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Addendum No - Pkg Contracting, Inc.

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November 2018
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June 9, 2017 SCOTT BUECKER TO O PR FOR FE G SS IONAL EN IN PROJECT MANUAL & PROJECT DRAWINGS June 9, 2017 No. 40518 PE LI C E NSED R NTANA MO EE ADDENDUM NO. 1 LIVINGSTON WATER RECLAMATION FACILITY UPGRADES CITY OF LIVINGSTON, MONTANA June 2017 This Addendum No. 1 forms part of the Contract Documents and modifies the original Bidding Documents as noted below. All provisions of the Contract Documents not in conflict with this Addendum shall remain in full force. Acknowledge receipt of this Addendum in the space provided on the Bid Form and on the outside of the Bid Envelope. Failure to do so may subject the Bidder to disqualification. This addendum consists of EIGHT (8) pages and EIGHT (8) attachments. ATTACHMENTS The following documents are included as attachments to this Addendum No. 1: 1. 2. 3. 4. 5. 6. 7. 8. Electronic Data Agreement for Use Section 00 35 00 – Instrumentation and Controls Information Section 01 79 00 – Classroom Demonstration Training Section 01 91 00 - Commissioning Section 26 32 13 – Engine Generators Temporary Construction Sign for Rural Development Projects Sheet GEN-P4_ADDENDUM 1 Sheet No. C-3 of 4 from record drawings labelled “As Constructed 4-8-83.” a) Project: City of Livingston Wastewater Treatment Facility Expansion b) Sheet Title: “Sludge Drying Beds, Modifications & Additions” c) Prepared By: Christian, Springs, Sielbach & Associates Livingston WRF Upgrades Livingston, Montana ADD1 - 1 June 2017 Addendum No. 1 CLARIFICATIONS 1. CAD files for the following facilities are available to potential bidders upon Engineer’s receipt of signed Electronic Data Agreement for Use forms (included as an attachment to this addendum): • • • • Grading Plan Site Work Solids Process Building UV Disinfection Facility Reactor Control Building 2. Engineer’s Opinion of Probable Construction Cost (EOPCC): • $14.3M 3. The Plan Holder’s List for the project is updated periodically and can be found online at the link provided below: http://www.ae2s.com/project-bidding-detail.php?ID=552 > “Plan Holders” 4. The existing WRF facility has an existing fence surrounding the property and no new fence alignments are scheduled for the project. However, the Contractor may find it necessary to cut and patch existing chain link fence to facilitate Work. Existing chain link fence disturbed for construction purposes shall be cut, patched, and restored in accordance with the requirements set forth in Section 01 73 29 – Cutting and Patching and the specific system requirements of Section 32 31 13 – Chain Link Fences and Gates. 5. The Reactor Control Building (RCB) is scheduled for construction on the site of the existing sludge drying beds. The record drawing (labeled “As Constructed 4-8-83”) of the existing sludge drying beds is provided as Attachment 3 to this Addendum. This record drawing is intended to provide clarification on the construction of the existing sludge drying beds for estimation of effort required for demolition, removal, and excavation in the general vicinity of the sludge drying beds. 6. General Note 1 on SPB Facility Drawings M1, M2, and M3 (and all other locations in the bidding documents requiring Bidders to visit the site) shall be satisfied by paragraph B of Article 3 – Bidder’s Representations. 7. Date of Substantial Completion: a. Bidder’s will notice that potential dates for Substantial Completion are defined in Article 14 of the Instructions to Bidders. vi. Base Bid Option 1 – 549 days from Notice to Proceed vii. Base Bid Option 2 – Bidder Defined # of days ranging between minimum of 486 days and maximum of 699 days. b. Based on the Bid Evaluation process of Article 19, the date for substantial completion will be the number of days corresponding with either Bid Option 1 or Bid Option 2 of the Bid Form, whichever is determined to be the Lowest Responsive, Responsible Bid. Livingston WRF Upgrades Livingston, Montana ADD1 - 2 June 2017 Addendum No. 1 8. Bid Evaluation: a. See Article 19 of the Bid Form. b. Equations shown in 19.03 of the Instructions to Bidders ARE FOR ENGINEER AND OWNER’S USE ONLY. c. On the Bid Form, Bidder’s “Lump Sum” costs should be equal to BB1 and BB2 of the aforementioned equations (not TBB1 or TBB2). CHANGES TO SPECIFICATIONS DIVISIONS 00 – FRONT END DOCUMENTS Section 00 35 00 – Instrumentation and Controls Information Add specification Section 00 35 00 – Instrumentation and Controls Information (Included as an attachment to this addendum.) Section 00 73 00 – Supplementary Conditions SC-1.01.A.20 (Page 00 73 00 – 3): Delete the following consultant from the list of ENGINEER’s Consultants on the Project: Wentz Associates, Inc. 7226 Ohms Ln Minneapolis, MN 55439 Add the following consultant to the list of ENGINEER’s Consultants on the Project: Karges-Faulconbridge, Inc. (KFI) 7225 Ohms Lane – Suite 160 Edina, MN 55439 SC-6.03.K.6 (Page 00 73 00 – 14): Delete the following party as an “Additional Insured”: Wentz Associates, Inc. 7226 Ohms Ln Minneapolis, MN 55439 Add the following party as an “Additional Insured”: Livingston WRF Upgrades Livingston, Montana ADD1 - 3 June 2017 Addendum No. 1 Karges-Faulconbridge, Inc. 7225 Ohms Lane – Suite 160 Edina, MN 55439 SC-6.05.A.1 (Page 00 73 00 – 16): Delete the following party as a named “insured”: Wentz Associates, Inc. 7226 Ohms Ln Minneapolis, MN 55439 Add the following party as a named “insured”: Karges-Faulconbridge, Inc. 7225 Ohms Lane – Suite 160 Edina, MN 55439 Section 00 73 40 – Funding Agency Requirements Replace the Project Sign Detail included in Exhibit A of Section 00900 with the Project Sign Detail for projects funded by multiple agencies. The appropriate project sign detail is included as an attachment to this addendum. Delete Montana Prevailing Wage Rates for Building Construction Services 2017 from Exhibit G of Section 00900. Clarification: Montana Prevailing Wage Rates for Heavy Construction Services 2017 shall be considered when computing prevailing wages. DIVISION 01 – GENERAL REQUIREMENTS Section 01 23 00 – Alternates Revise 1.04. G.1 as follows: One Primary Clarifier may be taken offline at any time after start of construction for demo and retrofit to WAS Holding Basin. At least one primary clarifier must remain in operation during high influent flow and load season, or until the new RCB facilities have been started up, commissioned and accepted by the Owner. Section 01 23 00 – Alternates Revise 1.03.G.1 as follows: Livingston WRF Upgrades Livingston, Montana ADD1 - 4 June 2017 Addendum No. 1 Existing Primary Clarifiers are to be converted to WAS Holding Basins. Concrete conditions of the existing primary clarifiers are unknown. Some concrete restoration may be required to rehabilitate portions of the existing concrete. Contractor to assume 1000 linear feet (LF) of crack injection (Epoxy Crack Injection Adhesive) per specification Section 03 01 00 – Maintenance of Concrete and 750 ft2-inches of concrete restoration (Epoxy Repair Mortar) per specification Section 03 01 00. Revise 1.03.J on page 01 23 00 – 4 as follows: Alternate J – Portable Compost Screening Plant 1. Furnish Portable Compost Screening Plant as indicated in the specifications. a. See Specification Section 46 70 15 – Portable Compost Screening Plant Section 01 55 00 – Vehicular Access and Parking Replace paragraph 1.04.B with the following: 1.04.B: All traffic control devices including signs, warning lights, and barricades shall conform to the requirements of the 2009 Manual on Uniform Traffic Control Devices (MUTCD). Replace paragraph 1.05.A and 1.05.B with the following: 1.05.A: Contractor shall maintain main site access road (Bennet Street) during the duration of construction activities. 1.05.B: NOT USED Add the following paragraph under part 1.06 – Haul Routes 1.06.B.: Contractor Shall Maintain Access for the City’s to access the conveyor on the east-side of the Dewatering Building with its dump-truck which is used to collect and haul dewatered biosolids. This City’s dump truck must be able park under the conveyor in a manner that allows the dewatered solids to fall into the box of the dump truck. Access must be maintained to allow for semi-regular arrivals and departures of the City’s dump truck. Section 01 79 00 – Classroom and Demonstration Training Replace Section 01 79 00 – Classroom and Demonstration Training with the revised specification section attached to this addendum. Section 01 91 00 – Commissioning Replace Section 01 91 00 – Commissioning with the revised specification section attached to this addendum DIVISION 26 – ELECTRICAL Livingston WRF Upgrades Livingston, Montana ADD1 - 5 June 2017 Addendum No. 1 Section 26 05 34 – Conduit Add the following paragraph after 2.02.E 2.02.F.: Provide Aluminum conduit with aluminum fittings. Provide 316 SS clamps where attaching to 316 stainless steel strut stand-offs. Section 26 32 13 – Engine Generators Add Section 26 32 13 – Engine Generators to Division 26. (Included as an Attachment to this Addendum.) DIVISION 40 – PROCESS INTEGRATION Section 40 27 30 – Process Gates Add the following to the list of Acceptable Manufacturers in Section 2.01.A 6. 7. RW Gate Company Or Equal DIVISION 46 – WATER AND WASTEWATER EQUIPMENT Section 46 05 01 – Wastewater Equipment General Provisions Revise 1.06. A. 2. On Page 46 05 01 – 3 as follows: The manufacturer must have supplied and had in satisfactory use for a period of not less than five (5) years a minimum of five (5) installations having similar size and type of equipment as compared to the equipment specified. In lieu of the manufacturer having supplied the equipment, the manufacturer may provide evidence of design engineering by current staff that will be considered by the Engineer for approval to supply equipment for the project. Section 46 70 15 – Portable Compost Screening Plant Revise 2.01.A. on Page 46 70 15 – 5 as follows: Acceptable manufacturers for a portable compost screening plant: Section 46 72 15 – Rotary Drum Thickener Equipment Livingston WRF Upgrades Livingston, Montana ADD1 - 6 June 2017 Addendum No. 1 Revise 2.02.A.3.b. on Page 46 72 15 – 6 as follows: Flow Rate @ 0.70%, gpd: 34,550 Revise 2.02.A.3.c. on Page 46 72 15 – 6 as follows: Flow Rate @ 0.85%, gpd: 28,453 Revise 2.02.A.4.b. on Page 46 72 15 – 7 as follows: Flow Rate @ 0.70%, gpd: 18,548 Revise 2.02.A.4.c. on Page 46 72 15 – 7 as follows: Flow Rate @ 0.85%, gpd: 15,275 Revise 2.02.A.5.f. on Page 46 72 15 – 7 as follows: Maximum Polymer Dose @ Maximum %-Solids Required, lbs/dry ton: 15.0 Section 46 73 21– Aerobic Digester Aeration Equipment Delete 1.05. A. 1. on Page 46 73 21 – 3 CHANGES TO DRAWINGS GEN-P4 Replace sheet GEN-P4 with the revised sheet GEN-P4_ADDENDUM 1 GEN-P9, GEN-P10, & GEN-P11 Replace, for all valve schedules, all occurrences of “ANSI CL 125 WAFER” in the columns labeled “CONNECTION” with “ANSI Class 150, FULL LUG STYLE” for butterfly valves with “SERVICE TYPE” listed as “AIR.” Where required, provide Butterfly Valves – Service Type: Air as indicated in specification Section 40 27 20 (2.08). Revise the UV Process Valve Schedule with the changes indicated below to the respective Valve Numbers: EFR-BFV-2: OPERATOR: Electrically Actuated (Electro-Mechanical Fail Safe Device) Livingston WRF Upgrades Livingston, Montana ADD1 - 7 June 2017 Addendum No. 1 RCB-A9 Revise the RCB Door Schedule with the changes indicated below to the respective Door Numbers: Door No. 102: o Hardware Group: o Panel Type: o Fire Rating: Door No. 103: o Hardware Group: Door No. 103B: o Insulated Panel: o Frame Type: o Frame Material: o Frame Finish: Door No. 109: o Fire Rating: 13 D 90 minutes 11 Yes 1 HM Paint 90 minutes SPB-M1; M3; M4; E4; E6 Clarification: The door to the Electrical Room (existing office) in the Solids Processing Building is shown as a double door – similar to Panel Type C or D, as shown in the “Door Panel Type” detail drawings on RCB-A9. This door is found in the south-east corner of the building on the south facing all and appear (at a minimum) on the following drawings: SPB-M1; M3; M4; E4; and E6. In reality, this door is a singe door – similar to Panel Type E (as shown in the “Door Panel Type” detail drawing on RCB-A9) and Doorframe Type 3 (as shown in the “Door Frame Type” detail drawing on RCB-A9). SPB-P9, P16 Clarification: The jet aeration header is 14” diameter, not 12” diameter. I hereby certify that this Addendum was prepared by me or under my direct supervision, and that I am duly registered as a Professional Engineer under the laws of the State of Montana. Scott L. Buecker, PE Registration Number 40518 PE END OF ADDENDUM NO. 1 Livingston WRF Upgrades Livingston, Montana ADD1 - 8 June 2017 Addendum No. 1 Livingston WRF Upgrade Addendum 1 - Attachments Attachment 1: Electronic Data Agreement for Use Advanced Engineering and Environmental Services, Inc. 4050 Garden View Drive Suite 200 Grand Forks, ND 58201 Phone 701-746-8087 Fax 701-746-0370 ELECTRONIC DATA AGREEMENT FOR USE DATE:___________________ PROJECT INFORMATION: Project Name: City of Livingston WRF Upgrade Project Location: Livingston, MT FIRM INFORMATION: Firm/User:_____________________________________________________________________ Street: ______________________________________________________________________ City/State/Zip: ________________________________________________________________ Telephone No: ________________________________________________________________ Signature by the firm’s representative with this completed request will constitute an agreement governed by the terms and conditions attached hereto (Third Party User Agreement For Electronic Data). ELECTRONIC DATA REQUESTED: Intended use of Electronic Data:____________________________________________________ File(s)/Drawing Numbers released (including file specification suffix and software version): 1 05/2017 THIRD PARTY USER AGREEMENT FOR ELECTRONIC DATA The User agrees to comply with the following terms and conditions: 1. Advanced Engineering and Environmental Services, Inc. (“Engineer”) retains all rights to ownership of the electronic data, including CAD, and any intellectual property associated with engineering services provided by the Engineer on the Project and the electronic data made available to the User. User specifically acknowledges that such electronic data is the proprietary information of the Engineer and is provided to the User solely for the purposes of facilitating the User’s work on the Project. No permission is granted to the User for copying or reusing electronic data on other projects, for additions to this Project, or the completion of the Project by another engineering professional. Any use of the electronic data, including CAD, by the User other than the facilitation of the User’s work on this Project is subject to written approval of the Engineer, which approval may be withheld for any reason. Approval may be contingent on the User providing the appropriate legal protection to the Engineer for the User’s use of the electronic data. 2. The electronic data represents only a portion of the engineering services performed by the Engineer on the Project. Engineer represents and the User specifically acknowledges that the electronic data, including CAD, may not contain all changes to the documents since the initial release for bidding or that such electronic data or CAD is without inaccuracies. Use of the electronic data, including CAD, by the User, without the Engineer’s written verification or adaptation for the specific purpose intended, will be at the User’s risk. The User may request the Engineer’s written verification or adaptation that the electronic data and CAD is current and that it is otherwise supported by additional documentation. If requested, the Engineer will provide such verification or adaptation provided the User fully compensates the Engineer for providing the requested information, which compensation will be determined in the sole discretion of the Engineer. 3. The User specifically acknowledges the following: a. The electronic data and CAD documents are provided by the Engineer for the convenience of the User only. b. The electronic data and CAD documents are prepared as the Engineer’s internal working documents and as such may be incomplete, contain deliberate or unintentional inaccuracies or be in part obsolete. c. That the Engineer makes no representation as to the electronic data and CAD documents completeness, currency, or accuracy. d. Any translation of electronic data, including CAD, from one computer system or computer environment can and often does result in the loss of important data, including portions of text and dimensions, the existence, location or scale of symbols or other elements of graphics, the internal structure of data including layers and data attributes, or the style or weight of lines. The Engineer specifically disclaims any liability associated with the User’s use of the electronic data and CAD on any system. e. The Engineer will not routinely issue updates to its electronic data and CAD. It is solely the responsibility of the User to identify and make all required revisions or corrections to this data or request a verification or adaptation from the Engineer. 2 05/2017 4. Because the information being provided by the Engineer to the User is being provided “AS IS” “with all faults”, without representation by the Engineer as to completeness, currency, or accuracy, the User specifically agrees to defend, indemnify and hold harmless the Engineer, its affiliated entities, directors, officers, and employees from and against any and all claims arising out of the User’s use of the electronic data and CAD and the preparation of information generated by the User through the Engineer’s electronic data and CAD. The indemnification shall include the User’s agreement to pay all reasonable attorney’s fees and expenses incurred by Engineer in defending against any claim or action. In no event will Engineer, its affiliated entities, directors, officers, and employees be liable to the user for indirect, general, incidental, consequential, or other damages. 5. Use of the electronic data and CAD by the User contrary to the terms and conditions of this Agreement shall constitute a breach of this Agreement and User, immediately upon the written demand of the Engineer, shall return to the Engineer all of the Engineer’s property, including the electronic data and CAD. Engineer shall be entitled to seek all other claims arising out of the User’s breach of this Agreement. 6. This Agreement includes a written description outlining the data requested by the User, which includes such information as sheet number and special instructions relating to the data. Accommodation of any User special instructions is at the sole discretion of the Engineer. 7. This Agreement shall be binding upon the respective successors and assigns of the parties hereto. User acknowledges that the data will not be provided until a signed Agreement is on file with the Engineer. USER: Accepted by: __________________________ Name: _______________________________ Title: ________________________________ Date:________________________________ 3 Livingston WRF Upgrade Addendum 1 - Attachments Attachment 2: Section 00 35 00 - Instrumentation and Control Information SECTION 00 35 00 Instrumentation and Control Information PART 1 1.01 SUMMARY A. 1.02 This Section includes: a. Summary of I&C Services provided by AE2S as a professional service. b. Livingston Water Reclamation Facility Control System Narrative INSTRUMENTATION AND CONTROLS AS A PROFESSIONAL SERVICE A. 1.03 GENERAL The City of Livingston has retained AE2S to provide Instrumentation and Controls services, including provisions to draft the Control Narrative, provide SCADA Programming, and Commissioning and check-out of the City’s SCADA system. CONTROL NARRATIVE A. Livingston Water Reclamation Facility Control System Narrative is provided for Bidder’s and Contractor’s information on the operational controls of the WRF. Work to provide Professional I&C Services for programming and commissioning/final check-out is not part of Bidder’s Base Bid. Bidder’s shall be responsible for facilitating the correction of any electrical and control’s wiring needed for successful start-up of SCADA system. END OF SECTION Livingston WRF Upgrades Livingston, Montana 00 35 00- 1 June 2017 Instrumentation and Controls Inforamtion Livingston Water Reclamation Facility L A LY A SE O N M FO R AE2S Project #: P05613-2015-001 U IN FO R B ID TI O N D ER S' Control System Narrative March 31, 2017 Rev Number 1 2 3 4 5 6 7 8 9 Date 11/21/16 12/6/16 12/19/16 1/17/17 1/26/17 1/30/17 2/2/17 3/30/17 3/31/17 Revision Original Revision 1 Revision 2 Revision 3 Revision 4 Revision 5 Revision 6 Revision 7 Revision 8 By RH SB RH RH RH/SJ RH SJ SJ RH Livingston Water Reclamation Facility Control System Narrative Contents Control System Overview.............................................................................................................................. 3 HEADWORKS CONTROL PANEL ................................................................................................................. 3 INFLUENT PUMP STATION CONTROL PANEL ............................................................................................ 3 REACTOR CONTROL BUILDING SUPERVISORY CONTROL PANEL .............................................................. 3 UV DISINFECTION/EFFLUENT REUSE CONTROL PANEL ............................................................................ 3 S' SOLIDS PROCESS BUILDING CONTROL PANEL........................................................................................... 4 ER Process Area Overview ................................................................................................................................. 5 L Area 1000 – Headworks ............................................................................................................................ 5 A D Influent Flow ......................................................................................................................................... 5 Screening ............................................................................................................................................... 5 ID TI O N Grit Removal ......................................................................................................................................... 5 B Area 2000 – Influent Pump Station........................................................................................................... 7 Influent Pumps ...................................................................................................................................... 7 A R Area 3000 –Reactor Control Building ....................................................................................................... 9 LY FO SBR Operations.................................................................................................................................... 10 M WAS Holding/Aerobic Digester Blowers.............................................................................................. 10 N FO R Area 4000 – Solids Processing Building................................................................................................... 12 O WAS Holding Basins ............................................................................................................................ 13 Thickener Feed Pumps......................................................................................................................... 13 SE Sludge Thickening ............................................................................................................................... 14 IN Aerobic Digestion ................................................................................................................................ 14 U Area 5000 – UV Disinfection/Effluent Reuse .......................................................................................... 17 UV Disinfection System ....................................................................................................................... 17 Effluent Reuse Pumps.......................................................................................................................... 17 Area 6000 – Biosolids Management ....................................................................................................... 20 Solids Handling .................................................................................................................................... 20 Composting ......................................................................................................................................... 20 Page 2 Livingston Water Reclamation Facility Control System Narrative Control System Overview There will be five (5) control panels each with Allen-Bradley ControlLogix PLC components S' 1. HEADWORKS (ControlLogix Remote I/O to Influent Pump Station PLC) 2. INFLUENT PUMP STATION (ControlLogix Processor) 3. REACTOR CONTROL BUILDING SUPERVISORY CONTROL PANEL (SCP) (ControlLogix Processor and separate SBR OEM Panel w/ ControlLogix Processor) 4. UV DISINFECTION/EFFLUENT REUSE (ControlLogix Remote I/O to Reactor Control Building PLC and separate UV OEM Panel) 5. SOLIDS PROCESS BUILDING (ControlLogix Processor) HEADWORKS CONTROL PANEL L A TI O N D ER Devices associated with the influent to the treatment plant will be wired to the HEADWORKS Control Panel (CP). The I/O system in the HEADWORKS CP will be Allen-Bradley 1756 ControlLogix I/O, and will be monitored and controlled by the PLC processor in the INFLUENT PUMP STATION PLC. The two systems will be connected via an Ethernet/IP connection. B ID Data will be messaged to the INFLUENT PUMP STATION PLC, the method of data telemetry will be Ethernet TCP/IP communication over fiber optic media, or wireless radio/cellular telemetry. INFLUENT PUMP STATION CONTROL PANEL LY A N M FO R The INFLUENT PUMP STATION PLC will control and monitor the devices associated with the influent pumping operation. The INFLUENT PUMP STATION PLC will be connected over Ethernet to the REACTOR CONTROL BUILDING SCP and other control systems to allow data to be messaged between the systems. Critical system information will be hardwired between the systems. FO R REACTOR CONTROL BUILDING SUPERVISORY CONTROL PANEL O SE U IN The REACTOR CONTROL BUILDING SCP panel will be the center of the control system network, with a ControlLogix platform PLC, being the primary connection to the SEQUENCE BATCH REACTOR (SBR) Original Equipment Manufacturer (OEM) panel(s). The REACTOR CONTROL BUILDING SCP will control and monitor the devices associated with the SBR OEM panel operation. The REACTOR CONTROL BUILDING SCP will connect, over Ethernet, to the SBR CP and other control system panels to allow data to be messaged and monitored between the systems. Critical system information may need to be hardwired between the systems. UV DISINFECTION/EFFLUENT REUSE CONTROL PANEL Devices associated with the effluent reuse for the treatment plant will be hardwired, and the UV Disinfection System OEM panel will be connected via Ethernet/IP connection, to the UV DISINFECTION/EFFLUENT REUSE CP. The I/O system in the UV DISINFECTION/EFFLUENT REUSE CP will be Allen-Bradley 1756 ControlLogix I/O, and will be monitored and controlled by the PLC processor in the REACTOR CONTROL BUILDING SCP. The two systems will be connected via an Ethernet/IP connection. Data will be messaged to the REACTOR CONTROL BUILDING SCP that will control and monitor the operation of the UV disinfection system and the Effluent Reuse Pumping system. The method of data Page 3 Livingston Water Reclamation Facility Control System Narrative telemetry will be Ethernet TCP/IP communication over fiber optic media, or wireless radio/cellular telemetry. SOLIDS PROCESS BUILDING CONTROL PANEL S' The SOLIDS PROCESS BUILDING PLC will control and monitor the devices associated with Waste Activated Sludge (WAS) Storage, Thickening and Aerobic Digestion operations. The SOLIDS PROCESS BUILDING PLC will be connected over Ethernet to the REACTOR CONTROL BUILDING SCP and other control systems to allow data to be messaged between the systems. Critical system information will be hardwired between the systems. L A LY A U SE O N M FO R IN FO R B ID TI O N D ER Data will be messaged to the remote PLCs that will control and monitor the operation of the solids processing equipment. The method of data telemetry will be Ethernet TCP/IP communication over fiber optic media, or wireless radio/cellular telemetry. Page 4 Livingston Water Reclamation Facility Control System Narrative Process Area Overview Area 1000 – Headworks Device List INF-LT1 INF-AS1 INF-AIT1 Influent Level Transmitter (Parshall Flume) Influent Auto Sampler Hydrogen Sulfide/Combustible Gas Detector L A D ER S' SCR1-LT1 Pre-screen Level Transmitter SCR1-M1 Influent Micro-screen No. 1 SCR1-SOL1 Micro-screen No. 1 Wash Water Solenoid SCR2-LT1 Pre-screen Level Transmitter SCR2-M1 Influent Micro-screen No. 2 SCR2-SOL1 Micro-screen No. 2 Wash Water Solenoid NOTE: All italicized devices above to be connected to the Screening OEM panels for local control B ID TI O N GRT-GP1 Grit Pump #1 (existing) GRT-GP2 Grit Pump #2 (existing) GRT-CNV Grit Removal Screw Conveyor (existing) NOTE: All italicized devices above to be connected to the Grit Pumping OEM panel for local control LY A FO R Influent Flow Monitor and record level/flow at INF-LT1. Influent sampled via Auto Sampler (INF-AS1), sample collection interval is flow-paced. N O SE FO R M Screening Micro-screens will operate on a level setpoint in the Pre-screen Level Transmitter (HW1-LT1 or HW2LT1). HW1 shall be the lead system; HW2 shall be the lag/standby system. The OEM local control panels will be added to operate the Screening systems, these panels will be connected via Ethernet/IP to the Headworks CP for complete process operation and alarm monitoring. U IN Grit Removal There is an existing OEM control panel which operates the Grit Removal system, this CP will be connected via Ethernet/IP to the Headworks CP for process operation and alarm monitoring. Area 1000 Process Alarms: NOTE: Alarms listed are for devices that are hardwired to this PLC, not OEM messaged data and alarms LAH-1001 HW Side 1 High Level (Start Screens) LAHH-1001 HW Side 1 High-High Level LAL-1001 HW Side 1 Channel Low Level (Shutdown Screens) LAH-1002 HW Side 2 High Level (Start Screens) LAHH-1002 HW Side 2 High-High Level LAL-1002 HW Side 2 Channel Low Level (Shutdown Screens) FALL-1001 Influent Low-Low Flow MN-1501 Screen #1 Motor Failed to Start MF-1501 Screen #1 Motor VFD Fault Page 5 Livingston Water Reclamation Facility Control System Narrative Screen #1 Motor Amp Overload Screen #1 Motor Thermal Overload Screen #2 Motor Fail Screen #2 Motor VFD Fault Screen #2 Motor Amp Overload Screen #2 Motor Thermal Overload L A LY A U SE O N M FO R IN FO R B ID TI O N D ER S' MA-1501 MT-1501 MN-1502 MF-1502 MA-1502 MT-1502 Page 6 Livingston Water Reclamation Facility Control System Narrative Area 2000 – Influent Pump Station S' Influent Wetwell Submersible Level Transducer Influent Wetwell High Level Float Influent Wetwell Low Level Float Influent Pump #1 (VFD) Influent Pump #2 (VFD) Influent Pump #3 (VFD) Influent Pump #4 (VFD) IPS MCC Surge Protective Device IPS MCC Power Monitor IPS Sump High Level Float Hydrogen Sulfide/Combustible Gas Detector L ER Device List INF-LT1 INF-LSH1 INF-LSL1 INF-IP1 INF-IP2 INF-IP3 INF-IP4 MCC2-SPD1 MCC2-PM1 INF-FS1 IPS-AIT1 ID A TI O N D Influent wastewater flows by gravity into the Influent Wetwell. Influent pumps will operate and control speed according to wetwell level. Influent Pump #4 (INF-P4) is a smaller jockey pump for low flow periods. LY A SE O N M FO R FO R B Influent Pumps Pumps will operate based on level setpoints from Influent Wetwell. When the level INF-LT1 is above the START setpoint Influent Pump #4 (INF-P4) will start and ramp up to 60% speed. The speed of INF-P4 will increase at a rate proportional to the rate of rise in the level of the Influent Wetwell. If the level in the wetwell continues to rise after INF-P4 has reached 100% speed, INF-P1 or 2 (the lead pump will cycle after each shutdown) will be called start at 60% speed and INF-P4 will be turned off. The speed of INFP1 (or 2) will increase at a rate proportional to the rate of rise in the level of the influent wetwell. If the level in the wetwell continues to rise after INF-P1 (or 2) has reached 100% speed, INF-P3 will be turned on. INF-P1 (or 2) will ramp down proportional to level in the wetwell. If it reaches 60% speed and remains at that speed for an operator settable time then INF-P3 will be turned off. U IN In high flow conditions, when the primary lead and INF-P3 cannot handle incoming flow, the primary lag will start. If all three larger pumps are in operation, INF-P4 (jockey pump) will then start. As the level (INF-LT1) drops past the staged setpoints, the pumps will shut off in reverse order. When the level INF-LT1 is below the primary STOP setpoint, and the jockey pump (INF-P4) is operating at low VFD frequency setpoint, the pump will stop. Pumps will be interlocked with a run permissive from the SBR controller. The pump drives/starters and Influent Wetwell level will be hardwired to the Influent Pump Station CP. Area 2000 Process Alarms: NOTE: Alarms listed are for devices that are hardwired to this PLC, not OEM messaged data and alarms LAH-2001 Influent Wetwell High Level (Start secondary pump) LAHH-2001 Influent Wetwell High-High Level (Start final pump in sequence) Page 7 Livingston Water Reclamation Facility Control System Narrative Influent Wetwell Low Level (Stop secondary pump, if running) Influent Wetwell Low-Low Level (Shut down primary pump) Pump #1 Failed to Start Pump #1 VFD Fault Pump #1 Thermal Overload Pump #1 Seal Failure Pump #2 Failed to Start Pump #2 VFD Fault Pump #2 Thermal Overload Pump #2 Seal Failure Pump #3 Failed to Start Pump #3 Thermal Overload Pump #3 Seal Failure Pump #4 Failed to Start Pump #4 VFD Fault Pump #4 Thermal Overload Pump #4 Seal Failure L A LY A U SE O N M FO R IN FO R B ID TI O N D ER S' LAL-2001 LALL-2001 MN-2501 MF-2501 MT-2501 MS-2501 MN-2502 MF-2502 MT-2502 MS-2502 MN-2503 MT-2503 MS-2503 MN-2504 MF-2504 MT-2504 MS-2504 Page 8 Livingston Water Reclamation Facility Control System Narrative Area 3000 –Reactor Control Building SBR No.1 Influent Feed Weir SBR No.1 Chlorine Feed Valve SBR No. 2 Influent Feed Weir SBR No.2 Chlorine Feed Valve SBR Splitter Box Submersible Level Transducer Aerobic Digester Blower No. 1 Aerobic Digester Blower No. 1 Pressure Transmitter Aerobic Digester Blower No. 2 Aerobic Digester Blower No. 2 Pressure Transmitter WAS Holding Blower No. 1 WAS Holding Blower No. 1 Pressure Transmitter WAS Holding Blower No. 2 WAS Holding Blower No. 2 Pressure Transmitter WAS Holding Air Flow Transmitter Hydrogen Sulfide/Combustible Gas Detector SBR1-M1 SBR1-SSS1 SBR1-DOS1 SBR1-LS1 SBR1-SF1 SBR1-TP1 SBR1-DF1 SBR1-FD1 SBR1-P1 SBR1-AFV1 SBR1-AFV2 SBR2-M1 SBR2-SSS1 SBR2-DOS1 SBR2-LS1 SBR2-SF1 SBR2-TP1 SBR2-DF1 SBR2-FD1 SBR2-P1 SBR2-AFV1 SBR2-AFV2 SBR-FIT1 SBR-SSS1 SBR-BLW1 BLW1-PT1 SBR-BLW2 BLW2-PT1 SBR-BLW3 SBR No.1 Mixer #1 SBR No.1 Mixed Liquor Suspended Solids Sensor SBR No.1 Dissolved Oxygen Sensor SBR No.1 Level Sensor SBR No.1 High Level Float SBR No.1 WAS Transfer Pump SBR No.1 Decanter Float SBR No.1 Final Decanter SBR No.1 Waste Sludge Pump SBR Basin No. 1 Main Reactor Air Flow Control Valve SBR Basin No. 1 Pre-Reactor Air Flow Control Valve SBR No.2 Mixer #1 SBR No.2 Mixed Liquor Suspended Solids Sensor SBR No.2 Dissolved Oxygen Sensor SBR No.2 Level Sensor SBR No.2 High Level Float SBR No.2 WAS Transfer Pump SBR No.2 Decanter Float SBR No.2 Final Decanter SBR No.2 Waste Sludge Pump SBR Basin No. 2 Main Reactor Air Flow Control Valve SBR Basin No. 2 Pre-Reactor Air Flow Control Valve SBR WAS Flowmeter SBR WAS Suspended Solids Transmitter SBR Blower No. 1 SBR Blower No. 1 Pressure Transmitter SBR Blower No. 2 SBR Blower No. 2 Pressure Transmitter SBR Blower No. 3 L A U SE O N LY A M FO R IN FO R B ID TI O N D ER S' Device List SBR1-WG1 CLR1-BLV1 SBR2-WG1 CLR2-BLV1 SBR-LT1 BLW-ADB1 ADB1-PIT1 BLW-ADB2 ADB2-PIT1 BLW-WBL1 WBL1-PIT1 BLW-WBL2 WBL2-PIT1 WHB-FIT1 RCB-AIT1 Page 9 Livingston Water Reclamation Facility Control System Narrative BLW3-PT1 SBR Blower No. 3 Pressure Transmitter NOTE: All italicized devices above to be connected to the SBR OEM panel for local control S' SBR Operations Influent will be pumped from the Influent Pump Station to the SBR splitter box. Flow from the splitter box will be controlled using two electrically actuated downward opening weir gates, one dedicated to each SBR basin, in the influent (splitter) box common to both Pre-React Zones. SBR Weir Gates will have open/close operation to control flow to each basin, to isolate a basin (when only one basin is needed for optimal treatment or for routine maintenance), and to prevent basin overflow events. ER Water surface elevation in the basins will be monitored within the ICEAS OEM panel. The SBR level signals will be hardwired (4-20 mA) to the OEM panel and will be used to control the SBR cycle times. ID L A TI O N D The SBR mixers/pumps/actuated valves will be hardwired to the ICEAS PLC to provide primary control of their operation. The ICEAS PLC will be connected to the REACTOR CONTROL BUILDING SCP to provide complete monitoring and control of process operations and alarms, as well as record process data. B WAS Holding/Aerobic Digester Blowers WAS Holding and Aerobic Digester Blowers are controlled within the Solids Processing Building CP, process operation data to be transferred via Ethernet messaging. LY A U SE O N M FO R IN FO R Area 3000 Process Alarms: NOTE: Alarms listed are for devices that are hardwired to this PLC, not OEM messaged data and alarms AM-3001 SBR No. 1 Weir Gate Failed to Close AN-3001 SBR No. 1 Weir Gate Failed to Open AM-3002 SBR No. 2 Weir Gate Failed to Close AM-3002 SBR No. 2 Weir Gate Failed to Open LAHH-3001 SBR Splitter Box High-High Level NOTE: SBR alarm programming to be determined by manufacturer’s assembly LAH-3301 SBR No. 1 Tank High Level LAHH-3301 SBR No. 1 Tank High-High Level LAL-3301 SBR No. 1 Tank Low Level LALL-3301 SBR No. 1 Tank Low-Low Level MN-3501 SBR No. 1 Mixer Failed to Start MF-3501 SBR No. 1 Mixer Fault MT-3501 SBR No. 1 Mixer Thermal Overload MS-3501 SBR No. 1 Mixer Seal Failure MN-3502 SBR No. 1 WAS Pump Failed to Start MF-3502 SBR No. 1 WAS Pump Fault MT-3502 SBR No. 1 WAS Pump Thermal Overload MS-3502 SBR No. 1 WAS Pump Seal Failure AH-3503 SBR No. 1 Decanter Fail (closes corresponding splitter box weir gate) LAH-3304 SBR No. 2 Tank High Level LAHH-3304 SBR No. 2 Tank High-High Level LAL-3304 SBR No. 2 Tank Low Level Page 10 Livingston Water Reclamation Facility Control System Narrative L A LY A U SE O N M FO R IN FO R B ID TI O N D ER S' LALL-3304 SBR No. 2 Tank Low-Low Level MN-3504 SBR No. 2 Mixer Failed to Start MF-3504 SBR No. 2 Mixer Fault MT-3504 SBR No. 2 Mixer Thermal Overload MS-3504 SBR No. 2 Mixer Seal Failure MN-3505 SBR No. 2 WAS Pump Failed to Start MF-3505 SBR No. 2 WAS Pump Fault MT-3505 SBR No. 2 WAS Pump Thermal Overload MS-3505 SBR No. 2 WAS Pump Seal Failure AH-3506 SBR No. 2 Decanter Fail (closes corresponding splitter box weir gate) NOTE: Aerobic Digester Blower alarm programming to be determined by manufacturer’s assembly MN-3704 AD Blower No. 1 Failed to Start MF-3704 AD Blower No. 1 VFD Fault MT-3704 AD Blower No. 1 Thermal Overload MN-3705 AD Blower No. 2 Failed to Start MF-3705 AD Blower No. 2 VFD Fault MT-3705 AD Blower No. 2 Thermal Overload PAH-3704 AD Blower No. 1 Discharge High Pressure PAHH-3704 AD Blower No. 1 Discharge High-High Pressure PAL-3704 AD Blower No. 1 Discharge Low Pressure PALL-3704 AD Blower No. 1 Discharge Low-Low Pressure PAH-3705 AD Blower No. 2 Discharge High Pressure PAHH-3705 AD Blower No. 2 Discharge High-High Pressure PAL-3705 AD Blower No. 2 Discharge Low PALL-3705 AD Blower No. 2 Discharge Low-Low Pressure NOTE: WAS Holding Basin Blower alarm programming to be determined by manufacturer’s assembly MN-3706 WH Blower No. 1 Failed to Start MF-3706 WH Blower No. 1 VFD Fault MT-3706 WH Blower No. 1 Thermal Overload MN-3707 WH Blower No. 2 Failed to Start MF-3707 WH Blower No. 1 VFD Fault MT-3707 WH Blower No. 1 Thermal Overload PAH-3706 WH Blower No. 1 Discharge High Pressure PAHH-3706 WH Blower No. 1 Discharge High-High Pressure PAL-3706 WH Blower No. 1 Discharge Low Pressure PALL-3706 WH Blower No. 1 Discharge Low-Low Pressure PAH-3707 WH Blower No. 2 Discharge High Pressure PAHH-3707 WH Blower No. 2 Discharge High-High Pressure PAL-3707 WH Blower No. 2 Discharge Low Pressure PALL-3707 WH Blower No. 2 Discharge Low-Low Pressure Page 11 Livingston Water Reclamation Facility Control System Narrative Area 4000 – Solids Processing Building L A LY A O N M U SE WAS Holding Basin #1 Air Flow Control Valve WAS Holding No. 1 Submersible Level Transducer WAS Holding Basin #1 Dissolved Oxygen Sensor WAS Holding Basin #1 pH Sensor WAS Holding Basin #1 Air Flow Control Valve WAS Holding No. 2 Submersible Level Transducer WAS Holding Basin #2 Dissolved Oxygen Sensor WAS Holding Basin #2 pH Sensor Thickener/Aerobic Digester Feed Flow Meter Thickener Feed Pump No. 1 Thickener Feed Pump No. 2 Hydrogen Sulfide/Combustible Gas Detector Aerobic Digester Feed Pump No. 1 Aerobic Digester Feed Pump No. 2 Aerobic Digester Feed Total Suspended Solids Sensor Aerobic Digester No. 1 Sludge Feed Valve IN WHB1-BFV1 WHB1-LT1 WHB1-AE1 WHB1-AE2 WHB2-BFV1 WHB2-LT1 WHB2-AE1 WHB2-AE2 TKF-FIT1 TKF-TP1 TKF-TP2 SPB-AIT1 ADF-DP1 ADF-DP2 ADF-AIT1 AD1-PV1 FO R FO R B ID TI O N D ER S' Device List TKU1-M1 Thickening Unit No. 1 TKU1-WWP1 Thickener Unit No. 1 Wash Water Pump TKU1-LIT1 TKU No. 1 Flocculation Tank Level Transmitter TKU1-LSH TKU No. 1 Flocculation Tank High Level Switch TST1-LIT2 TKU No. 1 Trough Level Transmitter TST1-LSH TKU No. 1 Trough High Level Switch PSD1-PLM1 Polymer Storage No. 1 Mixer PSS1-NPP1 Neat Polymer Pump No. 1 PSS1-PSH Polymer Skid System No. 1 High Pressure Switch PSS1-FIT1 Polymer Skid System No. 1 Dilution Water Flow Element PSS1-PIV1 Polymer Potable Water Feed Valve PSS1-BLV5 Polymer Potable Water Flow Control Valve PSS1-FSL1 Polymer Skid System No. 1 Dilution Water Low Flow Switch TKU2-M1 Thickening Unit No. 2 (future) TKU2-WWP1 Thickener Unit No. 2 Wash Water Pump (future) TKU2-LIT1 TKU No. 2 Flocculation Tank Level Transmitter (future) TKU2-LSH TKU No. 2 Flocculation Tank High Level Switch (future) TST2-LIT2 TKU No. 2 Trough Level Transmitter (future) TST2-LSH TKU No. 2 Trough High Level Switch (future) PSD2-PLM1 Polymer Storage No. 1 Mixer (future) PSS2-NPP1 Neat Polymer Pump No. 1 (future) PSS2-PSH Polymer Skid System No. 1 High Pressure Switch (future) PSS2-FIT1 Polymer Skid System No. 1 Dilution Water Flow Element (future) PSS2-PIV1 Polymer Potable Water Feed Valve (future) PSS2-BLV5 Polymer Potable Water Flow Control Valve (future) PSS2-FSL1 Polymer Skid System No. 1 Dilution Water Low Flow Switch (future) NOTE: All italicized devices above to be connected to the Thickening Unit and Polymer OEM panels for local control Page 12 Livingston Water Reclamation Facility Control System Narrative ID L A TI O N D ER S' Aerobic Digester No. 1 Feed Flow Meter Aerobic Digester No. 1 Air Flow Control Valve Aerobic Digester No. 1 Air Flow Meter Aerobic Digester No. 1 Dissolved Oxygen Sensor Aerobic Digester No. 1 pH/Temperature Sensor Aerobic Digester No. 1 Submersible Pressure/Level Transducer Aerobic Digester No. 1 Jet Mixing Pump Aerobic Digester Area No. 1 Sump Float Switch Aerobic Digester No. 2 Sludge Feed Valve Aerobic Digester No. 2 Feed Flow Meter Aerobic Digester No. 2 Air Flow Control Valve Aerobic Digester No. 2 Air Flow Meter Aerobic Digester No. 2 Dissolved Oxygen Sensor Aerobic Digester No. 2 pH/Temperature Sensor Aerobic Digester No. 2 Submersible Pressure/Level Transducer Aerobic Digester No. 2 Jet Mixing Pump Aerobic Digester Area No. 2 Sump Float Switch Digested Sludge Pump No. 1 Digested Sludge Pump No. 2 Digested Sludge Flow Meter B AD1-FIT1 AD1-BFV1 AD1-FIT2 AD1-AIT1 AD1-AIT2 AD1-LT1 AD1-MP1 AD1-FS1 AD2-PV1 AD2-FIT1 AD2-BFV1 AD2-FIT2 AD2-AIT1 AD2-AIT2 AD2-LT1 AD2-MP1 AD2-FS1 DSP-SP1 DSP-SP2 SDU-FIT1 LY A M FO R WAS Holding Basins WAS Holding Basins will function in a lead/lag scenario with the lag primarily being used in emergency flow and O&M-type instances. Each basin will serve as lead on an annual service basis. N O SE U IN FO R When the level in either WAS Holding Basin in service is greater than the corresponding low alarm level setpoint, WAS-BLW1 or 2 will start and the corresponding air flow control valve (WAS-AIR-BFV1 or 2) will open to supply the coarse air bubble diffusers within the basin. The aeration system will operate cyclically (based upon time operation and delay setpoints) or until the DO reaches design setpoint, at which time the system will shutdown for a corresponding delay time setpoint. NOTE: If the operator calls for Thickener Unit operation from a specified WAS Holding Basin, the aeration to that basin should be shutdown prior to this function. The system will operate as such until the WAS level in the basin drops below the LAL setpoint and the air supply system is shutdown. Thickener Feed Pumps Pumps will operate based on the demand from the Aerobic Digesters, with a permissive from the WAS Holding Basins (to ensure WAS level is sufficient to feed Thickeners and that motor actuated valves on the correct pump suction is open). The PLC will start/stop the WAS pumps and operate based on operator flow setpoint. The speed command for the pumps will be determined by the output of a PID loop in the PLC. The setpoint (SP) will be based on the required flow and the process variable (PV) will be the total of ADF-FM1. The pumps will alternate to allow for equal runtime of each pump. The pumps will shut down if low flow cutoff setpoint is met through the discharge flow meter. The alarm enable will be time delayed in order for the flow to reach normal operating range. Page 13 Livingston Water Reclamation Facility Control System Narrative The pumps will be interlocked with the Aerobic Digester levels and Thickening Unit process requirements (to ensure they are not operated if the downstream processes are not capable of handling the flow). S' Sludge Thickening The Sludge Thickening Unit will be fed a continuous flow (approximately 200 gpm) from the Thickener Feed Pumps. The sludge passes through a mixing valve where polymer is injected from the polymer feed skid. Thickened sludge is discharged from the Drum Thickener to a holding trough where the Aerobic Digester Feed pumps transfer the sludge. The Thickener Feed Pumps, Thickening Unit, Polymer Feed System, and Aerobic Digester Feed pumps will shut off if any of the following events occur: ID L A TI O N D ER 1. The level in the corresponding WAS Holding Basin reaches the low level setpoint 2. The Aerobic Digesters reach a high level setpoint 3. An error occurs with any component of the Thickening Unit or Polymer Feed System that requires shutdown of the respective unit 4. An error occurs downstream of the Aerobic Digester Feed Pumps (ie, no flow switch, high discharge pressure, etc) causing shutdown of the pumps B All Area 4000 process equipment (besides blowers and appurtenances) will be hardwired to the Solids Processing Building CP for process operation, control, and monitoring. LY A N M FO R Aerobic Digestion Aerobic Digester Blowers and appurtenance operation is controlled within the Reactor Control Building SCP, process operation data to be transferred via Ethernet messaging. O SE U IN FO R Each aerobic digester will be fed from the Sludge Thickening system; the sludge feed will be controlled off of thickened sludge troughs level and operation setpoints. The sludge feed pumps will be shut off if the level in the aerobic digester being fed reaches the high-high setpoint. The Aerobic Digester Mixing Pump operation is continuous. Air supply will be operated cyclically, based upon time of operation and delay time setpoints, until a DO setpoint is reached and held for an operator adjustable period of time, or until a low-low pH setpoint is reached. Digested Sludge pumping will be initiated by operations staff and then controlled off of the digester level transmitters and operation setpoints to maintain 40-50 gpm continuous flow to the dewatering system throughout the sludge pumping process. Aerobic Digester blowers will be shutdown on digester cycles not requiring air supply. If air supply is required, the blowers will be operated to maintain DO level setpoint. The aerobic digester system will have an automatic cleaning cycle. The cleaning cycle will be performed on an input time interval, typically every two (2) weeks for each aerobic digester. The automatic cleaning cycle for each digester is described as follows: 1. The cleaning cycle will not run unless the system is within the required operating parameters (ie, DO, pH, Temperature). Page 14 Livingston Water Reclamation Facility Control System Narrative S' 2. If within operating parameters, but not currently receiving air, corresponding valves (AD1-AFV1/ AD2-AFV1) will open to send air to digester. 3. The mixing pump for the corresponding aerobic digester will be shut down. The corresponding pump discharge valve will be closed by the associated motor actuator (ADP1-PV2/ADP2-PV2) after the pump is shutdown. 4. The valve located on the cleanout line will be opened by the associated motor actuator (ADP1PV3/ADP2-PV3). Cycle run time will be an operator setpoint, to be maintained within the recommendations of the manufacturer. 5. The valve located on the cleanout line will be closed. The valve located on the mixing pump discharge will be opened, and the mixing pump will be restarted. L A LY A U SE O N M FO R IN FO R B ID TI O N D ER Area 4000 Process Alarms: NOTE: Alarms listed are for devices that are hardwired to this PLC, not OEM messaged data and alarms LAH-4201 WAS Holding Basin #1 High Level LAHH-4201 WAS Holding Basin #1 High High Level LAL-4201 WAS Holding Basin #1 Low Level LAH-4202 WAS Holding Basin #2 High Level LAHH-4202 WAS Holding Basin #2 High High Level LAL-4202 WAS Holding Basin #2 Low Level PLL-4251 WH Basin No. 1 Low-Low pH THH-4251 WH Basin No. 1 High-High Temperature DLL-4251 WH Basin No. 1 Low-Low DO PLL-4252 WH Basin No. 2 Low-Low pH THH-4252 WH Basin No. 2 High-High Temperature DLL-4252 WH Basin No. 2 Low-Low DO MN-4501 Thickener Feed Pump No. 1 Failed to Start MF-4501 Thickener Feed Pump No. 1 Fault MT-4501 Thickener Feed Pump No. 1 Thermal Overload MS-4501 Thickener Feed Pump No. 1 Seal Failure MN-4502 Thickener Feed Pump No. 2 Failed to Start MF-4502 Thickener Feed Pump No. 2 Fault MT-4502 Thickener Feed Pump No. 2 Thermal Overload MS-4502 Thickener Feed Pump No. 2 Seal Failure MN-4503 Aerobic Digester No. 1 Mixing Pump Failed to Start MF-4503 Aerobic Digester No. 1 Mixing Pump Fault MT-4503 Aerobic Digester No. 1 Mixing Pump Thermal Overload MS-4503 Aerobic Digester No. 1 Mixing Pump Seal Failure MN-4504 Aerobic Digester No. 2 Mixing Pump Failed to Start MF-4504 Aerobic Digester No. 2 Mixing Pump Fault MT-4504 Aerobic Digester No. 2 Mixing Pump Thermal Overload MS-4504 Aerobic Digester No. 2 Mixing Pump Seal Failure PLL-4901 Aerobic Digester No. 1 Low-Low pH THH-4901 Aerobic Digester No. 1 High-High Temperature DLL-4901 Aerobic Digester No. 1 Low-Low DO PLL-4902 Aerobic Digester No. 2 Low-Low pH THH-4902 Aerobic Digester No. 2 High-High Temperature Page 15 Livingston Water Reclamation Facility Control System Narrative L A LY A U SE O N M FO R IN FO R B ID TI O N D ER S' DLL-4902 Aerobic Digester No. 2 Low-Low DO FAL-4000 Thickener Feed Low Flow FALL-4000 Thickener Feed Low-Low Flow * Enough time delay will be programmed into the alarm enable logic to allow the process value to get up to a normal operating range before enabling. Page 16 Livingston Water Reclamation Facility Control System Narrative Area 5000 – UV Disinfection/Effluent Reuse L A TI O N D ER S' Effluent Reuse Pump #1 Effluent Reuse Pump #2 Effluent Reuse Pump #3 Effluent Reuse Flowmeter Effluent Reuse Discharge Pressure Transmitter Effluent Reuse Reservoir Submersible Level Transducer Effluent Reuse Reservoir High-High Level Float Effluent Reuse Reservoir High Level Float Effluent Reuse Reservoir Low Level Float Effluent Reuse Reservoir Low-Low Level Float Effluent Reuse Reservoir Fill Valve Effluent Reuse Non-Potable Supply Valve Effluent Reuse Sodium Hypochlorite Feed Pump No. 1 Effluent Reuse Sodium Hypochlorite Feed Pump No. 2 Chlorine Distribution Flow Switch ID Device List EFR-RP1 EFR-RP2 EFR-RP3 EFR-FM1 EFR-PIT1 EFR-LT1 EFR-LSHH1 EFR-LSH1 EFR-LSL1 EFR-LSLL1 EFR-BFV2 EFR-BFV3 CLR-CMP1 CLR-CMP2 CLR-FSL1 LY A N M FO R FO R B UVI-FIT1 UV Flowmeter (Plant Effluent) UVC-B1 UV Bank No. 1 UVC-B2 UV Bank No. 2 UVC-B3 UV Bank No. 3 UVC-B4 UV Bank No. 4 UVC-AIT1 UV Transmittance Transmitter UVC-LIT1 UV Channel Level Transmitter UVC-LSL UV Channel Low Level Switch NOTE: All italicized devices above to be connected to the UV OEM panel for local control O Effluent will be sampled via Auto Sampler (EFF-AS1), sample collection interval is flow-paced. SE U IN UV Disinfection System The UV Disinfection System, and associated required devices, will be hardwired to the UV OEM PLC to provide primary control of their operation. The UV PLC will be connected to the UV DISINFECTION/ EFFLUENT REUSE CP to provide complete monitoring and control of process operations and alarms, as well as record process data. Effluent Reuse Pumps Pumps will operate based on the pressure demand from Effluent Reuse Distribution System. The sodium hypochlorite chemical feed will be operated as follows: 1. EFR-CP1 will operate when the Effluent Reservoir Feed Valve is open - and flow is registered at UV-FM1 - to provide a chlorine residual within the reservoir. 2. EFR-CP2 will be operated when either chlorine ring actuated feed valve is open. Chlorine ring actuated feed valves will be operated based on SBR operational status and settable delay timers. When flow is registered in the chlorine distribution flow switch and the respective chlorine feed Page 17 Livingston Water Reclamation Facility Control System Narrative valve is open, the mixer in the corresponding SBR basin will start. Chlorine injection into the SBR basins will be limited to occur only during staffed hours (7am-4pm). Chlorine injection will be limited to once per basin per day during the react cycle when system is in auto mode. When chlorine injection has concluded, the chemical feed pump (EFR-CP2) will turn off and the effluent reuse pumps will continue to pump for 5 minutes to flush the system during the react cycle. The PLC will operate the pump(s) to maintain pressure in the Effluent Reuse Water Distribution System header, downstream of a hydropneumatic tank, and will start/stop the pumps accordingly. L ER S' The speed command for the pumps will be determined by the output of a PID loop in the PLC. The setpoint (SP) will be based on the pressure required by Effluent Reuse Distribution System header, and the PV will be the total of EFRU-FM1. If two pumps are running, the VFD’s will operate in parallel. The equally sized pumps will alternate to allow for equal runtime of each pump. ID A TI O N D The pumps will shut down if setpoint pressure is maintained in the Distribution System Header for the desired time setpoint (in minutes) and/or the low flow cutoff setpoint is met. LY A SE O N M FO R FO R B Effluent Reuse Reservoir float tree will control the operations surrounding the reservoir as described below: • Low Low Level – Shuts off all vertical turbine pumps when the reservoir level reaches LALL setpoint. • Low Level – Opens potable water backup supply valve (EFRU-PV2) to supplement reservoir when the reservoir reaches LAL setpoint and Reuse Decant cycle is >30 minutes from occurring. • High Level – Closes Effluent Reuse (EFRU-PV1) and/or Potable Water Backup (EFRU-PV2) valves when the reservoir reaches LAH setpoint. • High High Level – At overflow, starts EFRU pumps and opens SBR Splitter Box valve to discharge excess reuse water when the reservoir reaches the LAHH setpoint, continues operation until the reservoir level drops below LAH setpoint. U IN The Effluent Reuse pump system, and associated process equipment, will be hardwired to the UV Disinfection/Effluent Reuse CP. The UV PLC will serve as the primary control for the UV system and will be connected to the UV Disinfection/Effluent Reuse CP to monitor operation and record process data. Area 5000 Process Alarms: NOTE: Alarms listed are for devices that are hardwired to this PLC, not OEM messaged data and alarms MN-5501 Effluent Reuse Pump #1 Failed to Start MF-5501 Effluent Reuse Pump #1 VFD Fault MT-5501 Effluent Reuse Pump #1 Thermal Overload MS-5501 Effluent Reuse Pump #1 Seal Failure MN-5502 Effluent Reuse Pump #2 Fail MF-5502 Effluent Reuse Pump #2 VFD Fault MT-5502 Effluent Reuse Pump #2 Thermal Overload MS-5502 Effluent Reuse Pump #21 Seal Failure Page 18 Livingston Water Reclamation Facility Control System Narrative L A LY A U SE O N M FO R IN FO R B ID TI O N D ER S' MN-5503 Effluent Reuse Pump #3 Fail MF-5503 Effluent Reuse Pump #3 VFD Fault MT-5503 Effluent Reuse Pump #3 Thermal Overload MS-5503 Effluent Reuse Pump #3 Seal Failure FAL-5000 Effluent Reuse Low Flow FALL-5000 Effluent Reuse Low-Low Flow PAH-5000 Effluent Reuse Discharge Header High Pressure PAHH-5000 Effluent Reuse Discharge High-High Pressure PAL-5000 Effluent Reuse Discharge Header Low Pressure PALL-5000 Effluent Reuse Discharge Header Low-Low Pressure LAHH-5000 Effluent Reuse Reservoir High High Level LAH-5000 Effluent Reuse Reservoir High Level LAL-5000 Effluent Reuse Reservoir Low Level LALL-5000 Effluent Reuse Reservoir Low Low Level FAH-5700 Plant Effluent/UV High Flow FAL-5700 Plant Effluent/UV Low Flow NOTE: UV Disinfection system alarm programming to be determined by manufacturer’s assembly * Enough time delay will be programmed into the alarm enable logic to allow the process value to get up to a normal operating range before enabling. Page 19 Livingston Water Reclamation Facility Control System Narrative Area 6000 – Biosolids Management Device List SDU1 Solids Dewatering Unit SPM1 Solids Pug Mill NOTE: All italicized devices above to be connected to the Huber Solids Dewatering (CV) OEM panel for local control L A LY A R B ID TI O N D ER S' CV-BLW1 Composting Blower No. 1 (existing) CV-BLW1-PT1 Composting Blower No. 1 Pressure Transmitter (existing) CV-BLW2 Composting Blower No. 2 (existing) CV-BLW2-PT1 Composting Blower No. 2 Pressure Transmitter (existing) CV1-BFV1 Composting Vessel No.1 Air Control Valve (existing) CV1-TS1 Composting Vessel No. 1 Temperature Transmitter (existing) CV2-BFV1 Composting Vessel No.2 Air Control Valve (existing) CV2-TS1 Composting Vessel No. 2 Temperature Transmitter (existing) CV3-BFV1 Composting Vessel No.3 Air Control Valve (existing) CV3-TS1 Composting Vessel No. 3 Temperature Transmitter (existing) CV4-BFV1 Composting Vessel No.4 Air Control Valve (existing) CV4-TS1 Composting Vessel No. 4 Temperature Transmitter (existing) CV5-BFV1 Composting Vessel No.5 Air Control Valve CV5-TS1 Composting Vessel No. 5 Temperature Transmitter NOTE: All italicized devices above to be connected to the Compost Vessel (CV) OEM panel for local control O N M FO R FO Solids Handling Solids Dewatering and Pug Mill operation will be controlled locally within the Huber OEM panel, the panel will be connected via Ethernet/IP to the Solids Process Building CP for complete process operation and alarm monitoring. The dewatering units will discharge into the selected composting vessel. SE U IN Composting The composting operation will be controlled locally within the existing OEM panel, the process and speed command for the blowers will be determined by the output of a PID loop in the PLC. The setpoint (SP) will be the desired vessel temperature and the PV will be the corresponding temperature transmitter data. Area 6000 Process Alarms: NOTE: Alarms listed are to be provided by OEM messaging AH-6301 Blower No. 1 Fail AH-6302 Blower No. 2 Fail TAH-6301 Compost Vessel No. 1 High Temperature TAHH-6301 Compost Vessel No. 1 High-High Temperature TAL-6301 Compost Vessel No. 1 Low Temperature TALL-6301 Compost Vessel No. 1 Low-Low Temperature TAH-6302 Compost Vessel No. 2 High Temperature TAHH-6302 Compost Vessel No. 2 High-High Temperature TAL-6302 Compost Vessel No. 2 Low Temperature Page 20 Livingston Water Reclamation Facility Control System Narrative L A LY A U SE O N M FO R IN FO R B ID TI O N D ER S' TALL-6302 Compost Vessel No. 2 Low-Low Temperature TAH-6303 Compost Vessel No. 3 High Temperature TAHH-6303 Compost Vessel No. 3 High-High Temperature TAL-6303 Compost Vessel No. 3 Low Temperature TALL-6303 Compost Vessel No. 3 Low-Low Temperature TAH-6304 Compost Vessel No. 4 High Temperature TAHH-6304 Compost Vessel No. 4 High-High Temperature TAL-6304 Compost Vessel No. 4 Low Temperature TALL-6304 Compost Vessel No. 4 Low-Low Temperature TAH-6305 Compost Vessel No. 5 High Temperature TAHH-6305 Compost Vessel No. 5 High-High Temperature TAL-6305 Compost Vessel No. 5 Low Temperature TALL-6305 Compost Vessel No. 5 Low-Low Temperature * Enough time delay will be programmed into the alarm enable logic to allow the process value to get up to a normal operating range before enabling. Page 21 Livingston WRF Upgrade Addendum 1 - Attachments Attachment 3: Section 01 79 00 - Classroom Demonstration Training SECTION 01 79 00 CLASSROOM AND DEMONSTRATION TRAINING PART 1 1.01 1.02 1.03 GENERAL SUMMARY A. Classroom training and demonstration training of products and systems to be commissioned and where indicated in specific specification sections. B. Training of City of Livingston personnel in operation and maintenance is required for: 1. All software-operated systems. 2. HVAC systems and equipment. 3. Plumbing equipment. 4. Electrical systems and equipment. 5. Conveying systems. 6. Items specified in individual product Sections. RELATED REQUIREMENTS A. Section 01 33 00 – Submittals B. Section 01 91 13 – General Commissioning Requirements C. Other Specification Sections: Additional requirements for classroom and demonstration training. SUBMITTALS A. Draft Training Plans: City of Livingston will designate personnel to be trained; tailor training to needs and skill-level of attendees. 1. Submit to AE2S for transmittal to City of Livingston. 2. Submit not less than four weeks prior to start of training. 3. Revise and resubmit until acceptable. 4. Provide an overall schedule showing all training sessions. 5. Include at least the following for each training session: a. Identification, date, time, and duration. b. Description of products and/or systems to be covered. c. Name of firm and person conducting training; include qualifications. d. Intended audience, such as job description. e. Objectives of training and suggested methods of ensuring adequate training. f. Methods to be used, such as classroom lecture, live demonstrations, hands-on, etc. g. Media to be used, such as slides, hand-outs, etc. h. Training equipment required, such as projector, projection screen, etc., to be provided by Contractor. Livingston WRF Upgrades Livingston, Montana 01 79 00 - 1 April 2017 Classroom and Demonstration Training 1.04 1.05 B. Training Manuals: Provide training manual for each attendee; allow for minimum of two attendees per training session. 1. Include applicable portion of O&M manuals. 2. Include copies of all hand-outs, slides, overheads, video presentations, etc., that are not included in O&M manuals. 3. Provide one extra copy of each training manual to be included with operation and maintenance data. C. Training Reports: 1. Identification of each training session, date, time, and duration. 2. Sign-in sheet showing names and job titles of attendees. D. Video Recordings: Submit digital video recording of each demonstration and classroom training session for City of Livingston's subsequent use. 1. Format: DVD Disc. 2. Label each disc and container with session identification and date. 3. Include only one training session on each DVD. SCHEDULE A. Classroom training shall occur after completion of Prefunctional Testing and prior to Performance and Operation Testing. B. Demonstration training shall occur after written acceptance of Functional Test completion. QUALITY ASSURANCE A. PART 2 Instructor Qualifications: Familiar with design, operation, maintenance and troubleshooting of the relevant products and systems. 1. Provide as instructors the most qualified trainer of those contractors and/or installers who actually supplied and installed the systems and equipment. 2. Where a single person is not familiar with all aspects, provide specialists with necessary qualifications. PRODUCTS NOT USED PART 3 3.01 EXECUTION DEMONSTRATION TRAINING A. Demonstrations conducted during system start-up and prefunctional testing do not qualify as demonstrations for the purposes of this section, unless approved in advance by City of Livingston. B. Demonstration Training for City of Livingston personnel shall not be conducted during Functional Testing. Livingston WRF Upgrades Livingston, Montana 01 79 00 - 2 April 2017 Classroom and Demonstration Training 3.02 C. Demonstration training may be conducted prior to or during Performance and Operational Testing. D. Provide a qualified person who is knowledgeable about the project and the specific equipment and systems to perform demonstration and instruction of Owner personnel. E. Operating Equipment and Systems: Demonstrate operation in all modes, including start-up, shut-down, seasonal changeover, emergency conditions, and troubleshooting, and maintenance procedures, including scheduled and preventive maintenance. F. Utilize operation and maintenance manuals as basis for demonstration training. G. Non-Operating Products: Demonstrate cleaning, scheduled and preventive maintenance, and repair procedures. CLASSROOM TRAINING A. Engineer will prepare the Training Plan based on draft plans submitted by Contractor. B. Conduct training on-site unless otherwise indicated. C. City of Livingston will provide classroom and seating at no cost to Contractor. D. Do not start training until Prefunctional Testing is complete, unless otherwise specified or approved by the Engineer. E. Provide training in minimum two hour segments. F. Training schedule will be subject to availability of City of Livingston's personnel to be trained; re-schedule training sessions as required by City of Livingston; once schedule has been approved by City of Livingston failure to conduct sessions according to schedule will be cause for City of Livingston to charge Contractor for personnel "show-up" time. G. Review of Facility Policy on Operation and Maintenance Data: During training discuss: 1. The location of the O&M manuals and procedures for use and preservation; backup copies. 2. Typical contents and organization of all manuals, including explanatory information, system narratives, and product specific information. 3. Typical uses of the O&M manuals. H. Product- and System-Specific Training: 1. Review the applicable O&M manuals. 2. For systems, provide an overview of system operation, design parameters and constraints, and operational strategies. Livingston WRF Upgrades Livingston, Montana 01 79 00 - 3 April 2017 Classroom and Demonstration Training 3. 4. 5. 6. 7. 8. 9. 10. 11. I. Review instructions for proper operation in all modes, including start-up, shut-down, seasonal changeover and emergency procedures, and for maintenance, including preventative maintenance. Provide hands-on training on all operational modes possible and preventive maintenance. Emphasize safe and proper operating requirements; discuss relevant health and safety issues and emergency procedures. Discuss common troubleshooting problems and solutions. Discuss any peculiarities of equipment installation or operation. Discuss warranties and guarantees, including procedures necessary to avoid voiding coverage. Review recommended tools and spare parts inventory suggestions of manufacturers. Review spare parts and tools required to be furnished by Contractor. Review spare parts suppliers and sources and procurement procedures. Be prepared to answer questions raised by training attendees; if unable to answer during training session, provide written response within three days. END OF SECTION Livingston WRF Upgrades Livingston, Montana 01 79 00 - 4 April 2017 Classroom and Demonstration Training Livingston WRF Upgrade Addendum 1 - Attachments Attachment 4: Section 01 91 00 - Commissioning SECTION 01 91 00 COMMISSIONING PART 1 1.01 1.02 1.03 GENERAL SUMMARY A. Requirements for functional testing, performance and operational testing, and commissioning of equipment and systems. B. Description of the commissioning process and responsibilities common to all parties. C. Commissioning, including Functional Tests, performance and operational testing, O&M documentation review, and training, is to occur after startup and initial checkout and be completed before Substantial Completion SCOPE OF COMMISSIONING A. The following are to be commissioned: 1. Plumbing Systems 2. HVAC Systems 3. Special Ventilation 4. Electrical Systems 5. Electronic Safety and Security 6. Process Integration Equipment 7. Material Processing and Handling Equipment 8. Process Gas and Liquid Handling Equipment 9. Water and Wastewater Equipment 10. Other equipment and systems identified elsewhere in Contract Documents as requiring commissioning. B. The commissioning process will be directed by the Contractor and monitored by the Engineer. C. Commissioning during the construction phase is intended to achieve the following specific objectives according to the Contract Documents: 1. Verify applicable equipment and systems are installed according to the manufacturer's recommendations and to industry accepted minimum standards and that they receive adequate operational checkout by installing contractors. 2. Verify and document proper performance of equipment and systems 3. Verify that O&M documentation is complete. 4. Verify that Owner's operating personnel are adequately trained. RELATED REQUIREMENTS A. Section 01 75 00 - Starting and Adjusting B. Section 01 78 23 - Operation and Maintenance Manuals Livingston WRF Upgrades Livingston, Montana 01 91 00 - 1 April 2017 Commissioning C. 1.04 1.05 Section 01 79 00 - Classroom and Demonstration Training SUBMITTALS A. Manufacturers' Instructions: Submit copies of all manufacturer-provided instructions that are shipped with the equipment as soon as the equipment is delivered. B. Product Data: If submittals to AE2S do not include the following, submit copies as soon as possible: 1. Manufacturer's product data, cut sheets, and shop drawings. 2. Manufacturer's installation instructions. 3. Startup, operating, and troubleshooting procedures. 4. Fan and pump curves. 5. Factory test reports. 6. Warranty information, including details of City of Livingston's responsibilities in regard to keeping warranties in force. C. Startup Plans and Reports. D. Completed Checklists. E. Commissioning Plan. F. Commissioning Reports. DEFINITIONS A. Commissioning Plan: An overall plan, developed in conjunction with Owner, Engineer, and Contractor, that provides the structure, schedule, and coordination planning for the commissioning process. B. Functional Tests (FT): Test of the dynamic function and operation of equipment and systems using manual (direct observation) and/or remote monitoring methods. Functional testing is the dynamic testing of systems (rather than just components) under full operations. Systems are tested under various modes, such as during low cooling or heating loads, high loads, component failures, unoccupied, varying temperatures, alarm, power failure, local/remote, etc. FTs are performed after prefunctional tests and startups are completed. C. Performance and Operational Testing (POT): Test of systems after written acceptance of the FT. The POT test period will be used develop adequate process conditions to fully establish compliance with the performance requirements of the Contract Documents. Contractor shall supervise, control and be responsible for the operation and maintenance of equipment and systems during POT providing qualified and appropriately licensed personnel. Livingston WRF Upgrades Livingston, Montana 01 91 00 - 2 April 2017 Commissioning PART 2 2.01 TEST EQUIPMENT A. Provide all standard testing equipment required to perform startup and initial checkout and required Functional Testing; unless otherwise noted such testing equipment will not become the property of City of Livingston. B. Calibration Tolerances: Provide testing equipment of sufficient quality and accuracy to test and/or measure system performance with the tolerances specified. If not otherwise noted, the following minimum requirements apply: 1. Temperature Sensors and Digital Thermometers: Certified calibration within past year to accuracy of 0.5 degree F and resolution of plus/minus 0.1 degree F. 2. Pressure Sensors: Accuracy of plus/minus 2.0 percent of the value range being measured (not full range of meter), calibrated within the last year. 3. Calibration: According to the manufacturer’s recommended intervals and when dropped or damaged; affix calibration tags or keep certificates readily available for inspection. C. Equipment-Specific Tools: Where special testing equipment, tools and instruments are specific to a piece of equipment, are only available from the vendor, and are required in order to accomplish startup or Functional Testