services: When encountered in work, remove, cap or plug inactive services. Notify utility companies or municipal agencies having jurisdiction prior to work. Protect or remove these services as directed by the Owner's Representative. C. Interruption of Services: Where work makes temporary shutdown of services is unavoidable, shut down at night, or at such times as approved by the Owner, which shall cause the least amount interference with established operation routine. Arrange work to assure that services shall be shut down only during time actually required to make connection to existing work. D. Existing piping and insulation removed or damaged during the work shall be replaced with new, alike materials. 1.29 SELECTION AND ORDERING OF MATERIALS A. Arrange for the purchase and delivery of materials and equipment required in ample quantities and at the proper time. Immediately notify the Owner's Representative of any inability to obtain suitable delivery of any apparatus or materials required. 1.30 NAMEPLATES A. The manufacturer's nameplates or trademark shall be permanently affixed to all equipment and materials furnished under this specification. The nameplate of a subSubcontractor or distributor is not acceptable. B. Project nameplates shall identify each item of equipment including controls with a permanently attached project nameplate, identifying each piece of equipment as identified on the equipment schedule or on the drawings. C. Project nameplates shall be at least one inch high engraved with letters at least one-half inch high. 1.31 DELIVERY, STORAGE AND HANDLING OF EQUIPMENT AND MATERIALS A. The Subcontractor shall give his personal supervision and direction to the work and shall give strict attention to time schedules as agreed upon. B. The Subcontractor shall have sufficient foresight to have materials on hand before they are needed and in such quantities that delays of railroads, other parties, weather conditions, etc., shall not delay this work. REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. 16 SPE-16040-15300 JAI 6040\SpecsTinahl 5300-Rev-A.doc E. At the completion of the work, this Subcontractor shall remove all tools, scaffolding, debris,waste and unused materials from and about the premises, and shall leave his work clean and ready for use. F. The decision of the Owner's Representative as to the character of any labor provided by the Subcontractor shall be final and conclusive on both the Subcontractor and the Owner. 1.26 PROTECTION OF WORK AND PROPERTY A. The Subcontractor shall be responsible for the care and protection of all work included under this section until it has been tested and accepted. B. All pipe openings shall be temporarily closed so as to prevent obstruction damage. C. Protect all equipment and materials from damage from all causes including weather,water, frost, accident and theft. All materials and equipment damaged or stolen shall be repaired or replaced with equal material or equipment. The Subcontractor shall protect all materials and workmanship of all other trades from damage that may be caused by the plumbing work and shall be responsible for repairing any damages caused. D. Protect all equipment, outlets and openings with temporary plugs, caps and covers. Protect work and materials or other trades from damage that might be caused by work or workmen and make good damage thus caused. E. This Subcontractor shall care for his own tools, equipment and materials, and shall be responsible for their safekeeping at all times. 1.27 SURVEYS AND MEASUREMENTS A. The Subcontractor shall base his measurements,both horizontal and vertical, from reference points established by the Owner's Representative and shall be responsible for correctly laying out his work. B. In the event of a discrepancy between actual measurements and those indicated, notify the Owner's Representative, in writing, and do not proceed with this work until written instructions have been issued by the Owner's Representative. 1.28 EXISTING BUILDING SERVICES AND UTILITIES A. Active Services: When encountered in the work,protect,brace and support as required, all existing services for proper execution of work. If existing active services are encountered.that require relocation,notify the Owner's REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 15 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc B. All materials furnished and all work installed shall comply with all requirements of the local utility companies,with the recommendations of local utility companies, and with the requirements of the State of Massachusetts and the Town of Northampton. 1.22 COMPLETENESS OF WORK A. The omission from the plans and specifications of expressed references to any reasonable labor or materials necessary for the proper executing or completion of the work, shall not relieve the Subcontractor from furnishing them in keeping with the basic character and intent of the work. 1.23 WORK PERSONNEL A. The Subcontractor shall furnish first-class skilled workmen for all work, and shall keep a competent foreman or superintendent on premises at all times during the progress of the work that shall have the authority to act for and in behalf of the Subcontractor during the latter's absence with regard to all directions given to him by the Owner's Representative. B. All careless or incompetent personnel shall be removed forthwith by the Subcontractor when he is notified to do so by the Owner's Representative or his authorized representative. 1.24 SAFETY PRECAUTIONS A. Comply with all of the safety requirements of OSHA throughout the entire construction period of the project. B. Furnish and maintain proper guards for prevention of accidents and provide any other necessary construction required to secure safety of life and property. 1.25 WORKMANSHIP A. The work included in the contract shall be executed as rapidly as possible, consistent with good workmanship. B. All piping shall be run in the most direct, straight and mechanical manner and be properly graded. Where drainage pipes terminate under this contract the invert elevations at such points shall be established by this Subcontractor. C. The Subcontractor shall perform the installation in a thoroughly professional manner with competent and skilled personnel. D. All piping shall be accurately fitted and no pipe shall be installed under a strain. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 14 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc B. The Subcontractor shall be responsible for any consequences arising from carelessness,negligence or dishonesty of those in his employ; he shall be responsible for and make good on any improper work or materials entering into the construction of the work, and hold the Engineer free from any and all claims, whatsoever in nature, arising during the erection and completion of this work. 1.19 TRANSFERRING OF INFORMATION A. Obtain detailed information from the manufacturers of the apparatus to be furnished as to the proper method of installing and connecting same. Obtain all required information from the other trades necessary to facilitate and complete the fire protection installation. B. It shall be the Subcontractor's responsibility to keep apprized as to the shape, size and position of all openings required for materials and equipment under this section and give full information to be other trades sufficiently in advance to allow proper access requirements. C. In case of failure on the part of the Subcontractor to give proper information as noted above and to save delays caused by necessary approvals, the Subcontractor shall be required to have all the necessary cutting and patching performed by the appropriate trade at this Subcontractor's expense,but in any case additional work shall be performed at no additional cost. D. All information furnished by the Subcontractor shall include sleeve opening sizes and locations and all other pertinent information relative to the fire protection installation that the Engineer deems necessary for a properly coordinated installation. The dimensions of all major pieces of mechanical equipment shall be furnished and the clearances that shall be required throughout the facility to allow for the passage of same through the facility to their required installation locations shall be scheduled. 1.20 RECORD DRAWINGS A. At the completion of the contract, the Subcontractor shall submit to the Owner's Representative a complete set of legible and reproducible record drawings (sepia) showing"as-built"corrections with all superseded data removed. 1.21 LAWS, ORDINANCES AND INSPECTIONS A. File all necessary drawings and specifications,prepare all documents and obtain all required Permits and Certificates of Inspection for the work, at the Subcontractor's expense, and deliver same to the Owner's Representative before submitting the request for acceptance and final payment for the work. REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. 13 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc F. Furnish advance information on locations and sizes of all frames,boxes, sleeves, and openings needed for this Subcontractor's work to the other trades. Furnish information and provide necessary drawings to permit trades affected by the fire protection work, to install their work properly and without delay. G. As approved by the Contractor, the Subcontractor may make reasonable modifications in the layout as needed to prevent conflicts with other trades, for the proper execution of work by the other trades, or for the proper execution of this Subcontractor's work. The Subcontractor shall pay all expenses for additional openings,relocations or enlargements of existing openings through concrete floors,walls,beams and roofing. 1.16 EXTRA WORK OR OMISSIONS A. In the event of any omissions or additions to the work called for in the specifications, a deduction/extra charge shall be made by/to the Subcontractor in proportion to the work or materials omitted or added. No work shall be performed and no materials added or omitted without written orders from the Owner, signed approval of the Owner's Representative, and the signed acceptance of the Subcontractor. In giving instructions,the Owner's Representative shall have the authority to make minor changes in the work which does not involve extra cost nor is inconsistent with the purpose and intent of the plans and specifications. 1.17 CLAIMS FOR EXTRAS A. Should the Subcontractor deem any work which he is called upon to perform extra to the Contract,by drawings or otherwise, he shall give the Owner's Representative written notice to that effect and await instructions before proceeding to execute such work. The Owner's Representative shall not be under obligation to consider claims for extra work unless so made by this Subcontractor. B. All such work shall be executed under the conditions of the original Contract, except that any claim for extension of time caused thereby shall be adjusted at the time of ordering such change. The Owner's Representative shall determine the method of computing the value of any changes to be made. 1.18 LIABILITY OF SUBCONTRACTOR A. The Subcontractor shall have sole charge and possession of the work covered by his Contract, except as otherwise specified, until it is completed and accepted by the Owner and Owner's Representative, and he shall hold the Owner and Owner's Representative harmless and protect them against all suits of any kind brought against them or on account of any liens for labor performed or material furnished. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 12 SPE-16040-15300 JAI 6040\SpecsTinahl5300-Rev-A.doc F. Provide test connections at the highest point of the main portion of each sprinkler system with a 1-inch pipe and valve. The test pipe shall be connected to the sprinkler pipe at least 1-1/4" in size and shall discharge outside the building through a full size smooth bore brass outlet. Outlet location shall be where it can be seen and in accordance with the local Fire Marshal's requirements. G. The fire protection plans are schematic representations of the work intended. Exact pipe and valve sizes, as well as locations, shall be determined once the hydraulic calculations are run by this Subcontractor. The exact location of all valves, appurtenances, and piping runs shall be coordinated with all other trades and the local Fire Marshal prior to installation. 1.15 COORDINATION A. Cooperation and coordination with all other trades in executing the fire protection work on the project is the responsibility of this Subcontractor. This Subcontractor shall not take liberties when installing the fire protection system throughout the facility. The Subcontractor shall coordinate with all other trades prior to installation, all pipe runs and system appurtenances including setting centerline elevations and pipe offsets from the facility walls. B. The Owner's Representative may request revisions. Such revisions to composite system drawings, when requested shall be made. C. Prior to submission of coordination drawings, the Subcontractor shall check approved equipment shop drawings to ascertain that they comply with the contract requirements, that the mechanical and electrical characteristics are correct, and that the dimensions submitted fit the available space. Any deviations from the Contract requirements shall not be acceptable without prior written approval from the Owner's Representative. D. If there is evidence that the fire protection work interferes with the work of any other trade in any manner, this Subcontractor shall assist in working out space conditions to make necessary and satisfactory adjustments. Coordination to avoid conflicts shall include but not limited to Electrical for location of lighting fixtures, cable trays, duct banks, and appurtenances; Mechanical for location of ductwork, diffusers,registers, and appurtenances; Process for location of process piping, instrumentation, and equipment; Structural for beams and columns, and Architectural for the facility's building footprints and finishes. E. If this Subcontractor purchases and/or installs any part of the fire protection system or appurtenance and if these systems cause any interference's with the work of other trades, this Subcontractor shall make all necessary changes in the work to correct the condition. All costs incidental to such changes shall be paid for by this Subcontractor without back-charges. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 11 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc r barricades, and smoking, and shall require all persons employed to comply with all facility or institutional regulations while on the premises. C. The Subcontractor shall conduct work so as not to interfere with the functioning of existing services. 1.13 INTERPRETATION OF DRAWINGS A. The drawings are intended to convey the general arrangement of the systems, the scope of work, and the function of those systems. B. The exact arrangement and location of piping and equipment shall be determined from shop drawings and accurate, field coordinated measurements and conditions. The Subcontractor shall provide a neat workable installation utilizing current good manufacturing practices (cGMP) and good craftsmanship. The exact locations necessary to secure the best conditions and results shall be determined at the project site with written approval from the Owner's Representative before proceeding with the installation. C. The Subcontractor shall follow the drawings in laying out the work and checking the drawings of other trades to verify spaces in which the work shall be installed. Maintain maximum headroom and space conditions at all points. Where headroom or space conditions appear inadequate, notify the Owner's Representative before proceeding with the installations. 1.14 DESIGN CRITERIA A. Secure water flow test data taken from fire hydrants nearest to the renovated areas. A minimum of 20 psi drop in pressure between the static and residual pressures shall be required to obtain accurate data. B. The renovated areas shall be protected by a system of wet pipe sprinkler heads and piping. C. This Subcontractor shall visit the site and verify the existing conditions that affect the extent of the fire protection work required in the areas relative to the location of the structural steel,pipe racks,horizontal obstructions, and alike. D. It is assumed that the pressure and flow characteristics of the fire water supply will support the proposed fire protection renovations. It is further assumed that the source of supply water is a separate fire water supply main,whereby the municipal or domestic water supply is protected by some means of backflow prevention complying with all applicable state and local codes. E. Run piping horizontally and at right angles to the structure. Slope to drain. REV. A PFI DESIGN, P.C. JANUARY 5, 2001 Pg. 10 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc proper evaluation may be made. A request for substitution only naming a trade name or dealer's name shall not be considered. C. Substitutions may be requested by the successful bidder after signing of the contract in the following manner: 1. Submit to the Owner's Representative four(4)copies of detailed data of the proposed item or items to be substituted, along with a letter notifying the Owner's Representative of the proposed change. 2. A statement indicating the amount of any change to the contract price for the proposed substitution. After reviewing the proposed change, the Owner's Representative shall inform the Subcontractor of his decision by letter. 3. The model and data specified for each item of equipment or material heading in these specifications relates to the brand name indicated and is used as the standard of quality,performance and suitability required. 4. The approval of substitution of equipment does not relieve the Subcontractor of any valid charges for additional work performed by the Owner's Representative, other Subcontractors, the Architect or the Owner's Representative. 1.11 EXAMINATION OF PREMISES A. Prior to the ordering or purchasing of any fire protection equipment or materials or the layout or installation of any work, the Subcontractor shall examine the premises and verify any and all of the existing conditions under which he shall be required to operate, or that shall in any manner affect the work under this contract. Report conditions that might affect work adversely in writing to the Owner's Representative. If any work is involved with existing equipment or services, all model numbers, sizes, electrical characteristics, etc., shall first be verified to correspond and be compatible with the work and equipment shown on the drawings. Commencement of work shall be construed as complete acceptance of existing conditions and preparatory work. 1.12 USE OF PREMISES A. The Subcontractor shall confine his apparatus, storage of materials and construction operations to such limits as may be directed by the Owner's Representative and shall not unreasonably encumber the premises with his materials. B. The Subcontractor shall enforce all instructions of the Owner and Owner's ' Representative regarding safety, signs, advertisements, fires, danger signals, REV. A PFI DESIGN, P.C. JANUARY 5,2001 Pg. 9 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc 4. Parts kit. N. Indicate hydraulic calculations,manufacturer's product data,performance data, detailed pipe layout,hangers and supports, components and accessories, field and functional testing submittals. O. Shop drawings shall include locations of cored holes and other openings,which pass through or into concrete construction. Shop drawings shall be prepared at the earliest practical date to expedite orderly progress of the work. P. Include written maintenance data on components of system, servicing requirements, and record drawings. Q. Indicate valve data and ratings. 1.9 SPECIAL REQUIREMENTS A. Hydraulic calculations and working drawings as performed by this Subcontractor shall bear the stamp and signature of approval of a registered professional engineer. They shall also bear the stamp of approval of the authority having jurisdiction, the Fire Marshall, and Factory Mutual. B. Refer to the applicable specification sections to provide the following: 1. Anchor bolts, nuts &bolts, concrete inserts, and sleeves. 2. Nameplates,nomenclature, tagging and identification. 3. Special project procedures. 4. Cathodic protection. 1.10 SUBSTITUTIONS A. Terms such as "or approved substitute" shall be understood to mean approved in equal in the opinion of the Owner's Representative. No material shall be used in "substitution"or as"equal"to that specifically designated by name in the specifications unless it has been approved in writing by the Owner's Representative. B. Requests for substitutions shall be made to the Owner's Representative, in writing,by the Bidder at least five (5) days, excluding Saturday, Sundays and legal holidays,prior to the receipt date of the bids. This request shall contain detailed material data,manufacturer's name, model and catalog numbers so that a REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. 8 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc 2. Core drill and sleeve packing and seal. 3. Valves, all types. 4. Sprinkler heads. 5. Alarm and supervisory switches. 6. Hydraulic calculations. 7. Valve and system identification. 8. Detailed and Stamped piping drawings. 9. Detailed and accurate dimensions of equipment and inserts. 10. Statement of methods of materials proposed to eliminate electrolytic action between dissimilar metals. H. Submit copies for approval and record of 1. All tests. 2. Pipe color code chart. I. Shop drawings shall include the location of pipe sleeves, core drillings, and other openings,which pass through or into concrete or steel construction. Drawings shall be prepared at earliest practicable date to expedite orderly progress of the work. J. Submit shop drawings indicating complete material data, a list of materials proposed for this project, and indicate thickness of material. K. Submit list of wording, symbols, letter size, and color coding for fire protection identification. L. Tabulate products by section number and paragraph. M. Contract closeout information: 1. Operating and Maintenance Data. 2. Owner Instruction Report. 3. Guarantees. REV. A PFI DESIGN, P.C. JANUARY 5,2001 Pg. 7 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc J. The Subcontractor shall become familiar with all details of the work, verify dimensions in the field, and advise the Owner's Representative of any discrepancy before performing the work. K. Valves shall bear UL and FM labels or markings. Provide manufacturer's name and pressure ratings marked on valve body. 1.8 SHOP DRAWINGS AND SUBMITTALS A. Submit for approval by the Owner's Representative shop drawings for equipment and materials proposed for installation prior to ordering,purchasing, or fabricating equipment or materials. Drawings shall be catalog cuts,material lists, and samples where necessary, containing complete performance data, engineering calculations, dimensions,power requirements, descriptions, installation requirements and particulars. Submittals only naming a trade name or dealer's name shall not be considered. B. Work shall not commence before the approval of the Owner's Representative has been received. Data shall be submitted sufficiently in advance of the work to allow proper time for examination and correction. C. The Owner's Representative's approval of submittals or data shall not relieve this Subcontractor from the responsibility for deviations from drawings and specifications, unless he has, in writing, called the Owner's Representative's attention to such deviations at time of submission. D. This Subcontractor shall check all shop drawings and submittals data for compliance with the plans and specifications shall stamp his approval on all such shop drawings and submittals prior to his submitting them for review and approval by the Owner's Representative. E. The Subcontractor shall review and check all shop drawings and submittals data. Prior to submitting shop drawings and submittals data,this Subcontractor shall affix a stamp indicating that he has determined and verified all field measurements and quantities, field construction"criteria, materials, catalog numbers and similar data, and that he has reviewed and coordinated the information in the shop drawings and submittals data with the requirements of work and the contract documents. F. Failure to comply with these stipulations shall cause immediate rejection of submittals. G. Equipment and materials requiring submittals for approval shall include,but not be limited to the following: 1. Pipe materials and fittings. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 6 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc 1.7 QUALITY ASSURANCE A. For each product specified,provide components by same manufacturer throughout. B. Materials shall be labeled with manufacturer's pertinent information. Materials and equipment shall be delivered in non-broken, factory-furnished packaging and stored in a clean, dry indoor space that provides protection against the weather. C. Welding Materials and Procedures: Conform to ASME Code and applicable state labor regulations. D. Welders Certification: In accordance with ANSFASME Section 9 and ANSFAWS D1.1. E. Progressive testing of the systems to be insulated shall be completed, inspected and approved by the Owner's Representative before insulation is applied. F. Equipment and Components shall bear UL and FM labels or markings. G. Welding shall be in accordance with latest applicable American Welding Society Code (AWS). Qualifications shall be as follows: 1. Provide certification that welders to be employed for work have passed AWS qualification tests. If re-certification of welders is required, re-test at no additional cost to the Owner. 2. Employ certified welders in accordance with ANSFASME Section 9 or AWS D10.9. H. Except as modified herein,work shall conform to the required and advisory provisions of NFPA and the Massachusetts Building Code for equipment, materials, installation,workmanship, examination, inspection and testing. Include materials, accessories and equipment for each system to be complete and ready for use. Provide each system to accommodate piping, electrical equipment, and other construction and equipment as indicated. Provide devices and equipment for fire protection service that is UL listed or FM approved for use in fire protection systems. In the NFPA publications referenced,the advisory provisions are considered to be mandatory, as though the word"shall" had been substituted for the word "should" wherever it appears. I. Provide materials and equipment,which are products of a manufacturer engaged in the manufacture of the products specified for at least the past five(5)years. Provide products that are equivalent to those that have been in operation in at least five(5) facilities.for a minimum of two (2)years. REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. 5 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc 11. Current Good Manufacturing Practices. 12. Requirements of the Owner's Insurance Underwriter. 1.6 REFERENCES A. ANSFASME B 16.3 - Malleable Iron Threaded Fittings, Class 150 and 300. B. ANSFASME B16.4 - Cast Iron Threaded Fittings, Class 125 and 250. C. ANSFASME B36.10 -Welded and Seamless Wrought Steel Pipe. D. ANSI/ASTM A47 -Malleable Iron Castings. E. MSS-SP-80 -Bronze, Gate, Globe, Angle and Check Valves. F. ASTM Al 81 -Malleable Iron. G. ASTM Al 82 - Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings. H. AWWA C606 - Cut Groove Fittings. I. ASTM A53 -Pipe, Steel, Black and Hot-Dipped,Zinc-coated(Galvanized) Welded and Seamless. J. ASTM A120 - Pipe, Steel, Black and Hot-Dipped, Zinc-coated(Galvanized) Welded and Seamless, for Ordinary Uses. K. AWS D10.9 - Specifications for Qualification of Welding Procedures and Welders for Piping and Tubing. L. ANSFASME Section 9 -Welding and Brazing Qualifications. M. ANSFASME B32 - Solder Metal. N. ANSFASME A13.1 - Scheme for the Identification of Piping Systems. O. ANSI/NFPA 70 -National Electric Code. P. AWS - Standard manual of pipe welding of the Heating and Piping Subcontractor's National Association. Q. AWS A5.8 -Brazing Filler Metal. R. State and Local Fire Marshals. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 4 SPE-16040-15300 JAI 6040\SpecsTinahl 5300-Rev-A.doc B. No additional compensation shall be granted for work, which must be changed as a result of the work not originally complying with codes, standards, etc., and not in accordance with the multiple trade coordination design criteria set forth. C. The Subcontractor shall file all drawings,pay all fees and obtain all permits and certificates of inspection relative to this work. The Subcontractor shall arrange inspection with proper authorities and include costs of inspections in his bid. . D. The Subcontractor shall arrange for and schedule the proper inspections required by the authorities having jurisdiction and schedule such inspections, giving the Owner's Representative a minimum of 48 hours advance notice such that the inspections may be witnessed. Copies of all permits and certificates of inspection shall be forwarded to the Owner's Representative. E. If the code or other requirements exceed the provisions indicated in the Contract Documents, the Owner's Representative shall be notified in writing. Where the work indicated on the Contract Documents exceeds code requirements, the installation shall be done in accordance with the Contract Documents. Any work done contrary to these requirements shall be removed and replaced at the expense of thexesponsible Subcontractor. F. The fire protection layout, workmanship, methods, and materials shall meet the highest standards of the trade and shall conform to the latest editions of the following associations: 1. Massachusetts Building Code, latest applicable edition. 2. Requirements of the Town of Northampton, Massachusetts, applicable local codes, and the authorities having jurisdiction. 3. National Fire Protection Association(NFPA), latest applicable sections. 4. American National Standards Institute(ANSI). 5. American Society for Testing Materials (ASTM). 6. National Bureau of Standards (NBS). 7. National Electrical Manufacturers Association(NEMA). 8. National Electric Code (NEC). 9. Occupational Safety and Health Act(OSHA). 10. Underwriters' Laboratories (UL). REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. 3 SPE-16040-15300 J:\16040\Specs\Final\15300-Rev-A.doc C. The fire protection work shall include,but not be limited to,the following items: 1. Shop drawings for materials and equipment. 2. Wet and dry pipe automatic sprinkler piping, alarm check valves, fittings, connections, and appurtenances. 3. Inspector's test connections and drains. 4. Sprinkler and spare heads. 5. Hydraulic calculations and working drawings. 6. Tags, charts,valve and system identification. 7. All core drilling necessary to complete the work under this section. 8. Hangers, supports, anchors, inserts and seals, conforming to local seismic requirements. 9. Cleaning and pressure testing of piping systems. 10. System identification. 11. Guarantees. 12. Record drawings. 1.4 RELATED WORK SPECIFIED ELSEWHERE A. Reference Division 1 requirements for temporary utilities such as water, fuel, electricity and sanitary facilities required during construction. 1.5 CODES AND STANDARDS A. All work shall be installed in conformance with the governing codes,regulations, local ordinances, and authorities having jurisdiction. It shall be the responsibility of the Subcontractor to familiarize himself with all governing codes and requirements and report any noncompliance of the plans and specifications to the Owner's Representative,prior to entering into the contract, and all the above requirements shall take precedence over the plans and specifications. These requirements are minimum criteria and no reductions permitted by code shall be allowed without written permission of the Owner's Representative. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 2 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc FIRE PROTECTION SECTION 15300 1.0 GENERAL 1.1 DESCRIPTION OF WORK A. The work under this Section of the Specifications shall include the furnishing and installation, herein referred to as "provide,"of all labor,materials, equipment and services required for a complete fire protection system. All new fire protection work for the renovated areas shall be done by a licensed fire protection contractor, as required by the State of Massachusetts, herein referred to as the Subcontractor, in strict accordance with applicable sections of NFPA, National Fire Code, Factory Mutual, and the local authorities having jurisdiction. These requirements are the minimum criteria and no reductions shall be permitted without written permission by the engineer. This Subcontractor shall make the fire protection system ready for regular operation and use by The Minute Maid Company, herein referred to as the "Owner." B. Facility work shall include additions to existing wet and dry pipe sprinkler systems, and installation of new piping,valves, heads, and fittings. 1.2 GENERAL REQUIREMENTS A. Examine all other sections of the project's contract specifications for requirements,which affect the work of this section whether or not such work is specifically noted herein. B. Coordinate work with that of other trades affecting or affected by the work of this section. Cooperate with all other trades such that work progresses smoothly without interference to other trades. 1.3 SCOPE OF WORK A. Perform work and provide all permits, transportation, freight, materials, appurtenances, machinery, equipment, tools, loading, unloading, rigging, blocking,core-drilling, testing, labor and supervision necessary, as shown on the drawings and as specified in the specifications, to install, complete, and make ready for continuous operation, all fire protection work. B. Drawings and Specifications form complementary requirements. Provide work specified and not shown, and work shown and not specified as though explicitly required by both. Although some work may not be specifically shown or specified,provide supplementary or miscellaneous items, appurtenances, devices and materials obviously necessary for a sound, secure and complete installation. REV. A PFI DESIGN,P.C. JANUARY 5,2001 Pg. 1 SPE-16040-15300 JAI 6040\Specs\Fina1\15300-Rev-A.doc 3.16 HYDRAULIC CALCULATIONS ....................................................................................34 3.17 TESTING AND FLUSHING............................................................................................35 3.18 COMMISSIONING OF SYSTEMS..................................................................................35 3.19 CHARTS AND SPARE SPRINKLERS............................................................................36 3.20 IDENTIFICATION............................................................................................................3 6 REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. iii SPE-16040-15300 JAI 6040\Specs\Final\15300-Rev-A.doc 1.44 TESTING AND ADJUSTING..........................................................................................20 1.45 CERTIFICATES OF APPROVAL ...................................................................................20 1.46 GUARANTEE...................................................................................................................20 1.47 MAINTENANCE MANUALS .........................................................................................21 1.48 POWER WIRING..............................................................................................................21 1.49 ELECTRICAL WORK......................................................................................................21 1.50 CLEAN UP AND REMOVAL OF RUBBISH.................................................................21 2.0 PRODUCTS ......................................................................................................................22 2.1 MATERIALS ....................................................................................................................22 2.2 ACCEPTABLE MANUFACTURERS.............................................................................22 2.3 PIPE AND FITTINGS.......................................................................................................23 2.4 JOINT MATERIALS........................................................................................................23 2.5 UNIONS,FLANGES, COUPLINGS................................................................................23 2.6 PIPE AND VALVE SPECIALTIES.................................................................................24 2.7 GATE VALVES................................................................................................................24 2.8 DRAIN VALVES..............................................................................................................24 2.9 BUTTERFLY VALVES ...................................................................................................24 2.10 VALVE CONNECTIONS.................................................................................................24 2.11 SPRINKLER HEADS .......................................................................................................25 2.12 INSERTS ...........................................................................................................................25 2.13 PIPE HANGERS AND SUPPORTS.................................................................................25 2.14 EXPANSION JOINTS.......................................................................................................25 2.15 PIPE ANCHORS AND GUIDES......................................................................................25 2.16 FIRE PROTECTION SYSTEM IDENTIFICATION MATERIALS ..............'.................26 2.17 PENETRATIONS AND CORE DRILLING.....................................................................26 2.18 CATHODIC/ELECTROLYTIC PROTECTION..............................................................28 2.19 GENERAL.........................................................................................................................28 2.20 SPARE PARTS AND SPECIAL TOOLS.........................................................................28 3.0 EXECUTION....................................................................................................................28 3.1 SUBCONTRACTOR RESPONSIBILITIES....................................................................28 3.2 MATERIALS AND WORKMANSHIP ...........................................................................29 3.3 CONTINUITY OF SERVICES ........................................................................................29 3.4 PREPARATION................................................................................................................29 3.5 PENETRATIONS .............................................................................................................30 3.6 PIPING AND FITTING INSTALLATION......................................................................30 3.7 VALVE INSTALLATION................................................................................................32 3.8 INSERT INSTALLATION...............................................................................................33 3.9 PIPE HANGERS AND SUPPORT INSTALLATION.....................................................33 3.10 ESCUTCHEON PLATE INSTALLATION......................................................................33 3.11 ANCHOR INSTALLATION.............................................................................................33 3.12 FLASHING INSTALLATION..........................................................................................33 3.13 EQUIPMENT INSTALLATION......................................................................................34 3.14 WELDING.........................................................................................................................34 3.15 WIRING.............................................................................................................................34 REV. A PFI DESIGN,P.C. JANUARY 5, 2001 Pg. ii SPE-16040-15300 JAI 6040\SpecsTinaAl5300-Rev-A.doc TABLE OF CONTENTS 1.0 GENERAL...........................................................................................................................1 1.1 DESCRIPTION OF WORK................................................................................................1 1.2 GENERAL REQUIREMENTS...........................................................................................1 1.3 SCOPE OF WORK.............................................................................................................1 1.4 RELATED WORK SPECIFIED ELSEWHERE................................................................2 1.5 CODES AND STANDARDS .............................................................................................2 1.6 REFERENCES....................................................................................................................4 1.7 QUALITY ASSURANCE...................................................................................................5 1.8 SHOP DRAWINGS AND SUBMITTALS.........................................................................6 1.9 SPECIAL REQUIREMENTS.............................................................................................8 1.10 SUBSTITUTIONS...............................................................................................................8 1.11 EXAMINATION OF PREMISES.......................................................................................9 1.12 USE OF PREMISES............................................................................................................9 1.13 INTERPRETATION OF DRAWINGS.............................................................................10 1.14 DESIGN CRITERIA .........................................................................................................10 1.15 COORDINATION.............................................................................................................11 1.16 EXTRA WORK OR OMISSIONS....................................................................................12 1.17 CLAIMS FOR EXTRAS...................................................................................................12 1.18 LIABILITY OF SUBCONTRACTOR..............................................................................12 1.19 TRANSFERRING OF INFORMATION..........................................................................13 1.20 RECORD DRAWINGS.....................................................................................................13 1.21 LAWS, ORDINANCES AND INSPECTIONS................................................................13 1.22 COMPLETENESS OF WORK.........................................................................................14 1.23 WORK PERSONNEL.......................................................................................................14 1.24 SAFETY PRECAUTIONS................................................................................................14 1.25 WORKMANSHIP .............................................................................................................14 1.26 PROTECTION OF WORK AND PROPERTY.................................................................15 1.27 SURVEYS AND MEASUREMENTS..............................................................................15 1.28 EXISTING BUILDING SERVICES AND UTILITIES ...................................................15 1.29 SELECTION AND ORDERING OF MATERIALS ........................................................16 1.30 NAMEPLATES.................................................................................................................16 1.31 DELIVERY, STORAGE AND HANDLING OF EQUIPMENT AND MATERIALS....16 1.32 EXTRA STOCK................................................................................................................17 1.33 CUTTING AND PATCHING...........................................................................................17 1.34 UTILITIES.........................................................................................................................17 1.35 REMODELING.................................................................................................................18 1.36 TEMPORARY OPENINGS..............................................................................................18 1.37 ACCESSIBILITY..............................................................................................................18 1.38 ACCESS PANELS ............................................................................................................18 1.39 FIREPROOFING...............................................................................................................18 1.40 SUPPLEMENTARY STEEL, CHANNELS AND SUPPORTS ......................................19 1.41 FASTENERS AND HANGERS........................................................................................19 1.42 PORTABLE OR DETACHABLE PARTS...................................................................'....20 1.43 CATHODIC/ELECTROLYTIC PROTECTION..............................................................20 REV. A PFI DESIGN, P.C. JANUARY 5,2001 Pg. i SPE-16040-15300 JAI 6040\Specs\Final\15300-Rev-A.doc lEt}`4[ I 1 kY PFI DESIGN,P.C. SPECIFICATION FOR FIRE PROTECTION SPE-16040-15300 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 Rev. Date Description,:, Admin Pre aced Checked Approved - A 1105101 Issue for Bid KAB KMCI,#4G AJFA0 HM Client Approval: Client: Date: may be required. At the conclusion of each such test, this Subcontractor shall submit a letter signed by the officer stating: 1. The individual is an officer of the company. 2. The individual has personally witnessed the tests (provide name). 3. Test dates. 4. Test results as compared to specified performance. 5. List the name, title and company affiliation of all those witnessing the test. D. All piping and systems testing require letters. ++END OF SECTION 15401 ++ REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 28 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc B. Provide services of qualified personnel, equipment and apparatus required to perform tests. C. A hydrostatic test shall be made of all parts of the drainage system, EXCLUSIVE of the sanitary process waste system,before the pipes are concealed. The test may be made in sections. All openings on the section to be tested shall be tightly closed except for the highest opening, and the entire section filled with water. Trapped air shall be bled from all dead ends of the section being tested. After air has been expelled, all parts of the system shall be subjected to 10 feet of hydrostatic head(4.3 pounds per square inch)without leaks. Individual systems tested shall be properly restrained at all bends, changes or directions, and at ends or runs. D. In lieu of a hydrostatic test, an air test shall be applied to all parts of the drainage system, EXCLUSIVE of the sanitary process waste system,before the pipes are concealed. With all openings tightly closed,pump air into the system until the pressure within the system is not less or greater than 5 pounds per square inch above atmospheric pressure. The air gauge used should slow a constant pressure with no further pumping of air into the system. E. Before date of acceptance,provide Contractor with certificates of testing and inspection indicating approval of authorities having jurisdiction and conformance with requirements of Contract Documents. 3.13 COMMISSIONING OF SYSTEMS A. The Contractor shall check the completed installation either sequentially as different parts are completed, or when the entire installation is complete, at the sole option of the Contractor. B. Prior to the Contractor's checking of part of this installation or the entire installation, this Subcontractor shall submit a letter signed by an officer of this Contracting company or the Contractor stating: 1. The individual is an officer of the company. 2. The individual has personally inspected the installations. 3. Inspection dates. 4. The installation is complete and tested and ready to be inspected by the Contractor, and that all required test reports have been submitted. C. The Subcontractor shall arrange for an officer of this Contracting company or of the Contractor to witness the listed tests, as well as to other test witnesses that REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 27 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc B. All floor drain outlets shall be caulked and sealed to their respective inlet pipes. The caulking or sealant used shall be unaffected by the materials being drained. C. Mount all floor and trench drains flush with finish flooring to prevent tripping. D. Floor drains shall be at the lowest point of floor area. E. Contractor to verify the exact location of the new trench and floor drains prior to installation. 3.10 FLOOR CLEANOUT INSTALLATION A. Before setting any cleanout, the Subcontractor shall obtain from the Contractor the exact information relative to finish grade at top of the floor cleanouts. B. Provide cleanouts in piping on straight runs, at changes in directions, and at the foot of stacks and other points where required by inspecting authorities. Cleanouts shall suit construction in which they are to be installed. C. Cleanouts shall be same size as pipe 4" and smaller. Cleanouts for piping larger than 4" shall not be less than 4'.' in diameter. No reduction in cleanout sizes for pipe 4" and smaller is permitted. D. Bodies of floor cleanout ferrules in bell and spigot piping shall be standard pipe sizes conforming in thickness to that required for pipe and fittings, and shall extend not less than 3/4" above hub of pipe. E. Cleanouts shall open in direction of flow of drainage line served or at right angles thereto. F. Keep cleanout plugs clean and unimpeded. Prevent covering cleanouts with cement,plaster or other permanent finishing materials. G. Lubricate all cleanout plugs with proper grease to prevent galling. H. Mount all floor cleanouts flush with finish flooring. 3.11 SPECIALTY INSTALLATION A. Install all specialties in accordance with manufacturer's instructions to permit intended performance. 3.12 TESTING OF UNDERSLAB PLUMBING SYSTEMS A. Testing,balancing and adjusting shall not relieve guarantee requirements. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 26 SPE-16040-15401 JA16040\Specs\Fina1115401-REV 0-doc a Q. Unless otherwise noted, field paint all exposed piping to comply with cGMP standards or with The Minute Main Company facility standards,whichever is more stringent. R. Horizontal piping: 1. Stabilize piping in position by partial backfilling and cradling to maintain proper alignment during backfilling. 2. Piping laid on grade shall be adequately secured to prevent misalignment when slab is poured. 3.7 BEDDING OF PIPING AND FITTINGS A. This Subcontractor is responsible for the bedding of all underslab piping. B. Interior buried drainage piping systems shall be bedded on 6" minimum of sand bedding, spread and tamped to prevent pipe deformation. All rocks shall be removed from trench before placement of sand. Piping systems shall then be backfilled with clean, select granular backfill material, free from rocks,roots, wood, cinders, and construction debris, for entire trench(6" minimum beyond each side of pipe). The remaining trench shall be evenly and continuously backfilled in uniform layers with this suitable backfill. No backfilling shall commence until all pipe testing and inspections have been made by the authorities having jurisdiction. C. Bedding of all waste piping system and appurtenances shall be in accordance with the pipe manufacturer's installation instructions if above methods are unacceptable to the Contractor. 3.8 JOINTS AND CONNECTION INSTALLATION A. Joints and connections shall be permanent and shall be gas and water-tight. Jointing shall be types specified for service indicated. Joints and connections shall meet requirements of manufacturer's recommended practice. Adapters for transitions between two types of piping materials shall be manufactured for the purpose intended. 3.9 FLOOR DRAIN AND TRENCH DRAIN INSTALLATION A. Before setting drains,the Subcontractor shall obtain from the Contractor the exact information relative to finish grades and elevations at top of the drains. The Subcontractor shall refer to the floor drain manufacturer's factory procedures for the exact method of floor drain installation. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 25 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc C. Route piping in orderly manner and maintain slope gradient. D. Install piping to conserve facility space and not interfere with use of space. E. Group piping at common elevations where ever practical. F. Install piping to allow for expansion and contraction without stressing pipe,joints, or connected equipment. G. All piping shall be accurately fitted and no pipe shall be installed under a strain. H. All drain outlets connecting into process waste drain piping shall be made using materials as recommended by the pipe manufacturer. I. Install process waste piping system in accordance with the manufacturer's installation standards. J. The Subcontractor shall install floor cleanouts at-locations required by Code for the sanitary process waste drainage system as shown on the Underslab Plumbing Systems Floor Plan. K. The Subcontractor shall not allow dirt, debris, or other extraneous materials to contaminate the underslab waste piping or fittings. The Subcontractor shall protect all pipe and fittings from sunlight until installed. L. Gaps at the joints between the floor drain/cleanout body outlets and the corresponding drainage piping inlets shall not be permitted. The Subcontractor shall set piping properly and apply the proper sealant to the joints to prevent water seepage. Ensure sealant used will not be affected by drainage effluent. M. The Subcontractor shall make as many field welds and interconnections between the fittings and piping as possible in lieu of using pre-purchased, factory assembled piping systems due to the extent that the pre-fabricated piping is inversely proportional to the degrees of freedom available for field modifications on site. N. The Subcontractor shall commence each system's invert elevations at the furthest floor drain to the connection point, if possible, and work the inverts out to these connection points to insure that proper slopes are maintained. The Subcontractor shall not work invert elevations from the site back into the building. O. Establish invert elevation slopes for drainage at 1/8 inch per foot,minimum for pipes 4" and larger, and 2% slope for pipes less than 4"diameter. P. Install bell and spigot pipe with bell end upstream. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 24 SPE-16040-15401 JAI 6040\Specs\Final\15401-REV O.doc 3.3 CONTINUITY OF SERVICES A. The Subcontractor shall not interrupt existing services without Contractor's approval and as specified. 3.4 PREPARATION A. Ream pipe and tube ends. Remove burrs and sharp edges by peening or filing the edge. B. Clean and remove scale, dirt,mud, gravel and other foreign material on the inside and outside of pipe and/or fittings before assembly. C. Prepare all surfaces in accordance with manufacturer's installation instructions. D. De-grease and clean all surfaces which shall receive adhesive or solder. 3.5 PENETRATIONS A. Installation Testing, Listings and Approvals: 1. Installation shall meet material manufacturer's installation instructions exactly,particularly in regards to preparation of surfaces,removal of foreign materials, safety requirements, ventilation and other details of installation. Dam openings as recommended. Remove flammable materials used for damming and forming seals in fire-rated construction. 2. Core drill seals shall be water- and gas-tight and shall meet the requirements of ASTM E-119 Standard Methods of Fire Tests of Building Construction and Materials. 3. Inspect sealant to ensure that installation achieves manufacturer's optimum structure. 3.6 UNDERSLAB PIPING AND FITTING INSTALLATION A. The Subcontractor shall be responsible for the purchase/rental time for the manual/power tools required for the pipe installation as well as training time for the Subcontractor's personnel. The Subcontractor shall review and become familiar with the general installation instructions and proper tool use recommendations. B. It shall be the Subcontractor's responsibility to thoroughly double check and verify,with the Contractor, all invert elevations shown on the contract drawings for continuity prior to purchase or installation of any pipe or system and shall adjust said inverts to achieve design objective. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 23 SPE-16040-15401 JAI 6040\SpecsTinaA15401-REV O.doe C. Observations by Owner: 1. Periodic observations by Owner, Architect or designated agent shall not be construed as supervision of actual construction, nor make either responsible for providing safe place for performance of work of various trades or suppliers, or for visitors or occupants, or make either responsible for omission of safety devices called for by codes, ordinances,or specifications of manufacturer of equipment supplied. D. Surveys and measurements: 1. The Subcontractor shall establish reference points to base his measurements,both horizontal and vertical, and be responsible for correctly laying out the work. 2. In the event of a discrepancy between the actual measurements and those indicated, the Subcontractor shall notify the Contractor in writing and not proceed with work until written instructions have been issued by Contractor. E. The Subcontractor shall provide for the necessary materials manufacturer's authorized factory personnel, on site, for final plumbing systems inspections,prior to backfilling, and shall include incidental costs in his bid. 3.2 MATERIALS AND WORKMANSHIP A. Work shall be neat and rectilinear. Install materials and equipment as recommended by manufacturer. Installation shall operate safely and without leakage,undue wear,noise, vibration, corrosion, or water hammer. Use dielectric nipples between dissimilar materials. Close pipe openings to prevent obstruction and damage prior to completion. B. Except as specified otherwise, all materials shall be new. Provide supplies, appliances and connections necessary for complete and operational installation. C. References to manufacturers and catalog designations are intended to establish standards of quality for performance and materials but imply no further limitation of competitive bidding. D. Finish of materials,components and equipment shall be approved by the Contractor and shall be resistant to corrosion and weather. E. Contractor shall not be responsible for materials and equipment before final acceptance. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10,2000 Pg. 22 SPE-16040-15401 JAI 6040\.Specs\Fina1115401-REV O.doc C. Penetrations through walls, floors, or ceilings to accommodate piping and appurtenances shall not increase the sound transmission class (STC) of construction. 2.8 CATHODIC/ELECTROLYTIC PROTECTION A. Provide ASTM F-492-77 Victaulic "Clearflow" Style 47 dielectric waterway nipples to inhibit galvanic corrosion between dissimilar metals in the presence of water. 3.0 EXECUTION 3.1 SUBCONTRACTOR'S INSTALLATION RESPONSIBILITIES A. Installation Items: 1. Where this Subcontractor is required to install items which he does not purchase,he shall coordinate their delivery and be responsible for their unloading from delivery vehicles and for their safe handling and field storage up to the time of installation. This Subcontractor shall be responsible for: a. All field assembly and internal connections,as well as mounting systems of piping including the purchase and installation of all supporting members and fastenings necessary to adapt and connect them out to the facility's utility systems. b. Their connection to the utility systems including the purchase and installation of all terminating fittings necessary to adapt and connect them to the facility's utility systems. 2. The Subcontractor shall carefully examine materials upon delivery. Claims that any of these materials have been received in such condition that their installation shall require procedures beyond the reasonable scope of work of this Subcontractor shall be considered only if presented in writing within one week of their data of delivery. Unless such claims have been submitted,this Subcontractor shall be fully responsible for the complete reconditioning or replacement of the damaged items. B. Maintenance of systems: 1. Maintain systems until final acceptance. Ensure adequate protection of materials during delivery, storage, installation and shutdown, and during delays pending final test of systems and equipment because of seasonal conditions. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 21 SPE-16040-15401 J:\16040\Specs\Fina1\15401-REV O.doc 2.6 BURIED UTILITY WARNING TAPE A. As required by the Contractor,provide an approved detectable aluminum foil plastic backed tape or detectable magnetic plastic tape manufactured specifically for warning and identification of buried piping per Owner's plant standards. Tape must be detectable by an electronic detection instrument. Provide tape in rolls, 3 inches minimum width, color coded for the utility involved,with warning and identification imprinted in bold black letters continuously and repeatedly over entire tape length. Warning and identification to read"CAUTION BURIED PIPING BELOW". Provide approved permanent code and letter coloring unaffected by moisture and other substances contained in trench backfill material. 2.7 PENETRATIONS AND CORE DRILLING A. This Subcontractor may make neat, cored holes with the written consent and approval of the Contractor and the Structural Engineer. The locations of the openings shall be laid out in advance and indicated with chalk. The sizes, locations and dimensions of the openings shall be checked and verified against the equipment and general arrangement plans by the Contractor prior to any core drilling. 1. The Subcontractor shall thoroughly investigate all piping systems and structural conditions in the vicinity of all openings prior to coring. The Subcontractor shall not disturb existing systems unless as specified. 2. The Subcontractor shall be responsible for all damages to the facility and its systems from core drilling operations. 3. For slab on grade construction,provide waterproofing membrane locking devices at floor penetrations. 4. Waterproof pipe penetrations (not for use for slotted concrete) shall include modular mechanical penetration seals with interlocking synthetic rubber links with galvanized carbon steel nuts,bolts, and pressure plates.to expand the rubber seals to make a watertight seal for the annular space between the pipe and the concrete opening. The seal shall be completely watertight, and shall be"Linkseal"Modular Mechanical Type Interlocking Links. B. For pipes which extend from the dry area above grade into a possible wet area below grade or where vibration suppression is required between the pipe and the concrete element through which it passes (not for use for slotted concrete),the pipe penetration shall be sealed with neoprene gaskets and compression flanges to ensure a watertight seal between the pipe and the wall, etc., surrounding the pipe. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 20 SPE-16040-15401 J:\16040\Specs\Fina1\15401-REV O.doc E. Hangers: Carpenter&Paterson, Grinnell,Michigan Hanger Co., or approved substitute. Except as otherwise noted,hanger and support figure numbers referred to are those of Carpenter&Paterson. F. Items of the same function and performance shall be acceptable if submitted and approved in conformance with the requirements of Division I. 2.3 WASTE AND VENT PIPING,BURIED A. Piping and fittings shall be manufactured using the same materials and manufacturer throughout. B. The Subcontractor shall provide the pipe manufacturer's end or terminating seals for the waste piping that terminates at all floor drains, floor cleanouts and trenchdrains. C. Due to the approximate depth of the existing underslab waste piping and structural features of the renovated areas, all new waste piping shall be run at the minimum allowable slope, as allowed by the local authority. 2.4 FLOOR AND TRENCH DRAINS A. Floor and trench drains shall be as scheduled on the drawings. B. Provide each floor drain and trench drain with a round,beveled, gas and watertight, heavy-duty stainless steel cover/plug with watertight gasket and lifting handle. Watertight covers/plugs shall be as manufactured by Josam. C. Provide pipe fitting gaskets for the anticipated wastes and temperatures encountered between each drain connection and its associated piping. The Subcontractor shall verify exact waste substances with Contractor's authorized personnel prior to bid submission or purchase. D. The Subcontractor shall submit with his bid separate unit prices for each floor drain specified as the types of floor drains delineated on the Underslab Plumbing Systems Floor Plan drawing have not been finalized as of this issue and is therefore subject to change. 2.5 FLOOR CLEANOUTS A. Process waste floor cleanouts shall be corrosion resistant manufactured from PVDF material conforming to ASTM D 3222, ferrule supplied with countersunk plug and adjustable top with square nickel bronze cover,with AWCO (Acid Waste Cleanout) cast in the cover. Orion or equal. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 19 SPE-16040-15401 JAI 6040\Specs\Final\15401-REV O.doc 1. PIPING SPECIFICATION: PP 1 SERVICE: Process Waste,Process Vent MAXIMUM OPERATING CONDITIONS: Gravity at 120°F ITEM SIZES GENERAL DESCRIPTION PIPING,BELOW All Schedule 40 polypropylene, flame retardant, GRADE DWV pattern. FITTINGS All DWV pattern schedule 40, fittings based on laying length dimensions in ANSI B16-12 wall thickness; shall conform to ASTM D2122 Section 4. JOINTS All Fusion method with fusion coils or fixed fusion fittings fabricated in accordance with manufacturer's recommendations. Joints made between polypropylene pipe and dissimilar materials shall be made with proper adapters and transitional fittings according to manufacturer's recommendations. PIPING, ABOVE All Schedule 40 flame retardant pipe(PPFR) GRADE manufactured to meet Schedule 40 iron pipe size dimensional standards in accordance with ASTM D2122, Section 4 and 7. FITTINGS All DWV pattern, flame retardant Schedule 40 fittings based on laying length dimensions in ANSI B16-12 wall thickness and shall conform to ASTM D2122, Section 4. 2.2 ACCEPTABLE MANUFACTURERS A. Process waste and process vent piping system and appurtenances: Enfield, Orion, or approved substitute. B. Trench drains: Polycast,presloped trench drain system. C. Floor drains: Enfield, Orion or approved substitute. D. Floor cleanouts: Enfield, Orion or approved substitute. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 18 SPE-16040-15401 JAI 6040\,SpecsTinahl5401-REV O.doc e C. All items shall be secured and in their final positions and shall present a neat and workmanlike appearance. D. All temporary bracing, cross ties and a like shall be removed. D. All items shall serve the purpose for which they are intended, i.e. to support, anchor, frame,block-out, etc. Finish items to present accurate,true,plumb, finished and completed appearances. E. All stains and/or damage done to the finish of the facility that is caused by faulty workmanship and/or improper handling of materials regarding to this installation shall be cleaned,removed and/or replaced. 2.0 PRODUCTS 2.1 MATERIALS A. All materials shall conform to the requirements of the Local Codes, Federal Specifications and/or standards listed as commercial and the requirements specifically stipulated herein. B. Each length of pipe, fitting,piece of material and/or device used in the underslab plumbing piping systems shall have cast, stamped, or indelibly marked on it,the manufacturer's name or mark, type, schedule and applicable ASTM/ASME standard numbers. C. Piping Material Index SPEC SERVICE DESIGNATION MATERIAL PRESSURE TEMP TYPE PSIG DEG. F PP 1 Process Waste PW Polypropylene Gravity 120°F Process Vent PV REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 17 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc 1.38 CERTIFICATES OF APPROVAL A. Upon completion of all work and after the necessary periodic inspections by the authorities having jurisdiction have been made, copies of inspection reports and approvals shall be forwarded to the Contractor by this Subcontractor. B. Refer to Contractor for requirements pertaining to substantial completion and Final Acceptance, all of which shall be provided for under this section. 1.39 GUARANTEE A. Manufacturers shall provide their standard warranties for materials and equipment provided under this section. Such warranties shall be in addition to and not in lieu of all liabilities which the manufacturer and Subcontractor may have by law or by provisions of the Contract Documents. It shall be the responsibility of the Subcontractor to obtain from the piping and equipment manufacturers written guarantees covering their respective equipment for the above period of time. B. All materials, equipment and work provided under this section shall be guaranteed, by this Subcontractor, against all defects in materials and workmanship for a period of 1.8 months commencing with the date of final acceptance. Any failure due to defective material, equipment or workmanship which may develop, shall be corrected at no expense to the Owner including all damage to areas,materials and other systems resulting from such failures. C. Upon receipt of notice from the Contractor of failure of any part of the systems during the guarantee period,the affected parts shall be replaced. Any piping requiring excessive service shall be considered defective and shall be replaced. D. If any part of a system should be stopped by foreign matter being placed in the systems,disconnect the system, clean,and reconnect wherever necessary to locate and remove obstructions. The Subcontractor shall repair or replace any work damaged in the course of removing obstructions. E. Refer to the sanitary process waste piping manufacturer for available extended warranties. 1.40 CLEAN UP AND REMOVAL OF RUBBISH A. The Subcontractor shall keep the facility and site clean from the accumulation of rubbish and waste materials and,upon completion, leave the facility,the site and the installation in a clean condition, completely acceptable to the Architect and to the Contractor. B. At the completion of the work,this Subcontractor shall remove all tools, scaffolding, debris and waste and unused materials from and about the premises. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10,2000 Pg. 16 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc B. Provide for temporary closings as work progresses, completely acceptable to the Contractor. Trenches shall be covered with steel plate(or other means acceptable to the Owner)when not in use. 1.34 ACCESSIBILITY A. Install all work so that all parts required shall be readily accessible for inspections, operation,maintenance, and repair. B. Install all work so that all cleanouts shall be readily accessible for inspection, maintenance, and rodding. C. It shall be the Subcontractor's responsibility to thoroughly coordinate the locations of all cleanouts with the equipment arrangement drawings and notify the Contractor immediately of any possible conflicts with cleanout accessibility. D. Minor deviations from the drawings may be made for this purpose,but changes of magnitude shall not be made without prior written approval of the Contractor. 1.35 PORTABLE OR DETACHABLE PARTS A. The Subcontractor shall retain in his possession and shall be responsible for all portable and detachable parts and portions of the installation and all other devices or materials that shall be relative to and necessary for the proper operation and maintenance of the underslab plumbing systems until final completion of the work.. B. The Subcontractor shall replace all stolen, lost, or damaged items relative to the installation and operation of the underslab plumbing systems before the facility is accepted. 1.36 CATHODIC/ELECTROLYTIC PROTECTION A. Connections between dissimilar metals shall be made with dielectric nipples. 1.37 TESTING AND ADJUSTING A. Test all work and systems and make all adjustments and corrections prior to backfilling to provide a complete first-class working system. B. Provide all labor,materials, and instruments necessary for completion of tests under observation of the local authorities and the designated inspectors. C. Make adjustments and place all piping systems in operation and demonstrate the proper,functions of the piping systems, equipment, and controls. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 15 SPE-16040-15401 JAI 6040\Specs\Final\15401-REV 0 A B. The Subcontractor shall have sufficient foresight to have materials on hand before they are needed and in such quantities that delays of railroads, other parties, weather conditions, etc., shall not delay this work. C. Store, handle and protect products under provisions set fourth by the piping and equipment manufacturers and as specified. 1.30 CUTTING AND PATCHING A. All core drilling and sleeving for the underslab plumbing systems shall be the responsibility of this Subcontractor. B. When materials of other trades are to be cut or fitted in the shop,this Subcontractor shall furnish the necessary drawings to the trades whose materials shall be cut or fitted. C. All concrete cutting and patching associated with the installation of the underslab plumbing systems shall be the responsibility of the General Gentmete this Subcontractor. He shall repair all disturbed concrete including steel reinforcing to I match existing conditions. 1.31 UTILITIES A. Provide all utilities such as water, fuel, and electricity for all tests associated with or specified for the underslab plumbing work. 1.32 EXCAVATION AND BACKFILLING A. All trenching and backfilling for the underslab plumbing systems shall be provided for by the Gener-,1 Gee#f wtekthis Subcontractor. B. Furnish all required information as to the locations, sizes, grades and elevations of all piping requiring excavation. C. All irregularities in the trench bottom or where the excavation has exceeded the depth required shall be filled with sand properly compacted to the required depth. D. Slope of the trench shall be the responsibility of this Subcontractor. 1.33 TEMPORARY OPENINGS A. The Subcontractor shall afmprg° the Geftt aet *-provide special temporary openings in the structure and in the exterior walls for the admission of apparatus provided as part of the underslab plumbing work. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 14 SPE-16040-15401 J:\16040\Specs\Final\15401-REV O.doc F. The Subcontractor shall replace all stolen, lost, or damaged items relative to the installation and operation of the underslab plumbing systems before the facility is accepted. 1.26 SURVEYS AND MEASUREMENTS A. The Subcontractor shall base his measurements,both horizontal and vertical, from reference points established by the Contractor and shall be responsible for correctly laying out his work. B. In the event of a discrepancy between actual measurements and those indicated, the Subcontractor shall notify the Contractor, in writing, and shall not proceed with this work until written instructions have been issued by the Contractor. 1.27 EXISTING BUILDING SERVICES AND UTILITIES A. When encountered in this work, the Subcontractor shall protect, brace and support all existing services for the proper execution of work. If existing services are encountered that require relocation,notify the Contractor and relocate as directed. Do not prevent or disturb operation of existing services that are to remain. B. Where work makes temporary shutdown of existing services unavoidable, shut down as specified, or at such times as approved by the Contractor,which shall cause the least amount interference with established operation routine: Arrange work to assure that services shall be shut down only during time actually required to make connection to existing work. The Subcontractor shall coordinate shutdowns a minimum of seven(7)working days in advance with the Contractor and the designated facility officials before proceeding with the work. C. Existing piping and appurtenances removed or damaged during the work shall be replaced with new, like materials. 1.28 SELECTION AND ORDERING OF MATERIALS A. Arrange for the purchase and delivery of materials and equipment required in ample quantities and at the proper time.Immediately notify the Contractor of any inability to obtain suitable delivery of any apparatus or materials required. 1.29 DELIVERY, STORAGE AND HANDLING OF MATERIALS A. The Subcontractor shall give his personal supervision and direction to the work and shall give strict attention to time schedules as agreed upon. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 13 SPE-16040-15401 J:\16040\Specs\Final\15401-REV O.doc B. Provide and maintain proper guards for prevention of accidents and to secure safety of life and property. C. The Subcontractor shall read, understand, and follow all portions of the Owner's Internal Safety and sign in/sign out programs. D. Prior to commencing work at the beginning of each work day,the Subcontractor shall report to the Contractor's site trailer for proper sign in/sign out. 1.24 WORKMANSHIP A. The Subcontractor shall provide a neat workable installation utilizing current good manufacturing practices, good craftsmanship and the work shall be executed as rapidly as possible. B. All piping shall be run in the most direct, straight and mechanical manner and be properly graded. Where pipes terminate under this contract,the invert and centerline elevations at such points shall be checked for conformity by this Subcontractor prior to installation. C. At the completion of the work,this Subcontractor shall remove all tools, scaffolding, debris,waste and unused materials from and about the premises, and shall leave his work clean and ready for use. D. The decision of the Contractor as to the character of any labor provided by the Subcontractor shall be final and conclusive on both the Subcontractor and the Contractor. 1.25 PROTECTION OF WORK AND PROPERTY A. The Subcontractor shall be responsible for the care and protection of all work included under this section until it has been tested and accepted. B. All pipe openings extending through the slab shall be temporarily closed so as to prevent obstruction damage. C. Protect all equipment and materials from damage from all causes including weather,water, frost, accident and theft. All materials and equipment damaged or stolen shall be repaired or replaced with equal material or equipment. D. Protect all equipment, outlets and openings with temporary plugs, caps and covers. Protect work and materials or other trades from damage that might be caused by work or workmen and make good damage thus caused. E. This Subcontractor shall care for his own tools, equipment and materials, and shall be responsible for their safekeeping at all time. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10,2000 Pg. 12 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc D. All information furnished by the Subcontractor shall include opening sizes and locations and all other pertinent information relative to the underslab plumbing installation that the Contractor may deem necessary for a properly coordinated installation. 1.19 RECORD DRAWINGS A. At the completion of the contract, the Subcontractor shall submit to the Contractor a complete set of legible and reproducible record drawings showing"as-built" corrections with all superseded data removed. 1.20 LAWS, ORDINANCES AND INSPECTIONS A. The Subcontractor shall file all drawings and specifications,prepare all documents and obtain all required Permits and Certificates of Inspection for the work, at this Subcontractor's expense, and deliver same to the Contractor before submitting the request for acceptance and final payment for the work. B. All materials provided shall comply with all requirements of the local utility companies,with the recommendations of local utility companies, and with the requirements of the State of Massachusetts and the City of Northampton. 1.21 COMPLETENESS OF WORK A. The omission from the plans and specifications of expressed references to any reasonable labor or materials necessary for the proper executing or completion of the work shall not relieve the Subcontractor from furnishing them in keeping with the basic character and intent of the work. 1.22 WORK PERSONNEL A. The Subcontractor shall furnish first-class skilled workmen for all work, and shall keep a competent foreman or superintendent on premises at all times during the progress of the work that shall have the authority to act for and in behalf of the Subcontractor during the latter's absence with regard to all directions given to him by the Contractor. B. All careless or incompetent personnel shall be removed forthwith by the Subcontractor when he is notified to do so by the Contractor or his authorized representative. 1.23 SAFETY PRECAUTIONS A. The Subcontractor shall comply with all of the safety requirements of OSHA and the Amgen Safety Standards throughout the entire period of construction. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 11 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc 1.16 CLAIMS FOR EXTRAS A. Should the Subcontractor deem any work which he is called upon to perform extra to the Contract,by drawings or otherwise, he shall give the Contractor written notice to that effect and await instructions before proceeding to execute such work. The Contractor shall not be under obligation to consider claims for extra work unless so made by this Subcontractor. B. All such work shall be executed under the conditions of the original Contract, except that any claim for extension of time caused thereby shall be adjusted at the time of ordering such change. The Contractor shall determine the method of computing the value of any changes to be made. 1.17 LIABILITY OF SUBCONTRACTOR A. The Subcontractor shall have sole charge and possession of the work covered by his Contract, except as otherwise specified, until it is completed and accepted by the Owner and Contractor, and he shall hold the Owner and Contractor harmless and protect them against all suits of any kind brought against them or on account of any liens for labor performed or material provided. B. The Subcontractor shall be responsible for any consequences arising from carelessness,negligence or dishonesty of those in his employ. C. He shall be responsible for and make good on any improper work or materials entering into the construction of the work, and hold the Engineer free from any and all claims,whatsoever in nature, arising during the erection and completion of this work. 1.18 TRANSFERRING OF INFORMATION A. The Subcontractor shall obtain detailed information from the manufacturers of the apparatus to be provided and from the other trades as to the proper method of installing and connecting the underslab plumbing systems. B. It shall be the Subcontractor's responsibility to keep apprized as to the shape, size and position of all openings required for materials and equipment under this section and give full information to be other trades sufficiently in advance to allow proper access requirements. C. In case of failure on the part of the Subcontractor to give proper information as noted above and to save delays caused by necessary approvals, the Subcontractor shall be required to have all the necessary cutting and patching performed by the appropriate trade at this Subcontractor's expense,but in any case additional work shall be performed at no additional cost._ REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 10 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc C. The Subcontractor shall be responsible for pre-verifying all invert and centerline elevations of all piping systems within the underslab plumbing scope of work with actual field conditions prior to core drilling,hanging,or supporting any pipe. If this Subcontractor purchases and/or installs any underslab plumbing system or appurtenance without first pre-verifying invert and centerline elevations of the piping, all costs incidental to making any changes shall be paid for by this Subcontractor without back-charges. D. If there is evidence that the underslab plumbing work interferes with the work of any other trade in any manner, this Subcontractor shall assist in working out space conditions to make necessary and satisfactory adjustments. Coordination to avoid conflicts shall include but not limited to Electrical for location of cable trays, duct banks, and appurtenances; Structural for beams, columns, footings,wall, and mats; and Architectural for the area footprints. E. Provide advance information on locations and sizes of all frames,boxes, and openings needed for this Subcontractor's work to the other trades. Provide information and provide necessary drawings to permit trades affected by the underslab plumbing work,to install their work properly and without delay. F. As approved by the Contractor, the Subcontractor may make reasonable modifications in the layout as needed to prevent conflicts with other trades, for the proper execution of work by the other trades, or for the proper execution of this Subcontractor's work. The Subcontractor shall pay all expenses for additional openings, relocations or enlargements of existing openings through concrete floors,walls,beams and roofing. G. The Subcontractor shall protect all materials and workmanship of all other trades from damage that may be caused by the underslab plumbing work and shall be responsible for repairing any damages caused. 1.15 EXTRA WORK OR OMISSIONS A. In the event of any omissions or additions to the work called for in the specifications, a deduction/extra charge shall be made by/to the Subcontractor in proportion to the work or materials omitted or added. Such omissions and/or additions shall be approved, in writing,by the Contractor. No work shall be performed and no materials added or omitted without written orders from the Contractor, and the signed acceptance of the Subcontractor. In giving instructions, the Contractor shall have the authority to make minor changes in the work not involving extra cost nor inconsistent with the purpose and intent of the plans and specifications. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 9 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc smoking, and shall require all persons employed to comply with all facility or institutional regulations while on the premises. C. The Subcontractor shall conduct work so as not to interfere with the functioning of existing services. 1.12 INTERPRETATION OF DRAWINGS A. The drawings are intended to convey the general arrangement of the underslab plumbing systems, the scope of work, and the function of those systems. B. The exact arrangement and location of piping and equipment shall be determined from shop drawings and accurate, field coordinated measurements and conditions. The exact locations necessary to secure the best conditions and results shall be determined at the project site with written approval from the Contractor before proceeding with the installation. C. The Subcontractor shall follow the drawings in laying out the work and checking the drawings of other trades to verify spaces in which the work shall be installed. Maintain maximum headroom and space conditions at all points. Where headroom or space conditions appear inadequate,notify the Contractor before proceeding with the installation. 1.13 TYPICAL DETAILS A. Where shown on the drawings, typical details shall apply to all similar items. Any alternate method requires prior approval of the Contractor. 1.14 COORDINATION OF TRADES A. Cooperation and coordination(prior to the installation)with all other trades in providing the underslab plumbing systems for the project is the responsibility of this Subcontractor. This Subcontractor shall not take liberties when installing the underslab plumbing systems within the project area. The Subcontractor shall coordinate all pipe runs and system appurtenances including setting invert and centerline elevations and pipe offsets from the facility walls and columns. The Contractor shall schedule discipline coordination meetings so as to allow a speedy and efficient completion of the project. As work progresses,the Subcontractor shall submit coordination drawings,to scale, to the Contractor for all areas of possible conflicts requiring close coordination with all other trades. B. Prior to submission of coordination drawings,the Subcontractor shall check approved equipment shop drawings to verify that they comply with the contract requirements, and that the dimensions submitted fit the available space. Any deviations from the Contract requirements shall not be acceptable without prior written approval from the Contractor. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 8 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc IN I B. Requests for substitutions shall be made to the Contractor in writing. This request shall contain detailed material data,manufacturer's name,model and catalog numbers so that a proper evaluation may be made. A request for substitution only naming a trade name or dealer's name shall not be considered. C. Substitutions may be requested by the successful bidder after signing of the contract in the following manner: 1. Submit to the Contractor copies of detailed data of the proposed item or items to be substituted along with a letter notifying the Contractor of the proposed change. 2. A statement indicating the amount of any change to the contract price for the proposed substitution. After reviewing the proposed change,the Contractor shall inform the Subcontractor of his decision by letter. 3. The model and data specified for each item of material heading in these specifications relates to the brand name indicated and is used as the standard of quality,performance and suitability required. 4. The approval of substitution of equipment does not relieve the Subcontractor of any valid charges for additional work performed by the Contractor, other Subcontractors,the Architect. 1.10 EXAMINATION OF PREMISES A. Prior to the ordering or purchasing of any underslab plumbing equipment or materials or the layout or installation of any work, the Subcontractor shall examine the premises and verify any and all of the existing conditions under which he shall be required to operate, or that shall in any manner affect the work under this contract. Report conditions that might affect work adversely in writing to the Contractor. If any work is involved with existing equipment or services, all model numbers, sizes, etc., shall first be verified to correspond and be compatible with the work and equipment shown on the drawings. Commencement of work shall be construed as complete acceptance of existing conditions and preparatory work. 1.11 USE OF PREMISES A. The Subcontractor shall confine his apparatus, storage of materials, and construction operations to such limits as may be directed by the Contractor and shall not unreasonably encumber the premises with his materials. B. The Subcontractor shall enforce all instructions of the Owner and Contractor regarding safety, signs, advertisements, fires, danger signals,barricades, and REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 7 SPE-16040-15401 J:\16040\SpecsTinal\15401-REV O.doc a stamp indicating that he has determined and verified all field measurements and quantities, field construction criteria,materials, catalog numbers and similar data, and that he has reviewed and coordinated the information in the shop drawings and submittal data with the requirements of work and the contract documents. Failure to comply with the above shall cause immediate rejection of submittal. H. Equipment and materials requiring submittal for approval shall include,but not be limited to the following: 1. Pipe materials, fittings, and appurtenances. 2. Trench drains, floor drains, cleanouts, equipment, and other underslab plumbing specialties. 3. Core drill packing and seals. I. Submit copies for approval and record of all tests. J. Shop drawings shall include location of core drillings and other openings,which pass through or into concrete construction. Drawings shall be prepared at earliest practicable date to expedite orderly progress of the work. K. Clearly indicate makes, models, locations, types, sizes,pressure ratings and system components. Delete all inapplicable material. L. Submit shop drawings indicating complete material data, a list of materials proposed for this project, and indicate thickness of material for individual services. M. Tabulate products by section number and paragraph. N. Contract closeout information shall include: 1. Operating and Maintenance Data. 2. Owner Instruction Report. 3. Guarantees. 1.9 SUBSTITUTIONS A. The term"or approved substitute"shall be understood to mean approved in equal in the opinion of the Contractor. No material shall be used in"substitution"to that specifically designated by name in the specifications unless it has been approved in writing by the Contractor. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 6 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc K. ANSI Al 12.2 1.1 -Floor Drains. L. NFPA 30-Flammable and Combustible Liquids Code. M. Individual Pipe Manufacturer's Installation Instructions. 1.7 QUALITY ASSURANCE A. For each product specified,provide components by same manufacturer throughout. B. Materials shall be labeled with manufacturer's pertinent information. Materials and equipment shall be delivered in non-broken, factory-furnished packaging and stored in a clean, dry indoor space that provides protection against the weather. 1.8 SHOP DRAWINGS AND SUBMITTALS A. Submit for approval by the Architect/Engineer shop drawings for equipment and materials proposed for installation prior to ordering,purchasing, or fabricating equipment or materials. Drawings shall be catalog cuts,material lists, and samples where necessary, containing complete performance data, engineering calculations, dimensions,descriptions, installation requirements and particulars. Submittals only naming a trade name or dealer's name shall not be considered. B. Work shall not commence before the approval of the Architect/Engineer has been received. Data shall be submitted sufficiently in advance of the work to allow proper time for examination and correction. C. The Architect/Engineer's approval of submittal or data shall not relieve this Subcontractor from the responsibility for deviations from drawings and specifications, unless he has, in writing, called the Architect/Engineer's attention to such deviations at time of submission. D. This Subcontractor shall check all shop drawings and submittal data for compliance with the plans and specifications. E. The Subcontractor shall stamp his approval on all such shop drawings and submittals prior to his submitting them for review and approval by the Architect/Engineer. F. If the Subcontractor fails to comply with the preceding requirements,the shop drawings and submittals shall be returned unapproved. G. The Subcontractor shall review and check all shop drawings and submittal data. Before submitting shop drawings and submittal data, this Subcontractor shall affix REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 5 SPE-16040-15401 JA 16040\.SpecsTina1\15401-REV O.doc 9. American Society for Testing Materials (ASTM). 10. National Bureau of Standards (NBS). 11. National Sanitation Foundation(NSF). 12. Cast Iron Soil Pipe Institute(CISPI). 13. American Water Works Association(AWWA). 14. Occupational Safety and Health Act(OSHA). 15. The Owner's Internal Safety Program. 16. Underwriters' Laboratories (UL). 17. Factory Mutual(FM). 18. Current Good Manufacturing Practices. 1.6 REFERENCES A. ASTM A74 - Cast Iron Soil Pipe and Fittings. B. ASTM B306 - Copper Drainage Tube(DWV). C. ASTM D4101 —Polypropylene pipe and fittings D. ASTM D635 —Flame Retardant Polypropylene pipe and fittings E. ASTM D 15 99 - Standard Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe, Tubing and Fittings. F. ASTM D2412 - Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate loading. G. ASTM C564 -Rubber Gaskets for Cast Iron Soil Pipe and Fittings. H. CISP/HSN-Neoprene rubber gaskets for hub and spigot cast iron soil pipe and Fittings. I. AWWA C601 - Standard Methods for the Examination of Water and Waste Water. J. CISPI 301 - Cast Iron Soil Pipe and Fittings for Hub-less Cast Iron Sanitary Systems. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 4 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc B. No additional compensation shall be granted for work which must be changed as a result of the work not originally complying with codes, standards, etc., and not in accordance with the multiple trade coordination design criteria set forth. C. The Subcontractor shall file all drawings,pay all fees and obtain all permits and certificates of inspection relative to this work. The Subcontractor shall arrange inspections with proper authorities and include costs of same in his bid. The Subcontractor shall not backfill installed piping before it is inspected by the authorities having jurisdiction and the City of Northampton,Massachusetts. D. The Subcontractor shall arrange for the proper inspections required by the authorities having jurisdiction, shall include costs of inspections in his bid, and shall schedule such inspections, giving the Contractor a minimum of 48 hours advance notice such that the inspections may be witnessed. Copies of all permits and certificates of inspection shall be forwarded to the Contractor. E. If the code or other requirements exceed the provisions indicated in the Contract Documents, the Contractor shall be notified in writing. Where the work indicated on the Contract Documents exceeds code requirements, the installation shall be done in.accordance with the Contract Documents. Any work done contrary to these requirements shall be removed and replaced at the expense of the responsible Subcontractor. F. The underslab plumbing layout,workmanship,methods, and materials shall meet the highest standards of the trade and shall conform to the latest editions of the following associations: 1. Uniform Plumbing Code, latest applicable edition. 2. Massachusetts Plumbing Code, latest applicable amendments. 3. Requirements of the City of Northampton,Massachusetts, applicable local codes, and the authorities having jurisdiction. 4. American Society of Plumbing Engineers (ASPE) Handbooks, Data books, and Standards. 5. American Society of Heating,Refrigeration, and Air Conditioning Engineers (ASHRAE)Handbooks,Data books, and Standards. 6. American Society of Mechanical Engineers (ASME). 7. National Fire Protection Association(NFPA). 8. American National Standards Institute(ANSI). REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 3 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc D. Drawings and Specifications form complementary requirements. Provide work specified and not shown, and work shown and not specified as though explicitly required by both. Although some work may not be specifically shown or specified,provide supplementary or miscellaneous items, appurtenances, devices and materials obviously necessary for a sound, secure and complete installation. E. The underslab plumbing systems shall include,but not be limited to,the following items: 1. Underslab sanitary process waste system complete with all fittings,joining materials and appurtenances, connecting to a exterior manhole as shown on the Underslab Plumbing Systems Floor Plan sheet. 2. Trench drains, floor drains, floor cleanouts, and other drainage specialties set at and below first floor slab elevation. 3. Core drilling and packing. 4. Shop drawings for materials and equipment. 5. Systems cleaning and testing. 6. Guarantees. 7. Record drawings. 8. Instruction manuals. 1.4 RELATED WORK SPECIFIED ELSEWHERE A. Reference Division 1 requirements for temporary utilities such as water, fuel, electricity and sanitary facilities required during construction. 1.5 CODES AND STANDARDS A. All underslab work shall be provided in conformance with the governing codes, regulations, local ordinances, and authorities having jurisdiction. It shall be the responsibility of the Subcontractor to familiarize himself with all governing codes and requirements and report any noncompliance of the plans and specifications to the Contractor,prior to entering into the contract, and all the above requirements shall take precedence over the plans and specifications. These requirements are minimum criteria and no reductions permitted by code shall be allowed without written permission of the Contractor. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 2 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc UNDERSLAB PLUMBING SYSTEMS SECTION 15401 1.0 GENERAL 1.1 DESCRIPTION OF WORK A. The work under this section of the Specifications shall include the fin-nishing and installation,herein referred to as"provide"of all materials, equipment, labor and services required for complete underslab plumbing systems including piping stub- ups through the first floor slab,herein referred to as"underslab plumbing systems" for the Pouch Line Addition,herein referred to as the"project area". The Plumbing Subcontractor,herein referred to as the"Subcontractor,"shall be currently licensed in the State of Massachusetts, and shall meet all performance requirements, all code requirements and all regulations to make these underslab systems ready for regular operation and use by The Minute Maid Company, herein referred to as the"Owner". 1.2 GENERAL REQUIREMENTS AND RESPONSIBILITIES A. The Subcontractor shall examine all other sections of the project's contract specifications for requirements which effect the work of this section whether or not such work is specifically noted herein. B. The Subcontractor shall coordinate work with that of other trades affecting or affected by the work of this section. Cooperate with all other trades such that work progresses smoothly without interference to other trades. 1.3 SCOPE OF WORK A. Perform work and provide all permits, transportation, freight, materials, appurtenances,machinery, equipment, tools, loading, unloading, core-drilling, grading of trenches,testing, labeling, labor and supervision_necessary, as shown on the drawings and as specified in this section of the specifications, to install, complete, and make ready for continuous operation, all underslab plumbing systems specified herein. B. Unless otherwise noted, all underslab waste piping shall be extended up through the floor a minimum of 24" above the first floor finished floor, via temporary capped outlets. C. The Subcontractor shall be responsible for the protection of each 24"piping stub- up extending up through the first floor slab and shall take the necessary precautions to prevent any damage or pipe breakage. REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. 1 SPE-16040-15401 JA16040\Specs\Fina1\15401-REV O.doc 2.2 ACCEPTABLE MANUFACTURERS .............................................................................18 2.3 WASTE AND VENT PIPING, BURIED..........................................................................19 2.4 FLOOR AND TRENCH DRAINS....................................................................................19 2.5 FLOOR CLEANOUTS......................................................................................................19 2.6 BURIED UTILITY WARNING TAPE.............................................................................20 2.7 PENETRATIONS AND CORE DRILLING.....................................................................20 2.8 CATHODIC/BLECTROLYTIC PROTECTION..............................................................21 3.0 EXECUTION.....................................................................................................................21 3.1 SUBCONTRACTOR'S INSTALLATION RESPONSIBILITIES...................................21 3.2 MATERIALS AND WORKMANSHIP............................................................................22 3.3 CONTINUITY OF SERVICES.........................................................................................23 3.4 PREPARATION................................................................................................................23 3.5 PENETRATIONS..............................................................................................................23 3.6 UNDERSLAB PIPING AND FITTING INSTALLATION.............................................23 3.7 BEDDING OF PIPING AND FITTINGS.........................................................................25 3.8 JOINTS AND CONNECTION INSTALLATION............................................................25 3.9 FLOOR DRAIN AND TRENCH DRAIN INSTALLATION ..........................................25 3.10 FLOOR CLEANOUT INSTALLATION..........................................................................26 3.11 SPECIALTY INSTALLATION........................................................................................26 3.12 TESTING OF UNDERSLAB PLUMBING SYSTEMS...................................................26 3.13 COMMISSIONING OF SYSTEMS..................................................................................27 REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. ii SPE-16040-15401 JAI 6040\Specs\Final\15401-REV O.doc TABLE OF CONTENTS 1.0 GENERAL............................................................................:..............................................1 1.1 DESCRIPTION OF WORK................................................................................................1 1.2 GENERAL REQUIREMENTS AND RESPONSIBILITIES .............................................1 1.3 SCOPE OF WORK..............................................................................................................1 1.4 RELATED WORK SPECIFIED ELSEWHERE.................................................................2 1.5 CODES AND STANDARDS..............................................................................................2 1.6 REFERENCES ....................................................................................................................4 1.7 QUALITY ASSURANCE...................................................................................................5 1.8 SHOP DRAWINGS AND SUBMITTALS.........................................................................5 1.9 SUBSTITUTIONS...............................................................................................................6 1.10 EXAMINATION OF PREMISES.......................................................................................7 1.11 USE OF PREMISES............................................................................................................7 1.12 INTERPRETATION OF DRAWINGS...............................................................................8 1.13 TYPICAL DETAILS...........................................................................................................8 1.14 COORDINATION OF TRADES ........................................................................................8 1.15 EXTRA WORK OR OMISSIONS......................................................................................9 1.16 CLAIMS FOR EXTRAS...................................................................................................10 1.17 LIABILITY OF SUBCONTRACTOR..............................................................................10 1.18 TRANSFERRING OF INFORMATION..........................................................................10 1.19 RECORD DRAWINGS.....................................................................................................11 1.20 LAWS, ORDINANCES AND INSPECTIONS................................................................11 1.21 COMPLETENESS OF WORK.........................................................................................11 1.22 WORK PERSONNEL.......................................................................................................11 1.23 SAFETY PRECAUTIONS................................................................................................11 1.24 WORKMANSHIP .............................................................................................................12 1.25 PROTECTION OF WORK AND PROPERTY................................................................12 1.26 SURVEYS AND MEASUREMENTS..............................................................................13 1.27 EXISTING BUILDING SERVICES AND UTILITIES ...................................................13 1.28 SELECTION AND ORDERING OF MATERIALS ........................................................13 1.29 DELIVERY, STORAGE AND HANDLING OF MATERIALS .....................................13 1.30 CUTTING AND PATCHING...........................................................................................14 1.31 UTILITIES.........................................................................................................................14 1.32 EXCAVATION AND BACKFILLING............................................................................14 1.33 TEMPORARY OPENINGS..............................................................................................14 1.34 ACCESSIBILITY..............................................................................................................15 1.35 PORTABLE OR DETACHABLE PARTS.......................................................................15 1.36 CATHODIC/ELECTROLYTIC PROTECTION..............................................................15 1.37 TESTING AND ADJUSTING..........................................................................................15 1.38 CERTIFICATES OF APPROVAL ...................................................................................16 1.39 GUARANTEE...................................................................................................................16 1.40 CLEAN UP AND REMOVAL OF RUBBISH.................................................................16 2.0 PRODUCTS.......................................................................................................................17 2.1 MATERIALS.....................................................................................................................17 REV. 0 PROCESS FACILITIES INC. NOVEMBER 10, 2000 Pg. i SPE-16040-15401 J:\16040\Specs\Final\15401-REV O.doc Z,5 PROCESS FACILITIES INC. SPECIFICATION FOR UNDERSLAB PLUMBING SYSTEMS SPE-16040-15401 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 ` e mate 7777,77,7 ecTip,fson #n �reprel fed 414'1 NIP A 10/31/00 Issue for Bid KAB KMC AJF HM 0 11/10/00 Issue for Construction KAB KMC G AJF HM Client Approval: Client: Date: C. Notify the Owner five (5) days in advance with the scheduled shipping date and location. The Owner reserves the right to inspect the boiler prior to unloading. D. Notify the Owner of any components that may suffer damage if stored outside while remaining shrink wrapped. E. Acceptance on Site: If the boiler is damaged upon arrival it will be rejected. ++END OF SECTION 15550++ REV. 0 PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 18 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev 0-doc D. All parts shall be identified in an appropriate manner. When parts are crated or boxed, detailed packing lists shall be provided with each crate or box. E. Component weights shall be plainly marked on all equipment requiring rigging so that field construction forces can suitably handle the equipment. F. Vendor shall notify Purchaser ten (10)working days prior to shipment. 3.4 START-UP ASSISTANCE A. Vendor shall provide startup assistance at Owner's facility in Northampton, Massachusetts. Startup assistance shall consist of- 1. Commissioning and startup of equipment. 2. Operator Training. 3. The Manufacturer shall provide on-site services of a factory authorized service representative to completely check the mechanical and electrical installation of each unit, and to start up and test each unit in cooperation with the installing contractor and the water balance contractor. The Vendor shall provide per diem costs for additional services if required. 4. The Manufacturer shall provide a checklist for completion by the contractor and approval by the Owner after installation of the units, to ensure that they are ready for start up. The Manufacturer shall schedule the start up service within two weeks of request given by the Owner. 5. The commissioning and start up service shall include full testing of the boiler and controls. 6. The service representative shall submit three (3) copies of the start up report to the Owner within two weeks of start up. B. Vendor to provide an estimate of the startup duration. 3.5 DELIVERY A. Ship boiler as a single piece. B. Ship machine sections with protective covers over all openings. Individually shrink wrap each section prior to loading onto truck. Shrink wrap starter, unit control panel and all other sections that will be adversely impacted by snow, ice, road salt, etc. After loading, secure tarps over boiler. Trucks arriving at site without protective packaging will not be allowed to unload. REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 17 SPE-16040-15550 1:\16040\Specs\Fina1\15550_Rev O.doc design pressures (225 psig). The test pressure shall be held for not less than 30 minutes. 3. The pressure specified shall be the pressure at the W of the equipment in its test position. All vertical equipment which is tested in the horizontal position must have the test pressure adjusted to suit the additional pressure due to the static head. 4. Water used for the hydrotest shall be potable or clean raw water. 5. Draining of the system shall be accomplished immediately after completion of the final hydrostatic test. Any remaining pockets of water shall be dried with air. 6. Flanged joints which have been taken apart after a hydrotest(for whatever reason) shall be reassembled with unused gaskets and then retested. 7. Test data shall include boiler firing rate, excess air, gas flow rate, heat input,burner manifold gas pressure,percent carbon monoxide(CO), percent oxygen(Oz),percent excess air, flue gas temperature, ambient temperature,percent stack loss,heat output and percent combustion efficiency. 3.2 CLEANUP A. All oil, grease, and dirt shall be removed by scrubbing with soap, alkali cleaners or suitable solvents. All welding flux shall be brushed or blasted free. After cleaning, the vendor shall protect the equipment from intrusion of dirt, debris, or foreign material. 3.3 PREPARATION FOR SHIPMENT A. Vendor shall make final check for completeness of equipment prior to shipment. B. All equipment and materials shall be suitably crated,boxed, equipped with handling fixtures, or otherwise prepared for shipment to prevent damage or contamination during handling and shipping. All parts which may be exposed to the weather due to physical size or arrangement shall be adequately protected by suitable weatherproofing. It shall be the responsibility of the Vendor to take any other precautions required to reasonably ensure jobsite arrival of the equipment in an undamaged and satisfactory working condition. C. All pipe ends shall be sealed,using plastic caps for flanged ends, and metal thread protectors or cap plugs for threaded ends to exclude entry of foreign matter. REV. 0 PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 16 SPE-16040-15550 J:\16040\Specs\Fina1\15550_Rev O.doc s 10. Seals shall be used to retain grease and to protect bearings from dust. 11. Motors shall have grease lubricated ball or roller bearings capable of in service lubrication. Bearings shall be of such design to provide extra long life. Permanently lubricated bearings will not be acceptable. Grease fittings shall be easily accessible and not interfere with machine operation. 12. All motors shall be designed for continuous duty and shall not exceed the temperature rises indicated for each insulation class, in NEMA Standards Publication MG1-1998. 13. Copper conductors shall be used for windings. 14. To provide resistance to chemical corrosion, no aluminum parts of the motor shall be exposed to the atmosphere. 15. For motors 10 HP and larger, the locked rotor kVA/HP shall not exceed locked rotor code letter"G" (5.6—6.29 kVA/HP). 16. A spring-loaded cap shall be installed on the outlet of each bearing grease chamber discharge port. Grease fittings shall be supplied on inlet grease connections. 17. Motors operating with VFDs shall be UL rated for Inverter.Duty and shall meet all requirements Part 31 of NEMA standard MG1-1998 for Inverter- Fed Polyphase Motors. 18. The motor shall be suitable for operation in the environment indicated in the data sheet(s). 19. Motors for use in areas subject to washdown shall be suitable for wet or washdown locations. 3.0 EXECUTION 3.1 TESTS A. Tests: 1. The Vendor shall make all shop tests necessary to insure that his material and workmanship are of the required quality and that the equipment furnished will perform as specified and guaranteed. 2. All shop fabricated equipment shall be hydrostatically tested in accordance with the ASME Code. Testing shall be done at 1.5 times the maximum REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 15 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doc D. Motors 1. The Vendor shall provide with their quotation the motor design requirements necessary to provide adequate operation as required by this specification. The motor design requirements shall include at a minimum the following: a. Motor horsepower. b. Motor speed. C. Motor torque. d. Range of motor frame sizes and mounting sizes easily adapted for each drive. e. Motor voltage 2. Motors greater than %Z HP shall be 480 volts, 3-phase, 60 hertz. Motors %2 HP or smaller shall be 120 volt, single phase, 60 hertz. 3. All motors will be designed and manufactured such as to conform to all applicable requirements of the latest editions of standards published by NEC, ANSI, IEEE,NFPA, and NEMA MG-1 standard. 4. All motors shall be premium efficiency. When the motor is operating at rated voltage and frequency, the minimum full load efficiency shall equal or exceed the nominal values in NEMA Standards Publications#MG1- 1998 and efficiencies list in this specification. 5. Motors shall be of the squirrel cage, induction type and shall be capable of starting and accelerating their load to normal operating speeds under the most severe conditions likely to be encountered without exceeding the horsepower rating indicated on the nameplate; and without usurping any portion of any specified service. 6. Speed and torque characteristics shall conform to NEMA Design B requirements. When speed and torque characteristics other than NEMA Design B are required, the bidder's proposal shall clearly indicate such requirements, and the motor shall have speed and torque characteristics, which will satisfy the requirements. Unless otherwise specified or required, motors shall have a Service Factor of 1.15, except inverter duty motors shall have a service factor of 1.0. 7. TEFC & ODP motors shall be rated for"mill and chemical duty". 8. Motors shall have NEMA Class F insulation minimum. 9. Motor nameplates shall be of stainless steel and shall be permanently fastened with stainless steel fasteners. REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 14 SPE-16040-15550 JAI 6040\Specs\Fina1\15550_Rev O.doc i 2.12 ELECTRICAL REQUIREMENTS, MOTORS A. Introduction 1. This specification contains general electrical requirements for equipment and should be considered as an integral part of the specification that it accompanies. Should any discrepancies occur between this specification and the accompanying equipment specification, the purchaser shall be the sole party responsible for clarifying the discrepancies. B. Scope 1. All electrical work shall meet the standards of the latest issue of the NEC, and shall comply with applicable state and municipal laws, and local plant safety regulations covering each class of work. 2. All electrical controls and control panels shall be located where accessible and, preferably, at grade. 3. Cables and conductors shall be sized in accordance with the National Electrical Code(NEC),based on the current-carrying capacity, voltage- drop considerations, short circuit rating, and derating due to heating effects. 4. Electrical power will be supplied at 480 Volt AC +10%, 3 phase, 3 wire, 60 hertz. C. General Requirements 1. All motors, electrical equipment and control devices shall be designed and manufactured to conform to all applicable requirements of the latest editions of the code and standards as specified in the attached process specification. 2. Unless specifically noted, all electrical and electronic accessories supplied by the Vendor shall have suitable enclosures and connection boxes for the unit's electrical classification. They must also be listed and labeled with a minimum of one of the electrical listing agencies in the attached process specification. 3. All electrical equipment shall be UL listed for its application and shall be stamped with this approval. 4. Where conflicts occur among the codes, ordinances, standards, and specifications, more restrictive requirements shall govern. REV. 0 PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 13 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doc 2.10 SAMPLE COOLER A. Furnish one (1) sample cooler consisting of 304 stainless steel head and shell, jointless coiled T304 stainless steel tubing, and a carbon steel mounting bracket. B. The sample cooler shall be compact bolted design and shall require no larger space than 3-1/2" square x 5 1/2". The tubing and shell shall be removable for cleaning without disturbing connections. The cooling water connections shall be 3/8" FPT and the sample tube connections shall be 1/4" OD. C. The tubing shall be rated at 2000 psig at 635°F. The surface area shall be 1.2 sq. ft. D. Sample cooler shall be shipped loose for field mounting at jobsite. 2.11 BLOWDOWN TANK A. Provide one blowdown tank with 14"diameter, 56" length, 3/8"thick plate thickness. B. The tank shall be manufactured in accordance with ASME Code for 150 psig design and tested to 225 psig. C. Provide tank with ASME label and National Board certificates. D. The tank shall be furnished with thread connections up through 3"diameter and .with 150# flanged connections for 4"diameter and above. E. The tank shall include a perforated baffle at the point of inlet impingement furnished by the Vendor. F. Accessories: An electronic temperature actuated mixing control valve to automatically control the flow of cold water by responding to temperature changes sensed at the thermostatic bulb in the aftercooler fitting. The tank shall include pressure gauge, glass gauge, inspection cover, 5"bottom drain, siphon breaker, 6" vent outlet, 2" blowdown inlet and 1-1/2" cold water inlet. G. The tank shall be furnished with a welded floor mounting stand. H. The tank shall be fitted with openings to facilitate cleaning and inspection. REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 12 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doe I. Electronic flame detector to prevent primary fuel valves from opening until pilot flame is established. 2.8 MARKING A. The boiler shall be provided with a stainless steel nameplate,permanently attached to the exterior of the equipment, in an accessible location external to any insulated surface, and observable while the equipment is in operation. The nameplate shall include the following information: 1. Manufacturer's name,model and serial number. 2. Year built. 3. Purchaser's purchase order number. 4. Purchaser's equipment identification number(BLR-3). 5. Weight of equipment. 6. Code symbol and national board number(where applicable). 2.9 CHEMICAL FEED SKID Chemical Feed Skid shall be furnished with the following associated equipment: A. Provide a pre-assembled,packaged chemical feed system without chemical metering pump. The unit shall be hydraulically and electrically tested at the factory and shall be assembled to the fullest extent possible. The package shall be furnished with all the required lubricants, special tools and installation instructions. B. Chemical feed pumps are currently installed at the jobsite. New chemical feed pumps and piping shall not be included in the pricing. C. The system shall consist of a tank with portable mixer,piping and accessories as defined below. The manufacturer will select all materials in contact with the chemical and guarantee their suitability for the particular service. D. The tank shall be 50-gallon capacity constructed of polyethylene and furnished with a hinged or removable cover. The tank shall include connections for pump suction, drain, level gauge, chemical fill, dilution water, and relief valve return piping. Drain connection shall be separate from the pump suction connection. Suction connection shall be on the sidewall of the tank a minimum of 2" above the bottom. E. The tank shall be furnished with a drain valve, level switch and level gauge. F. The mixer shall be an angle plate mounted mixer with a 304SS shaft and propeller. The mixer propeller shall operate at 1750 rpm. REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 11 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doe C. Electronic programming relay shall control ignition, starting and stopping of burner and provide both pre-combustion purge and post combustion purge. The controller shall have a self-checking logic and shall have a fixed operating sequence incapable of being manually altered. D. The controller shall be of the non-recycle type to allow for maximum safety. Any of the following conditions shall accomplish a safety shut down("first-out" annunciation will be signaled on the annunciator panel): • High Gas Pressure • Low Gas Pressure • Loss of Combustion Air Supply • Loss or Failure to Establish Flame • Loss of Control System Actuating Energy • Low Water Level as determined by the auxiliary low water level cut-out Additional lights shall indicate: • Load Demand • Fuel Valves Open Control Switches shall include: • Burner ON/OFF • Manual/Automatic • Manual Firing Rate Control E. The controller shall have a run/test switch. It shall allow interruptions to sequence after pre-purge, during pilot ignition trial and run cycles for adjustments for firing rate motor, damper linkages and pilot flame for minimum turndown tests. F. The panel shall contain the boiler flame safeguard controller,blower motor starter,plug-in type fuel modules,terminal blocks, control circuit transformer and circuit breaker. Power for the boiler and all auxiliary control components shall be via single point power connection. The panel shall have a separate hinged drop section for access to all wiring. G. Oil, heat and moisture resistant wire shall be used and identified with circuit numbers corresponding to electrical wiring diagrams furnished with the operating manual. H. Manual-automatic selectors switch and damper motor positioning switch to permit either automatic firing in accordance with load demand, or manual control of firing rate at any desired point between low fire and maximum rating. REV. 0 PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 10 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doc dbA(when measured in accordance with ABMA Sound Test Standards). 2. The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft. The blower and low NOx motors shall be premium efficiency meeting the following table criteria: TOTALLY ENCLOSED FAN-COOLED MOTORS TEFC 1200 RPM 1800 RPM 3600 RPM Motor HP Minimum Efficiency Minimum Efficiency % Minimum Efficiency 2 88.5 86.5 86.5 3 89.5 89.5 88.5 5 89.5 89.5 89.5 7.5 91.7 91.7 91.0 10 91.7 91.7 91.7 15 92.4 92.4 91.7 20 92.4 93.0 92.4 25 93.0 93.6 93.0 30 93.6 93.6 93.0 40 94.1 94.1 93.6 2.6 EMISSION CONTROLS A. Boiler shall be equipped with a Low Emission(LE) Option for guaranteed NOx performance at 30 ppm, dry volume basis and corrected to 3% O2 when firing natural gas. B. Boiler fuel-to-steam efficiency and rated boiler capacity shall be guaranteed while the boiler is operating at the low NOx performance levels. C. Burner,boiler and low NOx system shall be manufactured as a package by a single manufacturer. The Low Emission Option shall include factory testing as a package, and shall bear the UL packaged label. The boiler nameplate shall include the approved UL low NOx boiler model designation. 2.7 CONTROL PANEL A. The boiler control panel shall contain all motor starters, disconnect switch, step down transformers,power distribution, and controls required for boiler operation. The control panel will be powered from a 480 volt, 3 phase, 3 wire, 60 Hz dedicated feeder from a remote source. All interconnection wiring between the controller and the boiler equipment shall be provided by the boiler manufacturer. B. The hinged metal cabinet with key lock shall contain programming relay and blower motor starter. The cabinet shall be a NEMA 1 enclosed with neoprene dust seal gasket. REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 9 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doc integral with the front head of the boiler and shall be a high radiant multi-port type for gas. The burner turndown shall be 10:1 on natural gas. B. Provide one combustion air damper and cam operated fuel valve operated by a single damper control motor, which shall regulate the fire according to load demand. Controls shall regulate the operation of the damper control motor. Ignition shall be electronic. C. The gas pilot shall be pre-mix type with automatic electric ignition. Pilot shall be monitored via electronic flame detector so that the primary gas valve cannot open until pilot flame has been established. The pilot shall include two manual shut-off valves, solenoid valve,pressure regulator and pressure gage. D. Gas Burner Piping: Provide complete gas train conforming to IRI standards, FM Insurance and NFPA 8501, factory piped and wired on boiler skid. Gas train shall include: 1. Manual shutoff valve, lubricated plug type. 2. Pressure regulating valve. Provide high pressure IRI gas train for 10 psi inlet pressure. 3. Upstream and downstream pressure gauges with shutoff cocks. 4. Motor operated primary and secondary main gas valves,with spring return (normally closed). 5. Vent valve located between main gas valves, solenoid operated, spring return(normally open). A plugged leakage test connection and a second lubricated plug valve shall be provided as a means of testing for tightness of the primary shut-off valve. 6. Provide low and high gas pressure switches, proof of closure(limit) switch for the primary shut-off valve and a plugged test port. 7. Pilot gas train, including pressure regulator, manual and automatic shut off valves,vent valve, and pressure gauge. 8. All gas piping shall be Schedule 40 with flanged or threaded connections. E. Blower: Air for combustion shall be supplied by a forced draft blower mounted in the front of the boiler. 1. Maximum sound level of the boiler/burner package shall not exceed 88 REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 8 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doc appurtenances. 2.4 STEAM BOILER TRIM A. Provide pressure gauge,with 6" dial gauge (0-300 psi)with isolation valve, inspectors test cock, and syphon,piped to the steam drum. B. Provide water column with cocks; gauge glass set and blowdown valves for gauge glass and column. C. Provide float type low water cut-off with manual reset integral with water column to automatically prevent burner operation whenever boiler water falls below safe level. D. Provide probe type auxiliary low water cut off with manual reset,piped to the vessel and wired to the burner control circuit. E. Provide proportioning electrically actuated feed water control valve to maintain the boiler water level within normal limits. Provide a controller for the valve integral with the boiler package. Feed water control valve is to be field installed. F. Provide and install safety valves of size and type to conform with ASME code. G. A steam pressure controller shall regulate the burner to maintain steam pressure setting. Controller shall maintain steam header pressure at plus or minus 3 psig. H. A high limit pressure controller shall control burner to prevent steam pressure from exceeding safe system pressure. Control shall be a high limit (manual reset), operating limit (auto reset), and firing rate control. I. Provide a flanged 6" non-return valve straight pattern, a 6" flanged stop valve and an ASME stamped spool piece (inlet size of boiler x 6" outlet x 48" in length) with two free blow valves for direct mounting on boiler steam outlet. J. Supply bottom blowdown valves, three total with one slow opening valve. K. The modulating feedwater pump control shall be included as an integral part of the water column to automatically actuate a full-proportioning feedwater control valve to maintain the boiler water level within normal limit. 2.5 FUEL BURNING SYSTEM A. Provide one forced draft automatic low NOx burner designed to burn natural gas. Burner operation shall be full modulating with a low fire ignition position. Maintain fuel-air ratios automatically and maintain flue gas temperature minimum 68°F above dew point temperature of flue gases at boiler. The burner shall be REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 7 SPE-16040-15550 JAI 6040\Specs\Fina1\15550_Rev O.doc 2.0 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Kewaunee B. Cleaver Brooks C. Superior 2.2 GENERAL A. Provide factory assembled, factory fire-tested, self contained, readily transported unit ready for automatic operation except for connection of boiler feed water, steam distribution piping, natural gas, electrical, vents,breeching, ladder and platform and blowdown services. The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall be of the UL label. B. Unit: Mount on integral structural steel frame base and include integral forced draft burner, burner controls,boiler trim,refractory, insulation and jacket. 2.3 BOILER SHELL A. Construct and stamp in accordance with applicable ASME Boiler and Pressure Vessels Code for a design pressure of 150 psig steam and maximum operating pressure of 125 psig. B. Provide two lifting eyes on top of boiler. C. Provide hinged or davited front and rear doors, gas tight, insulated, and secured with heavy-duty cap screws and replaceable brass nuts. D. Front and rear tube sheets and flue shall be fully accessible for inspection and cleaning when doors are open. E. Provide observation ports at each end of boiler with accessibility for cleaning. F. Provide handholes and manhole for boiler inspection and cleaning. G. Insulate casing with readily removable 2-inch thick glass fiber blanket insulation covered by sectional preformed sheet metal jacket. H. Factory paint boiler,base, and other components with hard finish silicone enamel. I. Provide one thermometer, 3 1/2-inch diameter,black letters on white background, bi-metal type for stack temperature. J. The boiler tubes shall not include turbulators, swirlers, or other add-on REV. 0 PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 6 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doc gas. B. The complete unit shall be tested at the factory under full load, firing with natural gas. Submit a copy of the actual performance test. C. Each bid shall be accompanied by a performance sheet indicating the guaranteed overall thermal efficiency for the equipment offered, at 25, 50 and 100%rated capacity. Base performance calculations on the following excess air limits: 10% excess air at 100%MCR 15% excess air at 20%MCR D. The packaged boiler shall receive a factory test to check the construction, control and operation of the unit. All tests may be witnessed by the purchaser, if desired. 1.8 SELECTION CRITERIA A. The boiler selected shall meet or exceed the design data listed below: ITEM DESCRIPTION Unit Tag BLR-3 Boiler Capacity .P. 600 Design Pressure 150 psig Operating Pressure 100 psig Turndown natural as 10:1 Boiler Input natural as 25,104 cubic feet/hour Boiler Output 212°F 20,085 lbs/hour Blower Motor H.P. 25 Low NOx Recirculation Motor H.P. 15 Boiler Voltage 460 V—3 phase—60 Hz Minimum Total Amps 79.1 Minimum Boiler Efficiency 100% 80.0% Minimum Boiler Efficiency 25% 80.0% Minimum Gas Pressure 54.43 in w.g. Maximum Gas Pressure 10 psi in w.g. Unit Weight 40,000 lbs. B. Space Constraints 1. The boiler shall be sized to fit into an envelope space of 33'-6" L x 13'-0" W x 13'-0" H. The length specified includes the boiler tube removal space. REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 5 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doc ASTM American Society for Testing and Materials BOCA Buildings Officials and Code Administrators International FM Factory Mutual IRI Industrial Risk Insurers ISA Instrument Society of America NEC National Electric Code IEEE Institute of Electrical &Electronics Engineers NIST National Institute of Standards and Technology NEMA-MGI National Electrical Manufacturers Association-Motors and Generators OSHA Occupational Safety and Health Administration SSPC SP6 Steel Structures Painting Council, Systems and Specifications. Code of Commercial Blast Cleaning. 1.6 QUALITY ASSURANCE A. Manufacturer: Company specializing in manufacturing the products specified with minimum (5)years documented experience. B. Provide factory tests to check construction, controls, and operation of unit. C. Provide authorized boiler inspection prior to shipment and submit copy of manufacturers data report to the Engineer. D. Provide one-year manufacturer's warranty parts and labor of entire system package from date of start up and acceptance. E. Provide ten(10)year warranty on all door refractory lining. F. All boiler controls shall be Y2K compliant. 1.7 EFFICIENCY GUARANTEE A. Efficiency verified by factory and site test shall be as listed below. The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve 80.0% fuel-to-steam efficiency at 100%to 25% firing rate when burning natural REV. 0 PFI DESIGN, P.C. DECEMBER 20, 2000 Pg. 4 SPE-16040-15550 JAI 6040\Specs\Fina1\15550_Rev O.doc 1.3 SAFETY AND HEALTH A. All equipment shall comply with the latest edition of EPA, OSHA,NFPA,UL, ANSI, ASHRAE, ASTM,NFPA standards, and other National, state, and local codes and regulations applicable at the Owner's plant location in Northampton, Massachusetts. 1.4 DEFINITIONS A. Owner: The Minute Maid Company 45 Industrial Drive Northampton, MA 01060 B. Architect/Engineer: Process Facilities Inc. 160 Federal Street Boston, MA 02110-1700 (617) 946-9400 C. Contractor: PFI Construction Corp. 160 Federal Street Boston,MA 02110-1700 (617) 946-9400 1.5 CODES AND STANDARDS Various codes, standards, or other documents that are mentioned by short-form name elsewhere in this Specification are fully identified below. To the extent that these documents apply,the version of the document that is applicable at the time the purchase order is placed shall apply. Short Name Complete Identification of the Document ASME American Society of Mechanical Engineers Boiler and Pressure vessels Code, Section 1,Power Boilers ASME VIII American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section VIII, Division 1 for Pressure Vessels. ANSI American National Standards Institute B31.3 Code for Piping, Chemical Plant and Petroleum Refinery Piping. B16.5 Code for Steel Pipe Flanges,Flanged Valves and Fittings. ASHRAE American Society of Heating, Refrigerating, and Air-Conditioning Engineers REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 3 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doc E. Provide lead time for delivery of boiler to site. F. Furnished by Purchaser The following equipment,materials, utilities and services will be supplied by the Purchaser: 1. Labor and equipment for unloading and erection of all equipment at the job site. 2. Insulation of Vendor equipment as specified herein. 3. Concrete foundations, anchor bolts and grouting as required. 4. 460 volt, 3 phase, 60 Hz power supply. 5. 10 psig natural gas supply. 1.2 SUBMITTALS A. General: Submit each item in.this Article according to the conditions of the Contract. Obtain approval from PFID before proceeding with fabrication and work. Six (6) copies shall be submitted to the Construction Manager. B. Product data including the following: 1. Selection criteria and certified performance data. 2. Material gages and finishes. 3. All accessories being provided. 4. Code certificates. 5. Boiler auxiliaries. 6. Boiler controls. C. Shop Drawings from manufacturer detailing equipment assemblies and indicating dimensions, weights, loadings,required clearances,method of field assembly, components, and location and size of each field connection. D. Wiring diagrams detailing wiring for power and control systems and differentiating between manufacturer-installed and field-installed wiring. E. Spare parts list with part numbers and pricing for ordering and recommended locations to purchase parts. F. Installation, Operation, and Maintenance manuals. REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 2 SPE-16040-15550 JA16040\Specs\Fina1\15550_Rev O.doc + FIRE TUBE BOILER SECTION 15550 1.0 GENERAL REQUIREMENTS 1.1 SCOPE OF WORK A. The Vendor shall provide and deliver one(1) 600 BP gas-fired packaged steam fire tube boiler to Northampton, MA. The 600 BP boiler shall be capable of producing a steam rate of 20,085 lb/hr at 212°F, with a design pressure of 150 psig. The operating pressure shall be 100 psig. The boiler package shall include boiler shell and trim, controls, fuel trains and burner, all skid mounted as specified herein. Items furnished by the boiler manufacturer to be installed in the field by others shall include natural gas components, control panel, chemical feed skid etc. The boiler shall be designed to operate with 480V/3-phase/60 cycle electric power. B. The Vendor shall furnish all documentation as indicated in this specification and comply with all the requirements set forth on the Purchase Order. C. The Vendor shall submit with bid, three(3) copies of published catalog information indicating materials of construction and unit configuration with dimensioned record drawings for the boiler, along with all pertinent performance data, including but not limited to: 1. Product data indicating general assembly, components, safety controls, wiring diagrams, service connections, and service clearances for boiler package. 2. All accessories, valves, trim, etc., as described under paragraph 2.4. 3. Burner piping, valves, gas train, gas pressure requirements (minimum and maximum), etc., as described under paragraph 2.5 and 2.6. 4. Boiler controls as described under paragraph 2.7. 5. Boiler auxiliaries including chemical feed skid, sample cooler and boiler blowdown tank. 6. Emissions data. D. Submit wiring diagrams for electrically operated equipment. Differentiate between wiring that is factory installed and wiring that is field installed. Submit load calculations indicating Electrical Load. REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. 1 SPE-16040-15550 JA16040\.Specs\Fina1115550_Rev O.doc + TABLE OF CONTENTS 1.0 GENERAL REQUIREMENTS..........................................................................................1 1.1 SCOPE OF WORK.............................................................................................................1 1.2 SUBMITTALS ...................................................................................................................2 1.3 SAFETY AND HEALTH...................................................................................................3 1.4 DEFINITIONS....................................................................................................................3 1.5 CODES AND STANDARDS.............................................................................................3 1.6 QUALITY ASSURANCE..................................................................................................4 1.7 EFFICIENCY GUARANTEE............................................................................................4 1.8 SELECTION CRITERIA...................................................................................................5 2.0 PRODUCTS........................................................................................................................6 2.1 ACCEPTABLE MANUFACTURERS ..............................................................................6 2.2 GENERAL..........................................................................................................................6 2.3 BOILER SHELL................:................................................................................................6 2.4 STEAM BOILER TRIM.....................................................................................................7 2.5 FUEL BURNING SYSTEM...............................................................................................7 2.6 EMISSION CONTROLS....................................................................................................9 2.7 CONTROL PANEL............................................................................................................9 2.8 MARKING .......................................................................................................................11 2.9 CHEMICAL FEED SKID ................................................................................................11 2.10 SAMPLE COOLER..........................................................................................................12 2.11 BLOWDOWN TANK......................................................................................................12 2.12 ELECTRICAL REQUIREMENTS, MOTORS................................................................13 3.0 EXECUTION..................................................................................... .............................15 3.1 TESTS...............................................................................................................................15 3.2 CLEANUP........................................................................................................................16 3.3 PREPARATION FOR SHIPMENT.................................................................................16 3.4 START-UP ASSISTANCE..............................................................................................17 3.5 DELIVERY.......................................................................................................................17 REV. 0 PFI DESIGN,P.C. DECEMBER 20, 2000 Pg. i SPE-16040-15550 JA16040\Specs\Final\15550_Rev O.doc � g PFI DESIGN,P.C. SPECIFICATION FOR FIRE TUBE BOILER SPE-16040-15550 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 t,X A 11/17/00 Issue for Bid KAB TAE MJH HM 0 12/20/00 Issue for Construction KAB TAE MJH HM Client Approval: Client: Date: f t 1. Adjacent to each valve and fitting. 2. At each branch and riser take-off. 3. At each pipe passage through walls, floors or ceilings. 4. On all straight pipe runs every 20 feet. 3.24 VALVE CHART AND SCHEDULE A. Provide a valve chart and schedule in aluminum frame with clear plastic shield. Install at a location as directed by the Engineer. 3.25 FIXTURE ADJUSTING AND CLEANING A. Adjust stops or valves for intended water flow rate to fixtures without splashing, noise, or overflow. B. At completion, clean plumbing fixtures, trim and equipment of all debris, completely acceptable to the Engineer and the Owner. ++END OF SECTION 15400++ REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 46 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc i 3.20 INSULATION JACKET A. Insulation jackets shall be tight, free from fishmouths. 3.21 VAPOR BARRIER A. Vapor barrier shall be continuous, and shall be full vapor sealing at insulation termination and shall be installed in accordance with Part 2 of this Specification. 3.22 INSULATION SCHEDULE A. Insulation thickness and types for major plumbing items and systems shall be in accordance with Part 2 of this Specification. 3.23 SYSTEM IDENTIFICATION A. Install plastic nameplates with corrosive-resistant mechanical fasteners, or adhesive. B. See Division 1 for tagging requirements. C. Apply stencil painting in accordance with the requirements of Division I. D. Install plastic pipe markers in accordance with manufacturer's instructions. E. Install plastic tape pipe markers completely around pipe in accordance with manufacturer's instructions. F. Identify equipment with stencil painting. Small devices may be identified with plastic tags. Equipment nameplates and tags shall include the project symbol as listed in the equipment schedules on the drawings. G. Identify control panels and major control components outside of the panels with plastic nameplates. H. Identify valves in main and branch piping with tags. I. Identify piping, concealed or exposed,with plastic pipe markers. Tags may be used on small diameter piping. Identify service, flow direction, and pressure. Install markers in clear view and align with the axis of the piping. Locate identification not less than every 20 feet on straight runs, including risers and drops, adjacent to each valve, at "T's", at each side of penetrations of the structure or enclosure, and at each obstruction. J. Pipe markers and identification tag locations shall be as follows: REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 45 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doe c H. Take samples no sooner than 24 hours after flushing, from 10 percent of outlets and from water entry, and analyze in accordance with AWWA C601. 3.18 COMMISSIONING OF SYSTEMS A. The Owner shall check the completed installation either sequentially as different parts are completed, or when the entire installation is complete, at the sole option of the Owner. B. Prior to the Owner's checking a part of this installation or the entire installation, this Sub-contractor shall submit a letter signed by an officer of this Contracting company or an officer of the Engineer stating: 1. The individual is an officer of the company. 2. The individual has personally inspected the installations. 3. Inspection dates. 4. The installation is complete and tested and ready to be inspected by the Owner, and that all required test reports have been submitted. C. The Sub-contractor shall arrange for an officer of this Contracting company or of the Engineer to witness the listed tests, as well as to other test witnesses that may be required. At the conclusion of each such test,this Sub-contractor shall submit a letter signed by the officer stating: 1. The individual is an officer of the company. 2. The individual has personally witnessed the tests (provide name). 3. Test dates. 4. Test results as compared to specified performance. 5. List the name,title and company affiliation of all those witnessing the test. D. All piping and systems testing require letters. 3.19 INSULATION A. Insulation for piping, fittings, and other in-line items shall be installed in accordance with Part 2 of this Specification. B. Insulation shall be omitted at all equipment nameplates and/or data plates. REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 44 SPE-16040-15400 JAI 6040\SpecsWinal\15400_REV B.doc on the section to be tested shall be tightly closed except for the highest opening, and the entire section filled with water. Trapped air shall be bled from all dead ends of the section being tested. After air has been expelled, all parts of the system shall be subjected to 10 feet of hydrostatic head(4.3 pounds per square inch)without leaks. Individual systems tested shall be properly restrained at all bends, changes or directions, and at ends or runs. E. In lieu of a hydrostatic test, an air test shall be applied to all parts of the drainage and venting systems, EXCLUSIVE of the process waste and process vent systems,before the pipes are concealed or the fixtures installed. With all openings tightly closed,pump air into the system until the pressure within the system is not less or greater than 5 pounds per square inch above atmospheric pressure. The air gauge used should slow a constant pressure with no further pumping of air into the system for 30 minutes. F. Perform tests and adjustments on all process waste and process vent piping systems as recommended by the manufacturer's installation instructions. G. For the testing and adjusting of the process waste and process vent piping systems,this Sub-contractor shall refer to the latest edition of the pipe manufacturer's testing procedures. H. Before date of acceptance, furnish Owner with certificates of testing and inspection indicating approval of authorities having jurisdiction and conformance with requirements of Contract Documents. 3.17 DISINFECTION OF DOMESTIC WATER PIPING SYSTEM A. Prior to starting work, verify system is complete, flushed and clean. B. Ensure pH of water to be treated is between 7.4 and 7.6 by adding alkali (caustic soda or soda ash) or acid(hydrochloric). C. Inject disinfectant, free chlorine in liquid,powder, tablet or gas form,throughout system to obtain 50 to 80 mg/L residual. D. Bleed water from outlets to ensure distribution and test for disinfectant residual at minimum 15 percent of outlets. E. Maintain disinfectant in system for 24 hours. F. If final disinfectant residual tests less than 25 mg/L after 24 hours repeat treatment. G. Flush disinfectant from system until residual is equal to that of incoming water, or 1.0 mg/L. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 43 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc wwwwwr 3.11 VALVE INSTALLATION A. Install valves with stems upright or horizontal,not inverted. B. Install valves for shutoff and to isolate equipment and parts of the systems, including all sinks. C. Provide drain valves at low points of piping and valves at high points for venting. D. Install valves to permit easy operation,replacement, and repair. 3.12 PIPE ANCHORS A. Provide anchors as necessary for attachment of piping system supports. 3.13 INSERTS A. Use inserts for suspending hangers from reinforced concrete slabs and sides of reinforced concrete beams wherever practicable. 3.14 PIPE HANGERS AND SUPPORTS A. Provide Pipe hangers and supports as necessary for attachment of piping system in accordance with Part 2 of this Specification and with the latest applicable State Seismic Restraint Requirements. 3.15 FLASHING A. Flash and counter-flash where the plumbing piping systems pass through weather or waterproofed walls, floors, and roofs, in accordance with the requirements of the Architectural Specifications. 3.16 TESTING OF ABOVE GRADE PLUMBING SYSTEMS A. Testing, balancing and adjusting shall not relieve guarantee requirements. B. Provide services of qualified personnel, equipment and apparatus required to perform tests. C. All pressure and leak testing shall be completed prior to the application of the insulation. D. A hydrostatic test shall be made of all parts of the drainage and vent systems, including the process waste and vent systems,before the pipes are concealed and before the fixtures are installed. The test may be made in sections. All openings REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 42 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc X. Horizontal piping, suspended: 1. Support horizontal piping and fittings at sufficiently close intervals to maintain alignment and prevent sagging or grade reversal. Support each length of pipe by an approved hanger located not more than 18 inches from the joint. 2. Support terminal ends of all horizontal runs or branches and each change of direction or alignment with an approved hanger. 3.7 ESCUTCHEONS A. Install required escutcheons around exposed pipe passing through finished floors. Escutcheons shall be heavy cast brass, chromium-plated, adjustable, shall be of sufficient outside diameter to cover the opening and shall fit snugly around pipe. 3.8 JOINTS AND CONNECTIONS A. Joints and connections shall be permanent and shall be gas and watertight. Jointing shall be types specified for service indicated. Joints and connections shall meet requirements of manufacturers best-recommended practice. All transitions between different piping materials shall be made using approved adapters. Adapters for transitions between two types of piping materials shall be manufactured for the purpose intended. 3.9 CLEANOUTS A. Provide cleanouts in piping on straight runs, at changes in directions, and at the foot of stacks and other points where required by inspecting authorities. B. Cleanouts shall be same size as piping 4" and smaller. C. Cleanouts shall open in direction of flow of drainage line served or at right angles thereto. D. Keep cleanout plugs clean and unimpeded. Prevent covering with cement, epoxy or other permanent finishing materials. E. Lubricate all cleanout plugs with proper grease to prevent galling. F. All cleanouts shall be below floor. 3.10 SPECIALTIES A. Install all specialties in accordance with manufacturer's instructions to permit intended performance. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 41 SPE-16040-15400 JA16040\Specs\Fina1\15400_REV B.doc J. The Sub-contractor shall commence, if possible, each system's invert elevation work at the furthest floor drain from the tie-in connection point, if possible and work inverts out to insure proper slopes are maintained. K. Establish invert elevations of piping within the facility to ensure proper tie-in elevations into the existing drainage piping system. L. Establish invert elevation slopes for drainage at 1/8 inch per foot,minimum. Maintain gradients. M. Provide clearance for installation of insulation and access to valves and fittings. N. Piping shall not be installed below ceiling grid elevation unless otherwise noted. O. Provide proper caulk, sealant, or fire stop for all wall penetrations. P. Provide access where valves and fittings are not exposed. Coordinate size and location of access doors in accordance with the requirements of Division I. Q. Unless otherwise noted, field paint all exposed piping to comply with The Minute Maid Company facility standards, whichever is more stringent. R. Slope water piping and arrange to drain at low points. S. Prepare pipe, fittings, supports, and accessories not pre-finished,ready for finish painting. T. Use grooved mechanical couplings and fasteners only in accessible locations. U. Install unions downstream of valves and at equipment or apparatus connections. V. Install brass male adapters each side of valves in copper piped system. Sweat solder adapters to pipe. W. Vertical piping: 1. Secure vertical piping to keep in alignment and to support the weight of the pipe and its contents. Support stacks at the base and at each floor interval to meet the requirements of local codes. Approved metal clamps or hangers as specified shall be used. 2. If vertical piping is to stand free of any support and no structural element is available for support and stability during construction, secure piping in the proper position by means of adequate stakes or braces fastened to pipe. REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 40 SPE-16040-15400 JAI 6040\SpecsTinahl5400_REV B.doc 1. Installation shall meet material manufacturer's installation instructions exactly,particularly in regards to preparation of surfaces, removal of foreign materials, safety requirements, ventilation and other details of installation. Dam openings as required. Remove flammable materials used for damming and forming seals in fire-rated construction. 2. Core drill seals shall be water- and gas-tight and shall meet the requirements of ASTM E-119 Standard Methods of Fire Tests of Building Construction and Materials. 3. Inspect sealant to ensure that installation achieves manufacturer's optimum structure. 3.6 PIPING AND FITTING INSTALLATION A. Route all piping concealed, in an orderly manner, and maintain slope gradient. Exposed piping shall not be permitted. B. Install piping to conserve facility space and not interfere with use of space. C. Group piping whenever practical at common elevations. D. Install piping to allow for expansion and contraction without stressing pipe,joints, or connected equipment. E. "S"-trap pipe configurations shall not be permitted. F. Install process waste and process vent piping systems in accordance with manufacturer's installation standards. G. The Sub-contractor shall not allow dirt, debris, or other extraneous materials to contaminate waste and vent pipe or fittings. The Sub-contractor shall protect all pipe and fittings from sunlight until installed. H. Gaps at the joints between the floor drain/cleanout body outlets and the corresponding drainage piping inlets shall not be permitted. The Sub-contractor shall set piping properly and apply the proper sealant to the joints, as required, to prevent water seepage. Ensure sealant used will not be affected by drainage effluent. I. The Sub-contractor shall make as many field welds and interconnections between the fittings and piping as possible in lieu of using pre-purchased, factory assembled piping systems due to the extent that the pre-fabricated piping is inversely proportional to the degrees of freedom available for field modifications on site. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 39 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc B. Except as specified otherwise, material and equipment shall be new. Provide supplies, appliances and connections necessary for complete and operational installation. Provide components required or recommended by OSHA. C. References to manufacturers and catalog designations are intended to establish standards of quality for performance and materials but imply no further limitation of competitive bidding. D. Finish of materials, components and equipment shall be approved by the Engineer and shall be resistant to corrosion and weather as necessary. E. Owner shall not be responsible for materials and fixtures before final acceptance. 3.3 CONTINUITY OF SERVICES A. Do not interrupt existing services without Owner's approval. B. Schedule interruptions in advance, according to Owner's instructions, and as specified. Submit request for interruption with methods proposed to minimum length of interruption in writing a minimum of seven(7)working days in advance. C. Interruptions shall be scheduled at such times of day and work to minimize impact on Owner's operations. 3.4 PREPARATION A. Ream pipe and tube ends. Remove burrs and sharp edges by peening or filling the edge. B. Clean and remove scale, dirt,mud, gravel and other foreign material on inside and outside of pipe and/or fittings before assembly. C. Prepare all surfaces in accordance with manufacturers installation instructions and the requirements of Division 1. D. De-grease and clean all surfaces,which shall receive adhesive. E. Review plumbing fixture millwork shop drawings. Confirm location and size of fixtures and openings before rough in and installation. 3.5 PENETRATIONS A. Installation Testing, Listings and Approvals: REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 38 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc B. Provide valves with manufacturer's name and pressure rating clearly marked on outside of body. C. Manually operated valves shall close when rotated clockwise. D. Provide screw to solder adapters on valves for copper tubing where applicable. 3.0 EXECUTION 3.1 SUB-CONTRACTOR RESPONSIBILITIES A. Maintenance of fixtures and systems: Maintain fixtures and systems until final acceptance. Ensure adequate protection of fixtures and material during delivery, storage, installation and shutdown and during delays pending final test of systems and equipment because of seasonal conditions. B. Observations by Owner: Periodic observations by Owner, Architect or designated agent shall not be construed as supervision of actual construction, nor make observers responsible for providing safe place for performance of work of various trades or suppliers, or for visitors or occupants, or make either responsible for omission of safety devices called for by codes, ordinances, or specifications of manufacturer of equipment supplied. C. Surveys and measurements: 1. The Sub-contractor shall establish reference points to base his measurements,both horizontal and vertical, and be responsible for correctly laying out the work. 2. In event of discrepancy between actual measurements and those indicated, notify Engineer in writing and do not proceed with work until written instructions have been issued by Engineer. D. The Sub-contractor shall provide for the required equipment manufacturer's authorized factory personnel, on site, for final plumbing equipment inspection and start-up and include costs in his bid. 3.2 MATERIALS AND WORKMANSHIP A. Work shall be neat and rectilinear. Install materials and equipment as recommended by manufacturer. Installation shall operate safely and without leakage, undue wear,noise, vibration, corrosion, or water hammer. Use dielectric couplings between dissimilar materials. Close pipe openings to prevent obstruction and.damage prior to completion. ' REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 37 SPE-16040-15400 JAI 6040\SpecsTinahl5400_REV B.doc E. Penetrations through walls, floors, or ceilings to accommodate piping and appurtenances shall not increase the sound transmission class (STC) of construction. F. Sleeves at metal decking or flooring shall be welded to the decking or flooring as required to resist a 200 lb. horizontal force, applied in any direction at the top of the sleeve,without damage or permanent deformation of the sleeve,welds, deck or floor. G. All exposed lines,which pass through a floor, ceiling,wall,or partition shall have a chrome escutcheon cover plate. 1. The escutcheon plate shall make a snug sliding fit with the penetrating item, and the outer edge shall completely cover the opening in the structure penetrated and any patchwork around the opening. 2. Closures shall conform to all applicable codes and FM requirements. 3. The escutcheon plate at the insulated line shall be sized to fit over the insulation;which shall be adequately protected from chafing damage at the plate. Insulation shall be carried through the opening with no reduction in insulation thickness. 4. Each escutcheon plate at the floor shall cover the one-inch pipe extension above the finished floor. 5. In the exterior walls, the space between the pipe and the opening (the surface of the insulation and the opening for the insulated lines) shall be filled with as suitable non-combustible insulation, and the exterior face fully sealed against weather. The opening between the pipe and the wall shall be completely concealed, on both the inside and outside faces of the wall,by a neat cover or an escutcheon plate of non-corroding metal and shall be painted to match. The paint shall match as closely as possible in material, appearance, and durability of the finish on the walls. 6. Covers and escutcheon plates are not required where the pipe-wall joint shall not be visible in completed work, except as required to retain the insulation in the annular space between the pipe and the opening. 7. In interior partitions,walls, or floors, the space between the pipe and the opening shall be packed full with glass fiber insulation, held in place by a positive means, such as an escutcheon or a cover plate. 2.14 GENERAL A. Provide all plumbing items of the same manufacturer throughout where possible. REV. B PFI DESIGN,P.C. JANUARY 26,2001 Pg. 36 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc 2.13 PENETRATIONS AND CORE DRILLING A. The Sub-contractor shall not do any core drilling without the written consent and approval of the Engineer and the Structural Engineer. The locations of the openings shall be laid out in advance and indicated with chalk. The sizes, locations and dimensions of the openings shall be checked and verified against the equipment and general arrangement plans by the Engineer and the Structural Engineer prior to any core drilling. B. As permitted, the Sub-contractor may then make neat, cored holes in the concrete and masonry. 1. The Sub-contractor shall thoroughly investigate the existing conditions in the vicinity of required opening prior to coring. The Sub-contractor shall not disturb existing systems unless as specified. 2. The Sub-contractor shall be responsible for all damages to the facility and its systems from core drilling operations. 3. For slab on grade construction,provide waterproofing membrane locking devices at floor penetrations. Where penetrations occur at foundation walls,provide 150 lb. slip-on welding flanges. 4. Acceptable waterproof pipe penetrations(not for use for slotted concrete) shall include modular mechanical penetration seals shall be interlocking synthetic rubber links with galvanized carbon steel nuts,bolts, and pressure plates to expand the rubber seals to make an acceptable watertight seal for the annular space between the pipe and the concrete opening. The seal shall be completely watertight and shall be"Linkseal" modular mechanical type interlocking links. C. The cored opening in the floor shall have a tight-fitting 12 gauge galvanized sheet metal sleeve, adequately anchored and caulked to provide as watertight an instal- lation as a cast-in-place sleeve. The sheet metal sleeve shall extend above the finished floor. See detail. D. For pipes which extend from a dry area through a wall, ceiling or roof into a wet area or where vibration suppression is required between the pipe and the concrete element through which it passes (not for use for slotted concrete), the pipe penetration shall be sealed with neoprene gaskets and compression flanges or similar approved devices,to ensure a watertight seal between the pipe and the wall, etc., surrounding the pipe. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 35 SPE-16040-15400 JAI 6040\SpecsTinahl5400_REV B.doc Weight - oz./yd.2 7.8 8. PVC fitting covers shall conform to Fed. Spec..L-P-535, Composition A, Type II. 9. Staples and tack fasteners shall be outward clinching type, conforming to ASTM A 167, Type 304 or 316 stainless steel. 10. Vapor barrier coating shall conform to Mil. Spec. MIL-C-19565, Type H, white. 11. Wire shall be 16 gauge, soft-annealed, galvanized. 12. Protection shield(at hanger or support) shall be galvanized steel, conforming to Fed. Spec. WW-H-171, Type 41. 13. Piping supported by standard and split ring hangers shall have hangers insulated with the same insulation thickness as the adjacent pipe. All seams and butt joints shall be sealed with Armstrong 520 contact adhesive. Ring hangers may be sleeved using oversized tubular insulation. On cold piping, insulation shall extend up hanger rod a distance equal to four times the insulation thickness. Insulation tape may be used to a thickness equal to the adjacent insulation thickness. 14. Saddles shall be installed under all insulated lines at Unistrut clamps, clevis hangers or locations where the insulation may be compressed due to the weight of the pipe. Wood dowels or blocks of a thickness equal to the insulation shall be inserted and completely sealed into the insulation if the excessive compression of the insulation remains at the saddle locations. 15. Hangers shall be installed over insulation. 16. Insulation finish shall be equal to Armstrong WB,Armaflex Finish, or Armstrong 58 Armaflex Finish. 17. Anchors shall be field attached to internal pipe, as specified, and sealed to pipe jacketing with manufacturer's standard anchor insulation kit. K. Schedule of Pipe Insulation—Refer to 2.14 "I" Insulation Jacket Piping System Type Thickness Type Water Piping(all) Hot and Cold GD 1" a REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 34 SPE-16040-15400 JA16040\Specs\Fina1\15400_REV B.doc a. Contact adhesive shall conform to Mil. Spec. MIL-A-24179, Type H, Class I. b. Asphalt mastic shall conform to MIL. Spec. MIL-C-82052. C. Contact adhesive referred to in this specification shall be equal to Armstrong 520 adhesive. d. Self-sealing type lap may be used in lieu of the specified adhesive for sealing longitudinal seams and end joints of pipe insulation. 2. Bands a. Insulation bands shall be galvanized steel, 3/4x 0.015 in. b. Bands to secure aluminum jacket shall be 3/8 x 0.20 in. aluminum or stainless steel. 3. Bedding Compound shall conform to Mil. Spec. MIL-B-19564. 4. Thermal insulation cement shall conform to Spec. SS-C-160. 5. Glass tape shall conform to Mil. Spec. MIL-C-20079, Type H, Class 1. 6. Glass cloth shall conform to Mil. Spec. MIL-C-20079, Type I, Class 1, untreated. 7. Jacket, all jackets shall be aluminum or pvc. a. Jacket shall not support mold growth. b. Pipe and equipment vapor barrier jacket shall conform to Fed. Spec. HH-B-100, Type I. C. Jacket on insulation exposed in all areas shall have white finish suitable for cGMP areas. d. Pre-sized glass cloth jacket shall be mildew proof,with integral vapor barrier with perm rating equal to or smaller than that required for applicable service, and with the following properties: Prop= ASTM Test Units Value Bursting strength D 774 lb./in.2 >,200 Puncture resistance D 781 each >1 100 REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 33 SPE-16040-15400 JAI 6040%pecsTina1\15400_REV B.doc F. Except as otherwise noted, insulation shall have white jackets and adhesive shall be white or clear. G. Except as otherwise noted, the use of insulation tape shall not be acceptable. H. Insulation on strainers and other fittings, accessories, and equipment requiring servicing or inspection shall have insulated PVC covers packed with insulation, which shall be removable and replaceable without damaging insulation or vapor barrier. I. Insulation and jackets shall be types listed below. Thermal conductivity listed are maximum acceptable. Except as otherwise noted, conductivity shall be measured at mean temperature= 100°F. Conductivity of proprietary insulation,where not listed herein, shall be as standard with manufacturer for listed product. 1. Type CS -hydrous calcium silicate, temperature limit to 1200°F. (640°C), density of at least 13.8,thermal conductivity of 0.40, at a mean temperature of 300°F, compressive strength not less than 200 PSI at 5% compression,modulus of rupture of 70 PSI, equal to Schuller "Thermo-12Gold." Provide field applied rewettable glass fabric outer finish, or with outer finish equal to adjoining insulation outer finish. 2. Type GD—Factory molded glass fiber,temperature limits of-20°F (-29°C)to 450°F (232°C), thermal conductivity of 0.30 at a mean temperature of 75°F,with an all-service,vapor proof jacket and self- sealing lap,equal to Manson"AK Flex." Fittings and valves shall be insulated with pre-moulded PVC covers with precut fiberglass inserts and edges vapor sealed with tape, equal to Schuller Zeston 2000 fitting covers. 3. Type ES—Flexible closed-sell elastomeric, tubular or sheet form, temperature limits of-70°F (-57°C)to 220°F (104°C), thermal conductivity of 0.27 at a mean temperature of 75°F,maximum water vapor transmission of 0.10 perm-inches, equal to Armstrong"AP Armaflex,""AP Armaflex SS,"or"AP ArmaflexSA." 4. Type FP—Foamed polyolefin,pre-slit, flexible ammonia free,temperature limits of-165°F (109°C)to 210°F (99°C),thermal conductivity of 0.24 at a mean temperature of 75°F,maximum moisture vapor transmission of 0.0 perm-inches, equal to Imcoa Imcolock. 5. Type TB—One piece,premolded type, equal to True bro"Handilav"kit. J. Accessories shall conform to the following, except where other specific product is specified. 1. Adhesives REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 32 SPE-16040-15400 JAI 6040\Specs\Fina1115400_REV B.doc B. Alternative insulation is subject to Engineer's approval. Alternatives shall provide the same thermal resistance within 10%, at normal conditions, as materials specified. C. Definitions: 1. Cold piping: Pipes where the normal operating temperature is 60°F. or lower. 2. Third party supervision testing: Verification testing by a nationally recognized independent testing organization that will conduct sampling of the product through to simulated end use testing. 3. Thermal Conductivity: The amount of heat in Btu's transferred in one hour through one square foot of homogenous material one inch in thickness when there is a temperature difference of I'F. 4. Compression fit method: To allow for expansion and contraction of sheet and roll insulation, leave a %2"wide uncoated border at the butt edge seams on the surface to be insulated and the insulation surface. Overlap the insulation %4" at the butt edge and compress the edges into place. Apply adhesive to the butt edges of the insulation. D. Materials, coatings, and accessories listed below are exempted from the fire resistance requirements: Asphaltic mastic, nylon anchors,weatherproof coating. E. Physical values employed in this section are expressed in the following units: Quanti1y Unit Density lb./sq.ft.3 Temperature °F, or°C. Thermal conductance' "C"value Btu/hr x ft.2 x °F. Thermal conductivity2"k"value Btu x in./hr x ft.2 x °F. Thermal resistance"R"value hr. x ft.2 x °F/Btu 'Conductance is applicable to homogeneous materials. 2Conductivity is conductance of homogeneous material of unit thickness (inches in conventional units). REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 31 SPE-16040-15400 JA16040\Specs\Fina1\15400_REV B.doc 2.8 EXPANSION JOINTS A. Expansion joints shall be of the pack-less, corrugated type. Circumferential welded seams shall not be permitted in the bellows material except for seal welds, which join bellows to end connections. Bellows shall be fabricated from stainless steel. B. Expansion joints shall be suitable for the temperatures,pressures and thermal movements required. 2.9 PIPE ANCHORS AND GUIDES A. Anchors shall be secured to the facility's structural members only. B. Guides shall be equal to "Fabreeka,"Figure 189. 2.10 PLUMBING SYSTEMS IDENTIFICATION MATERIALS A. Unless specified otherwise, colors shall conform with ANSI/ASME A13.1 and Owner's facility standards. B. Nameplates shall be laminated three-layer plastic with engraved black letters on light contrasting background color. C. Plastic tags shall be laminated three-layer plastic with engraved black letters on light contrasting background color. Tag size minimum shall be 1-1/2 inch in diameter. Brass tags shall be 19 gauge, 12" diameter with 3" black-filled letters over 2" black-filled numbers. Coordinate with the requirements of Division 1. D. Stencil paint shall be in accordance with the requirements of Division I. E. Plastic pipe markers shall be factory fabricated, flexible, semi-rigid plastic, preformed to fit around the pipe or pipe covering with minimum information indicating flow direction arrow and the fluid being conveyed. F. Plastic tape pipe markers shall be flexible vinyl film tape with pressure sensitive adhesive backing and printed markings. 2.11 INSULATION A. Furnish all insulation,jacketing, caulking, finishing materials, including bands, wiring, supports, and any other fasteners required to secure the insulation to the plumbing piping and to protect the insulation from weather and moisture penetration. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 30 SPE-16040-15400 JA16040\Specs\Fina1\15400_REV B.doc B. Shut-off valves isolating emergency fixtures shall be left normally open and shall have removable handles with removed handles turned over to the Owner. 2.5 UNIONS, AND COUPLINGS A. Furnish all unions and couplings as listed in Piping Material Index. Size 2-inch and under shall be all bronze for copper piping. B. Dielectric connections shall be equal to"Clearflow Fittings"by Victaulic. 2.6 INSERTS A. Inserts shall have a malleable iron case with a galvanized steel shell and expander plug for threaded connection with a lateral adjustment, top slot for reinforcing rods, lugs for attaching to forms; Figure 650 for 1/4 inch through 5/8 inch rods and Figure 266 for 3/4 inch to 1 inch rods. 2.7 PIPE HANGERS, SUPPORTS, AND HANGER RODS A. Hangers for pipe sizes %Z inch through 1-1/2 inches shall be adjustable wrought steel swivel ring band type with knurled nut and threaded, self-locking insert; Figure 800. B. Hangers for pipe sizes 2 inches through 5 inches shall be adjustable wrought steel clevis; Figure 100 or Figure 265 CVB with insulating saddle for insulated pipe. C. Hangers for pipe sizes 6 inches and large shall be roll hanger type; Figure 142 or Figure 265 CVB with insulating saddle for insulated pipe. D. Wall support for pipe sizes to 3 inches shall be light welded steel bracket; Figure 69 or Figure 78. E. Wall support for pipe sizes 4 inches and over shall be welded steel bracket; Figure 84 or Figure 139. F. Vertical pipe support or riser clamp shall be steel riser clamp; Figure 126 or Figure 89 for special log dimensions. G. Floor support for pipe sizes to 4 inches shall be offset pipe clamp; Figure 179, or Figure 351 with Figure 64, locknut nipple, floor flange, Figure 185, and steel support,Figure 333. H. Design hangers to impede disengagement by movement of the support pipe. I. Provided continuous threaded steel hanger rods; Figure 94. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 29 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc 2.2 ACCEPTABLE MANUFACTURERS A. Process waste and process vent piping system and appurtenances: Enfield, George Fisher, or approved substitute. B. Floor Cleanouts: Enfield, Josam,Zum, or approved substitute. Trench Drains: PolyCast, Aco drains or approved substitute. C. Shut-off valves: Crane, Grinnell, Jenkins,Nibco, Stockham, Watts, or approved substitute. D. Plumbing system identification: Seton,Brady, or approved substitute. E. Insulation: Armstrong, Imcoa, Knauf, Manson, Owens-Corning, Schuller, Zeston, or approved substitute. F. Pipe fitting covers: Armstrong, Imcoa, Manson, Owens-Corning, Zeston, or approved substitute. G. Vapor barrier coatings: Armstrong, Benjamin-Foster, Childers, Insul-Coustics, or approved substitute. H. Adhesives: Armstrong, Imcoa, Insul-Coustic, Schuller, or approved substitute. I. Emergency safety equipment: Encon, Speakman or Sunroc. J. Hangers: Carpenter&Paterson, Grinnell, Michigan Hanger Co., or approved substitute. Except as otherwise noted, hanger and support figure numbers referred to are those of Carpenter&Paterson. K. Items of the same function and performance shall be acceptable if submitted and approved in conformance with the requirements of Division I. 2.3 CLEANOUTS A. Process waste floor ceanouts shall be located flush with the floor. 2.3 FLOOR AND TRENCH DRAINS A. Process waste trench and floor drains shall be installed flush with the floor. 2.4 SHUT-OFF VALVES A. Furnish all shut-off valves as listed in Piping Material Index. REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 28 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc 4. PIPING SPECIFICATION: CS 2 SERVICE: Natural Gas MAXIMUM OPERATING CONDITIONS: 10 psi at 120°F ITEM SIZES GENERAL DESCRIPTION PIPING 2 %"and smaller Schedule 40 carbon steel ASTM A53 Grade B, A106 Grade A or A120. 3" and larger Schedule 40 carbon steel ASTM A53 Grade B, A106 Grade A or A120. FITTINGS 2 %z " and smaller Screwed malleable iron, 125 psi 3" and larger Butt weld carbon steel Schedule 40,A234 forged steel. UNIONS 2 % "and smaller Screwed 150#malleable iron Al 05. 3"and larger Flanges. FLANGES 21/2"and smaller 150#raised face, A105. 3"and larger 150#raised face weld neck A105,ASTM A181, Grade 1. 150# flat face for cast iron valve. VALVES Plug, Gas Cock 2Y2 " and smaller Bronze screwed end 125 psi working pressure, Class 254. 3"and larger Iron body, lubricated tapered plug, flanged end, 175 psi working pressure,Nordstrom 143. Check 2V2 " and smaller 150#,bronze swing check valve, screwed cap, with threaded ends. 3"and larger -- GASKETS 2V2 " and smaller 1/16"red rubber,wire inserts, 150#raised face and 125#flat face gasket. REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 27 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc 3. PIPING SPECIFICATION: CU2 SERVICE: Compressed Air DESIGN CONDITIONS: 150 psig @ 150°F ITEM SIZES GENERAL DESCRIPTION PIPING 1/2"thru 3" Schedule 40 welded&seamless carbon steel ASTM A53 Grade B,A106 Grade A or A120. FITTINGS %2"thru 3" Screwed malleable iron, 125 psi. . Mechanical grooved couplings with malleable iron housing clamps,bolts and gaskets. UNIONS ''/z"thru 2" Screwed 150x malleable iron A105 Grade II FLANGES ''/z"thru 3" Class 150# raised face, screwed,A105 GASKETS All sizes Class 150,inorganic fiber gasket with NBR(Nitrile) binder, 1/16"thick,per ASME B16.21 • Garlock style IFG 5500 or approved equal BOLTING All sizes Hex head machine bolts to ASTM A307 Gr.B with heavy hex nuts to ASTM A563 Gr.A BRANCH %z"thru 3" Use reducing tee. CONNECTIONS BLOCK VALVES '/2"thru 3" C1a%600 WOG ball valve;threaded ends; one piece bronze body chrome plated ball,RITE seats, seals and packing,wrench operator. • Apollo Figure 70-100-10 or approved equal THROTTLING ''/z"thru 3" Class 300 WOG globe valve;threaded ends;bronze VALVES body union bonnet,integral seat,renewable disc TFE packing. • NIBCO Figure T235 or approved equal DRAIN VALVE All sizes 600 WOG bronze ball valve, SWT x3/4"hose,with gasketed cap and chain.Milwaukee BA-100-4 or Apollo 78-100-01 CHECK AIR ''/Z"thru 3" 150#Class,bronze swing check valve,aluminum disk, screwed cap and threaded ends. Approved equal to Eclipse,Inc. Series 1000. CARBON FILTERS All Sizes Filter to remove liquid and particles below 0.01 micron.Residual oil content below 0.005 ppm. • SULLAIR model AF2406-A or approved equal REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 26 SPE-16040-15400 JA16040\Specs\Fina1\15400_REV B.doc s PIPING SPECIFICATION: CU 1 (CONTINUED) ITEM SIZES GENERAL DESCRIPTION THROTTLING 1/2"thru 3" Class 300 WOG globe valve;threaded ends;bronze VALVES body union bonnet, integral seat,renewable disc TFE packing. • NIBCO Figure T433 or approved equal. CHECK VALVES 1/2"thru 3" Class 300 WOG Y pattern horizontal swing check valve,threaded ends,bronze body,integral seat, screwed cap. • NIBCO T433 or approved equal. STRAINER 1/2" thru 2" Class 400 WOG Y type strainer,threaded ends, cast iron body to ASTM A126-C1.B, screwed screen retainer with threaded blowoff connection, 304SS screen with 0.031"perforations. • Mueller Figure 11 M or approved equal. HOSE STATIONS 3/4" Wall mounted mixing unit hose station for hot and cold water with 50' of white hose. • Strahman model M-159. NOTES: 1. Use full faced gaskets on flat faced flanges. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 25 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc 2. PIPING SPECIFICATION: CU 1 SERVICE: Process Hot and Cold Water MAXIMUM OPERATING CONDITIONS: 150 psig @150°F ITEM SIZES GENERAL DESCRIPTION TUBING 1/2"thru 3" Copper tubing,ASTM B88,UNS C12200,seamless, H temper,Type L. FITTINGS 1/2" thru 3" Wrought copper fittings with solder joint ends per ANSI B 16.22. UNIONS 1/2"thru 2" Wrought/cast copper union fittings with solder joint ends per ANSI B 16.18. BRANCH CONNS 1/2"thru 3" Use solder joint tee/reducing tee. FLANGES 1/2"thru 3" Class 150,cast copper alloy flange with solder joint end per ANSI B 16.24. Flat face. PIPE JOINTS 1/2"thru 3" Wrought copper full coupling with solder joint ends per ANSI B 16.22. SOLDER FOR JOINTS All sizes Lead free per Section 1417 of U.S. Federal Safe Drinking Water Act. • Silverbrite 100 or Staysafe 50 or approval equal. GASKETS All sizes Class 150,inorganic fiber gasket with Nitrile binder, (Note 1) 1/16" thick per ANSI B 16.21. • Garlock style IFG 5500 or approved equal. BOLTING All sizes Hex head machine bolts to ASTM A307 Gr.B with heavy hex nuts to ASTM A563 Gr.A. BLOCK VALVES: 1/2"thru 3" Class 600 WOG ball valve;threaded ends; one piece bronze body chrome plated ball,RTFE seats,seals and packing wrench operator. • Apollo Figure 70-100-10 or approved equal. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 24 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc 1. PIPING SPECIFICATION: PP2 SERVICE: Process Waste,Process Vent MAXIMUM OPERATING CONDITIONS: Gravity at 120°F ITEM SIZES GENERAL DESCRIPTION PIPING, BELOW All Schedule 40 polypropylene, flame retardant, GRADE DWV pattern. FITTINGS All DWV pattern schedule 40, fittings based on laying length dimensions in ANSI B16-12 wall thickness; shall conform to ASTM D2122 Section 4. JOINTS All Fusion method with fusion coils or fixed fusion fittings fabricated in accordance with manufacturer's recommendations. Joints made between polypropylene pipe and dissimilar materials shall be made with proper adapters and transitional fittings according to manufacturer's recommendations. PIPING, ABOVE All Schedule 40 flame retardant pipe(PPFR) GRADE manufactured to meet Schedule 40 iron pipe size dimensional standards in accordance with ASTM D2122, Section 4 and 7. FITTINGS All DWV pattern, flame retardant Schedule 40 fitfings based on laying length dimensions in ANSI B16-12 wall thickness and shall conform to ASTM D2122, Section 4. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 23 SPE-16040-15400 JA16040\Specs\Finah15400_REV B.doc i 2.0 PRODUCTS 2.1 MATERIALS A. All materials shall conform to the requirements of the Local Codes,Federal Specifications and/or standards listed as commercial, ASTM, and the requirements specifically stipulated herein B. Each length of pipe, fitting,trap,piece of material and/or device used in the plumbing piping systems shall have cast, stamped, or indelibly marked on it,the manufacturer's name or mark, weight and quality of product, when such markings are required by the approval standards. C. Piping Material Index SPEC SERVICE DESIGNATION MATERIAL PRESSURE TEMP TYPE PSIG DEG. F PP 2 Process Waste PW Polypropylene Gravity 120°F Process Vent PV CU 1 Process Hot & CWS, WFI Copper 150 120°F Cold Water WDO, WPO CU 2 Compressed Air CA Black Steel 150 150°F CS 2 Natural Gas G Black Steel 10 psi 120°F Su 1 Pi in REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 22 SPE-16040-15400 JA16040\Specs\Fina1115400_REV B.doc 1.50 ELECTRICAL WORK A. This Sub-contractor shall provide appurtenances as specified for the plumbing systems in accordance with the manufacturer's requirements for a complete system. Wiring for systems operation, control devices, circuit breakers, switches, control panels and enclosures shall be by the Electrical Sub-contractor and shall conform to the requirements of Division 16. 1.51 CLEAN UP AND REMOVAL OF RUBBISH A. The Sub-contractor shall keep the facility and site clean from the accumulation of rubbish and waste materials and, upon completion, leave the facility,the site and the installation in a clean condition, completely acceptable to the Architect and to the Engineer. B. At the completion of the work, this Sub-contractor shall remove all tools, scaffolding, debris and waste and unused materials from and about the premises. C. All items shall be secure and in their final positions, and shall present a neat and workmanlike appearance. D. All temporary bracing, cross ties and the like shall be removed. E. All items shall serve the purpose for which they are intended, i.e., to support, anchor, frame,block-out, etc. Finish items to present accurate, true,plumb, finished and completed appearances. F. All stains and/or damage done to the finish of the facility that is caused by faulty workmanship and/or improper handling of materials regarding to this installation shall be cleaned,removed and/or replaced. REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 21 SPE-16040-15400 J:\16040\Specs\Fina1\15400_REV B.doc 1 B. Refer to Division 1 for requirements pertaining to substantial completion and Final Acceptance, all of which shall be provided for under this section. 1.47 GUARANTEE A. Manufacturers shall provide their standard warranties for materials and equipment furnished under this section. Such warranties shall be in addition to and not in lieu of all liabilities which the manufacturer and Sub-contractor may have by law or by provisions of the Contract Documents. It shall be the responsibility of the Sub-contractor to obtain from the piping and equipment manufacturers written guarantees covering their respective equipment for the above period of time. B. All materials, equipment and work furnished under this section shall be guaranteed,by this Sub-contractor, against all defects in materials and workmanship for a period of one (1)year commencing with the date of final acceptance. Any failure due to defective material, equipment or workmanship which may develop, shall be corrected at no expense to the Owner including all damage to areas, materials and other systems resulting from such failures. C. Upon receipt of notice from the Owner of failure of any part of the systems during the guarantee period, the affected parts shall be replaced without cost to the Owner. Any equipment requiring excessive service shall be considered defective and shall be replaced. D. If any part of a system should be stopped by foreign matter being placed in the systems, disconnect the system, clean, and reconnect wherever necessary to locate and remove obstructions. Repair or replace any work damaged in the course of removing obstructions. E. Refer to the process waste-piping manufacturer for available extended warranties. 1.48 MAINTENANCE MANUALS A. Provide bound manuals containing operating, installation, and maintenance instructions for plumbing fixtures and equipment in numbers acceptable to the Owner. 1.49 POWER WIRING A. All power wiring shall conform to the requirements of Division 16 and as shown on electrical drawings. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 20 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc 1 or materials that shall be relative to and necessary for the proper operation and maintenance of the plumbing systems until final completion of the work. B. The Sub-contractor shall replace all stolen, lost, or damaged items relative to the installation and operation of the plumbing systems before the facility is accepted. 1.43 VIBRATION ISOLATION AND SEISMIC RESTRAINTS A. Provide the necessary vibration isolation materials to eliminate excessive noise and vibration from being transmitted to the occupied areas of the structure and serve as the basis for the seismic restraint system for the entire plumbing systems within the facility. B. Work shall include the following: 1. Vibration isolation elements. 2. Equipment isolation bases. 3. Flexible piping connectors. 4. Seismic restraints. 5. Certification of seismic restraint designs and installation supervision. 1.44 CATHODIC/ELECTROLYTIC PROTECTION A. Connections between dissimilar metals shall be cathodically protected by suitable methods acceptable to the Engineer. 1.45 TESTING AND ADJUSTING A. Test all work and systems and make all adjustments and corrections as required to provide a complete, first-class working system. B. Provide all labor,materials, and instruments necessary for completion of tests under observation of the local authorities and the designated inspectors. C. Make adjustments and place all piping systems in operation and demonstrate the proper functions of the piping systems, equipment, and controls. 1.46 CERTIFICATES OF APPROVAL A. Upon completion of all work and after the necessary periodic inspections by the authorities having jurisdiction have been made, copies of inspection reports and approvals shall be forwarded to the Engineer. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 19 SPE-16040-15400 JAI 6040\SpecsTinal\15400 REV BAm equipment requiring access and all other items requiring maintenance and adjustment. B. All access panels shall be located in a professional manner in accordance with the requirements of Division I. C. All access panels shall have a fire rating equal to or better than the wall it serves. 1.38 FIREPROOFING A. All clips,hangers, clamps, supports and other attachments to the fireproofed structure shall be coordinated with other trades in order to avoid any damage to the fire proofing. B. All items which would interfere with the proper application of fireproofing shall be installed after the application of fireproofing work. This Sub-contractor shall provide all patching of disturbed fireproofing to match existing. 1.39 SUPPLEMENTARY STEEL, CHANNELS AND SUPPORTS A. Furnish and install all supplementary steel and structural supports required for the proper installation,mounting and support of all equipment. B. The type and size of the supporting steel shall be determined by the installer in conformance with cGMP guidelines and shall be of sufficient strength and size to allow only a minimum deflection in conformance with the manufacturer's requirements. 1.40 FASTENERS AND HANGERS A. The Sub-contractor shall furnish and install hangers and fasteners, as required as well as miscellaneous steel required for pipe support and for attachment of hangers. The work shall be designed and installed with specific regard to appearance and convenience as well as be in compliance with all applicable laws, regulations, industry standards. 1.41 SUPPORTS A. Unless otherwise shown or specified,this Sub-contractor shall furnish and install all plates, shields, turnbuckles,brackets, stands,bases, supplementary steel, and other items required to support all equipment and piping. 1.42 PORTABLE OR DETACHABLE PARTS A. The Sub-contractor shall.retain in his possession and shall be responsible.for all portable and detachable parts and portions of the installation and all other devices REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 18 SPE-16040-15400 J:\16040\SpecsTinal\15400_REV B.doc a D. Inserts, anchor bolts and similar items set into concrete or masonry or the work of other trades shall be furnished and installed by the Sub-contractor. The Sub- contractor shall be responsible for all such items necessary to hang or support his work. 1.32 UTILITIES A. Provide all utilities such as water, fuel, and electricity for all tests associated with or specified for the plumbing work. 1.33 REMODELING A. Disconnecting, capping off, and re-connection of"live" ends of existing piping within the existing facility to portions of the new plumbing system shall be included as part of plumbing work to be accomplished by the Sub-contractor. 1.34 TEMPORARY OPENINGS A. Arrange for the Engineer to provide special temporary openings in the structure and in exterior walls as required for the admission of apparatus furnished as part of the plumbing work. B. Provide for temporary closings as work progresses. 1.35 EXCAVATION AND BACKFILLING A. All trenching and backfilling required for the under slab piping shall be provided for under this section and as shown on the Structural sheets. B. Furnish all required information as to the locations, sizes, grades and elevations of all piping requiring excavation. C. All irregularities in the trench bottom or where the excavation has exceeded the depth required shall be filled with sand properly compacted to the required depth. 1.36 ACCESSIBILITY A. Install all work so that all parts required shall be readily accessible for inspections, operation,maintenance, and repair. Minor deviations from the drawings may be made for this purpose,but changes of magnitude shall not be made without prior written approval of the Engineer. 1.37 ACCESS PANELS A. Provide access panels for walls, ceilings and floors as required to permit access for adjustment,removal and replacement, and servicing of all concealed plumbing REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 17 SPE-16040-15400 JAI 6040\Specs\Fina1\15400 REV B.doc 1.29 NAMEPLATES A. The manufacturer's nameplates or trademark shall be permanently affixed to all equipment and materials furnished under this specification. The nameplate of a Sub-Sub-contractor or distributor is not acceptable. B. Project nameplates shall identify each item of equipment including controls with a permanently attached project nameplate, identifying each piece of equipment as identified on the equipment schedule or on the drawings. C. Project nameplates shall be at least one inch high, engraved with letters at least one-half inch high. 1.30 DELIVERY, STORAGE AND HANDLING OF EQUIPMENT AND MATERIALS A. The Sub-contractor shall give his personal supervision and direction to the work and shall give strict attention to time schedules as agreed upon. B. The Sub-contractor shall have sufficient foresight to have materials on hand before they are needed and in such quantities that delays of railroads,other parties,weather conditions, etc., shall not delay this work. C. The Sub-contractor shall give sufficient supervision to the work using his best skills and attention. He shall carefully study and compare all drawings, specifications and other instructions, and shall report at once to the Engineer any error, inconsistency or omission which he may discover but he shall not be held responsible for the existence or discovery. D. Store, handle and protect products under provisions set fourth by the piping and equipment manufacturers and as specified. 1.31 CUTTING AND PATCHING A. All core drilling for the piping systems shall be done by this Sub-contractor. Any injury to the facility caused by this Sub-contractor shall be repaired by him, leaving the work equal to the surrounding work. B. When finished materials of other trades are to be cut or fitted in the shop, this Sub-contractor shall furnish the necessary drawings to the trades whose materials shall be cut or fitted. C. All concrete patching associated with the plumbing system installation shall be the responsibility of this Sub-contractor. He shall repair all disturbed concrete including steel reinforcing to match existing conditions. REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 16 SPE-16040-15400 JAI 6040\Specffinahl5400_REV B.doc A. The Sub-contractor shall base his measurements,both horizontal and vertical, from reference points established by the Engineer and shall be responsible for correctly laying out his work. B. In the event of a discrepancy between actual measurements and those indicated, notify the Engineer, in writing, and do not proceed with this work until written instructions have been issued by the Engineer. 1.28 SELECTION AND ORDERING OF MATERIALS A. Arrange for the purchase and delivery of materials and equipment required in ample quantities and at the proper time. Immediately notify the Engineer of any inability to obtain suitable delivery of any apparatus or materials required. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 15 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc r A. The work included in the contract shall be executed as rapidly as possible, consistent with good workmanship. B. All piping shall be run in the most direct, straight and mechanical manner and be properly graded. Where drainage pipes terminate under this contract,the invert elevations at such points shall be established by this Sub-contractor. C. The Sub-contractor shall perform the installation in a thoroughly professional manner with competent and skilled personnel. D. All piping shall be accurately fitted and no pipe shall be installed under a strain. E. At the completion of the work, this Sub-contractor shall remove all tools, scaffolding, debris,waste and unused materials from and about the premises, and shall leave his work clean and ready for use. F. The decision of the Engineer as to the character of any labor provided by the Sub- contractor shall be final and conclusive on both the Sub-contractor and the Owner. 1.26 PROTECTION A. The Sub-contractor shall be responsible for the care and protection of all work included under this Section until it has been tested and accepted. B. All pipe openings shall be temporarily closed so as to prevent obstruction damage. C. Protect all equipment and materials from damage from all causes including weather,water, frost, accident and theft. All materials and equipment damaged or stolen shall be repaired or replaced with equal material or equipment. D. Protect all equipment, outlets and openings with temporary plugs, caps and covers. Protect work and materials or other trades from damage that might be caused by work or workmen and make good damage thus caused. E. This Sub-contractor shall care for his own tools, equipment and materials, and shall be responsible for their safekeeping at all time. F. The Sub-contractor shall replace all stolen, lost, or damaged items relative to the installation and operation of the plumbing systems before the facility is accepted. 1.27 SURVEYS AND MEASUREMENTS REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 14 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc MW A. At the completion of the contract,the Sub-contractor shall submit to the Engineer a complete set of legible and reproducible record drawings showing as-built corrections with all superseded data removed. See Section 01400 for document control requirements. 1.21 LAWS, ORDINANCES AND INSPECTIONS A. File all necessary drawings and specifications,prepare all documents and obtain all required Permits and Certificates of Inspection for the work, at the Sub- contractor's expense, and deliver same to the Engineer before submitting the request for acceptance and final payment for the work. B. All materials furnished and all work installed shall comply with all requirements of the local utility companies,with the recommendations of local utility companies, and with the requirements of the State of Massachusetts and the City of Northampton,Ma. 1.22 COMPLETENESS OF WORK A. The omission from the plans and specifications of expressed references to any reasonable labor or materials necessary for the proper executing or completion of the work shall not relieve the Sub-contractor from furnishing them in keeping with the basic character and intent of the work. 1.23 WORK PERSONNEL A. The Sub-contractor shall furnish first-class skilled workmen for all work, and shall keep a competent foreman or superintendent on premises at all times during the progress of the work that shall have the authority to act for and in behalf of the Sub-contractor during the latter's absence with regard to all directions given to him by the Engineer. B. All careless or incompetent personnel shall be removed forthwith by the Sub- contractor when he is notified to do so by the Owner, Engineer or his authorized representative 1.24 SAFETY PRECAUTIONS A. Comply with all of the safety requirements of OSHA throughout the entire construction period of the project. B. Furnish and maintain proper guards for prevention of accidents and provide any other necessary construction required to secure safety of life and property. 1.25 WORKMANSHIP REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 13 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc 1.18 LIABILITY OF SUB-CONTRACTOR A. The Sub-contractor shall have sole charge and possession of the work covered by his Contract, except as otherwise specified, until it is completed and accepted by the Owner and Engineer, and he shall hold the Owner and Engineer harmless and protect them against all suits of any kind brought against them or on account of any liens for labor performed or material furnished. B. The Sub-contractor shall be responsible for any consequences arising from carelessness, negligence or dishonesty of those in his employ; he shall be responsible for and make good on any improper work or materials entering into the construction of the work,and hold the Engineer free from any and all claims, whatsoever in nature, arising during the erection and completion of this work. 1.19 TRANSFERRING OF INFORMATION A. Obtain detailed information from the manufacturers of the apparatus to be furnished as to the proper method of installing and connecting same. Obtain all required information from the other trades necessary to facilitate and complete the plumbing installation. B. It shall be the Sub-contractor's responsibility to keep apprized as to the shape, size and position of all openings required for materials and equipment under this section and give full information to be other trades sufficiently in advance to allow proper access requirements. C. In case of failure on the part of the Sub-contractor to give proper information as noted above and to save delays caused by necessary approvals,the Sub-contractor shall be required to have all the necessary cutting and patching performed by the appropriate trade at this Sub-contractor's expense,but in any case additional work shall be performed at no additional cost. D. All information furnished by the Sub-contractor shall include core drill opening sizes and locations and all other pertinent information relative to the plumbing installation that the Engineer may deem necessary for a properly coordinated installation. The dimensions of all major pieces of mechanical equipment shall be furnished and the clearances that shall be required throughout the facility to allow for the passage of same through the facility to their required installation locations shall be scheduled. 1.20 RECORD DRAWINGS REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 12 SPE-16040-15400 J:\16040\Specs\Fina1\15400_REV B.doc E. If this Sub-contractor purchases and/or installs any part of the plumbing system or appurtenance and if these systems cause any interference's with the work of other trades,this Sub-contractor shall make all necessary changes in the work to correct the condition. All costs incidental to such changes shall be paid for by this Sub- contractor without back-charges. F. Furnish advance information on locations and sizes of all frames,boxes, and openings needed for this Sub-contractor's work to the other trades. Furnish information and provide necessary drawings to permit trades affected by the plumbing work,to install their work properly and without delay. G. As approved by the Contractor, the Sub-contractor may make reasonable modifications in the layout as needed to prevent conflicts with other trades, for the proper execution of work by the other trades, or for the proper execution of this Sub-contractor's work. The Sub-contractor shall pay all expenses for additional openings,relocations or enlargements of existing openings through concrete floors,walls, and roofing. H. The Sub-contractor shall protect all materials and workmanship of all other trades from damage that may be caused by the plumbing work and shall be responsible for repairing any damages caused. 1.16 EXTRA WORK OR OMISSIONS A. In the event of any omissions or additions to the work called for on the drawings and in the specifications, a deduction/extra charge shall be made by/to the Sub- contractor in proportion to the work or materials omitted or added. No work shall be performed and no materials added or omitted without written orders from the Owner, signed approval of the Engineer, and the signed acceptance of the Sub- contractor. In giving instructions,the Engineer shall have the authority to make minor changes in the work, which does not involve extra cost or is inconsistent with the purpose and intent of the plans and specifications. 1.17 CLAIMS FOR EXTRAS A. Should the Sub-contractor deem any work which he is called upon to perform extra to the Contract,by drawings or otherwise,he shall give the Engineer written notice to that effect and await instructions before proceeding to execute such work. The Engineer shall not be under obligation to consider claims for extra work unless so made by this Sub-contractor. B. All such work shall be executed under the conditions of the original Contract, except that any claim for extension of time caused thereby shall be adjusted at the time of ordering such change. The Engineer shall determine the method of computing the value of any changes to be made. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 11 SPE-16040-15400 JA16040\Specs\Fina1\15400_REV B.doc 7' 1 project site with written approval from the Engineer before proceeding with the installation. C. The Sub-contractor shall follow the drawings in laying out the work and checking the drawings of other trades to verify spaces in which the work shall be installed. Maintain maximum headroom and space conditions at all points. Where headroom or space conditions appear inadequate,notify the Engineer before proceeding with the installations. 1.14 TYPICAL DETAILS A. Where shown on the drawings,typical details shall apply to all similar items. Any alternate method requires prior approval of the Engineer. 1.15 COORDINATION OF TRADES A. Cooperation and coordination with all other trades in executing the plumbing work on the project is the responsibility of this Sub-contractor. This Sub- contractor shall not take liberties when installing the plumbing systems throughout the facility. The Sub-contractor shall coordinate with all other trades prior to installation, all pipe runs and system appurtenances including setting invert and centerline elevations and pipe offsets from the facility walls. The Engineer shall schedule discipline coordination meetings so as to allow a speedy and efficient completion of the project. As work progresses, the Sub-contractor shall submit scaled coordination drawings, to scale, to the Engineer for all areas of possible conflicts requiring close coordination with all other trades. B. The Engineer may request revisions. Such revisions to composite system drawings,when requested shall be made. C. Prior to submission of coordination drawings,the Sub-contractor shall check approved equipment shop drawings to verify that they comply with the contract requirements, and that the dimensions submitted fit the available space. Any deviations from the Contract requirements shall not be acceptable without prior written approval from the Engineer. D. If there is evidence that the plumbing work interferes with the work of any other trade in any manner,this Sub-contractor shall assist in working out space conditions to make necessary and satisfactory adjustments. Coordination to avoid conflicts shall include but not limited to Electrical for location of lighting fixtures, cable trays, duct banks, and appurtenances; Mechanical for location of ductwork, diffusers,registers, and appurtenances;Process Piping for location of process piping, instrumentation, and equipment; Structural for beams, columns and footings; and Architectural for the facility's building footprints and finishes. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 10 SPE-16040-15400 J:\16040\Specs\Fina1\15400_REV B.doc 1.11 USE OF PREMISES A. The Sub-contractor shall confine his apparatus, storage of materials and construction operations to such limits as may be directed by the Engineer and shall not unreasonably encumber the premises with his materials. B. The Sub-contractor shall enforce all instructions of the Owner and Engineer regarding safety, signs, advertisements, fires, danger signals,barricades, and smoking, and shall require all persons employed to comply with all facility or institutional regulations while on the premises. C. The Sub-contractor shall conduct work so as not to interfere with the functioning of existing services. 1.12 EXISTING BUILDING SERVICES AND UTILITIES A. Active Services: When encountered in the work,protect,brace and support as required, all existing active sewer, gas,water and other services for proper execution of work. If existing active services are encountered that require relocation, notify the Engineer and relocate as directed. Do not prevent or disturb operation of active services that are to remain. B. Interruption of Services: Where work makes temporary shutdown of services unavoidable, shut down at night, or at such times as approved by the Owner, which shall cause the least amount interference with established operation routine. Arrange work to assure that services shall be shut down only during time actually required to make connection to existing work. The Sub-contractor shall coordinate existing utility shutdowns a rriinimum of seven(7)working days in advance with Owner's Project Manager and all designated officials prior to proceeding with the work. C. Existing piping and insulation removed or damaged during the work shall be replaced with new, alike materials. 1.13 INTERPRETATION OF DRAWINGS A. The drawings are intended to convey the general arrangement of the systems,the scope of work, and the function of those systems. B. The exact arrangement and location of piping and equipment shall be determined from shop drawings and accurate field coordinated measurements and conditions. The Sub-contractor shall provide a neat workable installation utilizing current good manufacturing practices and good craftsmanship. The exact locations necessary to secure the best conditions and results shall be determined at the' REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 9 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc i l 1.9 SUBSTITUTIONS A. The term"or approved substitute"shall be understood to mean approved in equal in the opinion of the Engineer. No material shall be used in substitution or as equal to that specifically designated by name in the specifications unless it has been approved in writing by the Engineer. B. Requests for substitutions shall be made to the Engineer, in writing,by the Bidder at least five (5) days, excluding Saturday, Sundays and legal holidays,prior to the receipt date of the bids. This request shall contain detailed material data, manufacturer's name,model and catalog numbers so that a proper evaluation may be made. A request for substitution only naming a trade name or dealer's name shall not be considered. C. Substitutions may be requested by the successful bidder after signing of the contract in the following manner: 1. Submit to the Engineer four(4) copies of detailed data of the proposed item or items to be substituted, along with a letter notifying the Engineer of the proposed change. 2. A statement indicating the amount of any change to the contract price for the proposed substitution. After reviewing the proposed change, the Engineer shall inform the Sub-contractor of his decision by letter. 3. The model and data specified for each item of equipment or material heading.in these specifications relates to the brand name indicated and is used as the standard of quality,performance and suitability required. 4. The approval of substitution of equipment does not relieve the Sub- contractor of any valid charges for additional work performed by the Engineer, other Sub-contractors,the Architect or the Engineer. 1.10 EXAMINATION OF PREMISES A. Prior to the ordering or purchasing of any plumbing equipment,materials, or the layout or installation of any work, the Sub-contractor shall examine the premises and verify any and all of the existing conditions under which he shall be required to operate, or that shall in any manner affect the work under this contract. Report conditions that might affect work adversely in writing to the Engineer. If any work is involved with existing equipment or services, all model numbers, sizes, electrical characteristics, etc., shall first be verified to correspond and be compatible with the work and equipment shown on the drawings. Commencement of work shall be construed as complete acceptance of existing conditions and preparatory work. REV. B PFI DESIGN, P.C. JANUARY 26,2001 Pg. 8 SPE-16040-15400 JA16040\Specs\Fina1\15400 REV B.doc 6. Color samples for pipe coding system. 7. Submit copies for approval and record of: a. All tests. b. Pipe color code chart. I. Shop drawings shall include the location of core drillings, and other openings, which pass through or into concrete or steel construction. Drawings shall be prepared at earliest practicable date to expedite orderly progress of the work. J. Include component sizes,piping connections to fixtures, equipment and piping, rough-in requirements,replacement parts lists, service sizes, and finishes. K. Clearly indicate makes,models, locations, types, sizes,pressure ratings and system components. Delete all inapplicable material. L. Submit shop drawings indicating complete material data, a list of materials proposed for this project, and indicate thickness of material for individual services. M. Submit valve chart and ordering schedule for approval before ordering valves, including valve tag number,location, function, and valve manufacturer's name and model number. N. Submit operation and maintenance data under provisions of Division 1. O. Submit samples of proposed insulating materials, as requested by Engineer. P. Submit list of wording, symbols, letter size, and color coding for plumbing systems identification. Q. Tabulate products by section number and paragraph. R. Contract closeout information: 1. Operating and Maintenance Data. 2. Owner Instruction Report. 3. Guarantees. 4. Parts kit. REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 7 SPE-16040-15400 JA16040\Specs\Fina1\15400_REV B.doc dimensions, descriptions, installation requirements and particulars. Submittals only naming a trade name or dealer's name shall not be considered. B. Work shall not commence before the approval of the Engineer has been received. Data shall be submitted sufficiently in advance of the work to allow proper time for examination and correction. C. The Engineer's approval of submittal or data shall not relieve this Sub-contractor from the responsibility for deviations from drawings and specifications,unless he has, in writing, called the Engineer's attention to such deviations at time of submission. D. This Sub-contractor shall check all shop drawings and submittal data for compliance with the plans and specifications. E. The Sub-contractor shall stamp his approval on all such shop drawings and submittals prior to his submitting them for review and approval by the Engineer and Owner. F. If the Sub-contractor fails to comply with the preceding requirements, the shop drawings and submittals shall be returned unapproved. G. The Sub-contractor shall review and check all shop drawings and submittal data. Before submitting shop drawings and submittal data, this Sub-contractor shall affix a stamp indicating that he has determined and verified all field measurements and quantities, field construction criteria,materials, catalog numbers and similar data, and that he has reviewed and coordinated the information in the shop drawings and submittal data with the requirements of work and the contract documents. Failure to comply with the above shall cause immediate rejection of the submittals. H. Equipment and materials requiring submittal for approval shall include,but not be limited to the following: 1. All waste and vent system connections,bleanouts, other drainage specialties, and appurtenances, including floor drains and trench drains. 2. All air, gas,water supply, drainage and vent piping materials, fittings, valves, and system appurtenances. 3. Core drilling packing, sleeves, and seals. 4. Insulation. 5. Plumbing equipment and specialties. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 6 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV B.doc • F. AWWA C601 - Standard Methods for the Examination of Water and Waste Water. G. ANSI/ASME B16.23 - Cast Copper Alloy Solder Joint Drainage Fittings -DWV. H. ANSI/ASME B 16.29 - Wrought Copper and Wrought Copper Alloy Solder Joint Fittings for solvent drainage systems-DWV. I. ANSI/ASME Section 9 - Welding and Brazing Qualifications. J. ANSI/A WS D1.1 - Structural Welding Code. K. ANSI/ASME B32 - Solder Metal. L. ANSUNFPA 30 Flammable and Combustible Liquids Code. M. ANSI Al 12.2 1.1 -Floor Drains. N. ANSUASME A13.1 - Scheme for the Identification of Piping Systems. O. ANSI Z359.1 -Emergency Eye Wash and Shower Equipment. P. AWS - Standard manual of pipe welding of the Heating and Piping Sub- contractor's National Association. Q. AWS A5.8 -Brazing Filler Metal. 1.7 QUALITY ASSURANCE A. For each product specified,provide components by same manufacturer throughout. B. Materials shall be labeled with manufacturer's pertinent information. Materials and equipment shall be delivered in non-broken, factory-furnished packaging and stored in a clean, dry indoor space that provides protection against the weather. C. Progressive testing of the systems to be insulated shall be completed,inspected and approved by the Engineer before insulation is applied. 1.8 SHOP DRAWINGS AND SUBMITTALS A. Submit for approval by the Engineer shop drawings for equipment and materials proposed for installation prior to ordering,purchasing, or fabricating equipment or materials. Drawings shall be catalog cuts,material lists, and samples where necessary, containing complete performance data, engineering calculations, REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 5 SPE-16040-15400 JAI 6040\Specs\Fina1115400_REV B.doc 3. Requirements of the City of Northampton, latest applicable local codes, and the authorities having jurisdiction. 4. American Society of Plumbing Engineers(ASPE)Handbooks,Data books, and Standards. 5. American Society of Mechanical Engineers (ASME). 6. National Fire Protection Association(NFPA). 7. American National Standards Institute (ANSI). 8. American Society for Testing Materials (ASTM). 9. National Bureau of Standards (NBS). 10. National Sanitation Foundation(NSF). 11. Cast Iron Soil Pipe Institute(CISPI) 12. American Water Works Association(AWWA). 13. Occupational Safety and Health Act(OSHA). 14. The Owner's Internal Safety Program. 15. Underwriters' Laboratories (UL). 16. Current Good Manufacturing Practices Guidelines (cGMP). 1.6 REFERENCES A. ASTM B88 - Seamless Copper Water Tube. B. ASTM D4101 -Polypropylene pipe and fittings. C. ASTM D635 -Flame Retardant Polypropylene pipe and fittings. D. ASTM D 15 99 - Standard Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe, Tubing and Fittings. E. ASTM D2412 - Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate loading. REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 4 SPE-16040-15400 JA16040\Specs\Fina1\15400_REV B.doc 1.4 RELATED WORK SPECIFIED ELSEWHERE A. Reference Division 1 requirements for temporary utilities such as water, fuel, electricity and sanitary facilities required during construction. 1.5 CODES AND STANDARDS A. All work shall be installed in conformance with the governing codes,regulations, local ordinances, and authorities having jurisdiction. It shall be the responsibility of the Sub-contractor to familiarize himself with all governing codes and requirements and report any noncompliance of the plans and specifications to the Engineer,prior to entering into the contract, and all the above requirements shall take precedence over the plans and specifications. These requirements are minimum criteria and no reductions permitted by code shall be allowed without written permission of the Engineer. B. No additional compensation shall be granted for work which must be changed as a result of the work not originally complying with codes, standards, etc., and not in accordance with the multiple trade coordination design criteria set forth. C. The Sub-contractor shall file all drawings,pay all fees and obtain all permits and certificates of inspection relative to this work. The Sub-contractor shall arrange inspection with proper authorities and include costs of inspections in his bid. Sub-contractor shall not conceal installed piping before it is inspected by the authorities having jurisdiction of the City of Northampton,Massachusetts. D. The Sub-contractor shall arrange for and schedule the proper inspections required by the authorities having jurisdiction and schedule such inspections, giving the Engineer a minimum of 48 hours advance notice such that the inspections may be witnessed. Copies of all permits and certificates of inspection shall be forwarded to the Engineer. E. If the code or other requirements exceed the provisions indicated in the Contract Documents,the Engineer and Owner shall be notified in writing. Where the work indicated on the Contract Documents exceeds code requirements,the installation shall be done in accordance with the Contract Documents. Any work done contrary to these requirements shall be removed and replaced at the expense of the responsible Sub-contractor. F. The plumbing layout,workmanship, methods, and materials shall meet the highest standards of the trade and shall conform to the latest editions of the following associations: 1. Uniform Plumbing Code, latest applicable edition. 2. Massachusetts Building Code, latest applicable edition. REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 3 SPE-16040-15400 JA16040\Specs\Fina1\15400_REV B.doc , including the installation of a trench drain in the boiler room, floor drain on the mezzanine and extending of existing vent piping through the roof. 2. Interior Process Hot and Cold water piping additions and alterations complete with all fittings,joining materials, supports, and appurtenances, with connections into the existing systems within the confines of the existing facility, including the installation of hose stations and future connections to equipment and appurtenances where shown on drawings. Subcontractor to file all permits pertaining to the installation of back-flow protection devices where shown on drawings. 3. Compressed air piping system additions and alterations, including valved and capped future equipment connection points where shown on drawings. 4. Final connections to all Gebo and Alloy equipment by others. 5. Natural gas piping system additions and alterations, including the installation of high pressure gas connections to the boiler and make up air units. 6. Floor cleanouts, trench drains, floor drains, and other drainage specialties. 7. Pipe insulation. 8. Shop drawings for materials and equipment. 9. All core drilling deemed necessary to complete the work under this section. 10. Hangers, supports, anchors, inserts and seals, including vibration isolation and seismic restraints. Subcontractor to install piping on racks provided by mechanical subcontractor where shown on drawings. Subcontractor to provide hangers for all other piping as required. 11. All supplementary materials for piping supports. 12. Systems cleaning and testing of piping systems. 13. Disinfecting of water supply lines. 14. Systems identification. 15. Guarantees. 16. Record drawings. REV. B PFI DESIGN, P.C. JANUARY 26, 2001 Pg. 2 SPE-16040-15400 JAI 6040\,SpecsTinahl5400_REV BAm 1 PLUMBING SYSTEMS SECTION 15400 1.0 GENERAL 1.1 DESCRIPTION OF WORK A. The work under this Section of the Specifications shall include the furnishing and installation,herein referred to as "provide" all labor, materials, equipment and services required for a complete plumbing systems. The Plumbing Sub- contractor,herein referred to as the"Sub-contractor" shall meet all performance requirements, all code requirements and regulations to make these systems ready for regular operation and use by The Minute Maid Company,herein referred to as the"Owner". 1.2 GENERAL REQUIREMENTS 1. Examine all other sections of the project's contract drawings and specifications for requirements, which affect the work of this section whether or not such work is specifically noted herein. 2. Coordinate work with that of other trades affecting, or affected by, the work of this Section. Cooperate with all other trades such that work progresses smoothly without interference to other trades. 1.3 SCOPE OF WORK A. Perform work and provide all permits, transportation, taxes, freight,materials, appurtenances, machinery, equipment, tools, loading, unloading, rigging, blocking,excavation, trenching, core-drilling, sleeving, de-watering, shoring, back-filling,washed gravel beds, grading of trenches, compacting,testing, labor and supervision necessary, as shown on the drawings and as specified to install, complete, and make ready for continuous operation, the listed plumbing systems. B. Drawings and Specifications form complementary requirements. Provide work specified and not shown, and work shown and not specified as though explicitly required by both. Although some work may not be specifically shown or specified,provide necessary supplementary or miscellaneous items, appurtenances, devices and materials obviously necessary for a sound, secure and complete installation. C. The plumbing systems shall include,but not be limited to,the following items: 1. Interior process waste and process vent piping complete with all fittings, joining materials, and appurtenances, with waste and vent connections into existing process waste system within the confines of the existing facility, REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. 1 SPE-16040-15400 JAI 6040\Specs\Fina1\15400_REV BAm 3.22 INSULATION SCHEDULE .............................................................................................45 3.23 SYSTEM IDENTIFICATION...........................................................................................45 3.24 VALVE CHART AND SCHEDULE................................................................................46 3.25 FIXTURE ADJUSTING AND CLEANING.....................................................................46 REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. iii SPE-16040-15400 iA16040\Specs\Fina1115400_REV B.doc 1, 1.43 VIBRATION ISOLATION AND SEISMIC RESTRAINTS............................................19 1.44 CATHODIC/ELECTROLYTIC PROTECTION..............................................................19 1.45 TESTING AND ADJUSTING..........................................................................................19 1.46 CERTIFICATES OF APPROVAL ...................................................................................19 1.47 GUARANTEE...................................................................................................................20 1.48 MAINTENANCE MANUALS .........................................................................................20 1.49 POWER WIRING..............................................................................................................20 1.50 ELECTRICAL WORK......................................................................................................21 1.51 CLEAN UP AND REMOVAL OF RUBBISH.................................................................21 2.0 PRODUCTS.......................................................................................................................22 2.1 MATERIALS .....................................................................................................................22 2.3 CLEANOUTS ....................................................................................................................28 2.4 SHUT-OFF VALVES ........................................................................................................28 2.5 UNIONS, AND COUPLINGS...........................................................................................29 2.6 INSERTS............................................................................................................................29 2.7 PIPE HANGERS, SUPPORTS,AND HANGER RODS..................................................29 2.8 EXPANSION JOINTS.......................................................................................................30 2.9 PIPE ANCHORS AND GUIDES ......................................................................................30 2.10 PLUMBING SYSTEMS IDENTIFICATION MATERIALS...........................................30 2.11 INSULATION....................................................................................................................30 2.13 PENETRATIONS AND CORE DRILLING.....................................................................35 2.14 GENERAL.........................................................................................................................36 3.0 EXECUTION....................................................................................................................37 3.1 SUB-CONTRACTOR RESPONSIBILITIES...................................................................37 3.2 MATERIALS AND WORKMANSHIP ...........................................................................37 3.3 CONTINUITY OF SERVICES ........................................................................................38 3.4 PREPARATION................................................................................................................38 3.5 PENETRATIONS .............................................................................................................38 3.6 PIPING AND FITTING INSTALLATION......................................................................39 3.7 ESCUTCHEONS ..............................................................................................................41 3.8 JOINTS AND CONNECTIONS.......................................................................................41 3.9 CLEANOUTS ...................................................................................................................41 3.10 SPECIALTIES...................................................................................................................41 3.11 VALVE INSTALLATION................................................................................................42 3.12 PIPE ANCHORS...............................................................................................................42 3.13 INSERTS...........................................................................................................................42 3.14 PIPE HANGERS AND SUPPORTS.................................................................................42 3.15 FLASHING........................................................................................................................42 3.16 TESTING OF ABOVE GRADE PLUMBING SYSTEMS ..............................................42 3.17 DISINFECTION OF DOMESTIC WATER PIPING SYSTEM.......................................43 3.18 COMMISSIONING OF SYSTEMS..................................................................................44 3.19 INSULATION...................................................................................................................44 3.20 INSULATION JACKET ...................................................................................................45 3.21 VAPOR BARRIER............................................................................................................45 REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. ii SPE-16040-15400 JAI 6040\Specs\Final\l5400_REV B.doc t J f TABLE OF CONTENTS 1.0 GENERAL...........................................................................................................................1 1.1 DESCRIPTION OF WORK................................................................................................1 1.2 GENERAL REQUIREMENTS...........................................................................................1 1.3 SCOPE OF WORK.............................................................................................................1 1.4 RELATED WORK SPECIFIED ELSEWHERE................................................................3 1.5 CODES AND STANDARDS .............................................................................................3 1.6 REFERENCES....................................................................................................................4 1.7 QUALITY ASSURANCE...................................................................................................5 1.8 SHOP DRAWINGS AND SUBMITTALS.........................................................................5 1.9 SUBSTITUTIONS ..............................................................................................................8 1.10 EXAMINATION OF PREMISES.......................................................................................8 1.11 USE OF PREMISES............................................................................................................9 1.12 EXISTING BUILDING SERVICES AND UTILITIES .....................................................9 1.13 INTERPRETATION OF DRAWINGS...............................................................................9 1.14 TYPICAL DETAILS.........................................................................................................10 1.15 COORDINATION OF TRADES......................................................................................10 1.16 EXTRA WORK OR OMISSIONS....................................................................................11 1.17 CLAIMS FOR EXTRAS...................................................................................................11 1.18 LIABILITY OF SUB-CONTRACTOR............................................................................12 1.19 TRANSFERRING OF INFORMATION..........................................................................12 1.20 RECORD DRAWINGS.....................................................................................................12 1.21 LAWS, ORDINANCES AND INSPECTIONS................................................................13 1.22 COMPLETENESS OF WORK.........................................................................................13 1.23 WORK PERSONNEL.......................................................................................................13 1.24 SAFETY PRECAUTIONS................................................................................................13 1.25 WORKMANSHIP.............................................................................................................13 1.26 PROTECTION...................................................................................................................14 1.27 SURVEYS AND MEASUREMENTS..............................................................................14 1.28 SELECTION AND ORDERING OF MATERIALS ........................................................15 1.29 NAMEPLATES.................................................................................................................16 1.30 DELIVERY, STORAGE AND HANDLING OF EQUIPMENT AND MATERIALS.....................................................................................................................16 1.31 CUTTING AND PATCHING...........................................................................................16 1.32 UTILITIES.........................................................................................................................17 1.33 REMODELING.................................................................................................................17 1.34 TEMPORARY OPENINGS..............................................................................................17 1.35 EXCAVATION AND BACKFILLING............................................................................17 1.36 ACCESSIBILITY..............................................................................................................17 1.37 ACCESS PANELS............................................................................................................17 1.38 FIREPROOFING...............................................................................................................18 1.39 SUPPLEMENTARY STEEL, CHANNELS AND SUPPORTS ......................................18 1.40 FASTENERS AND HANGERS........................................................................................18 1.41 SUPPORTS.................................................................................................................:......18 1.42 PORTABLE OR DETACHABLE PARTS.......................................................................18 REV. B PFI DESIGN,P.C. JANUARY 26, 2001 Pg. i SPE-16040-15400 J:\16040\Specs\Final\15400_REV B.doc PFI DESIGN, P.C. SPECIFICATION FOR PLUMBING SYSTEMS SPE-16040-15400 The Minute Maid Company Pouch Line Addition Northampton,MA Project No. 16040 ' "� : ��� .:,,,,,5 '..t 3"S'; � " ,�"�.. ,''� d.w M-a `'��` ,�M ( " a��� ..C',: ,_c •�VV A 12/20/00 Issue for Review KAB KMC AJF HM B 1/26/01 Issue for Bid KAB EW KMC r« AHW HM Client Approval: Client: Date: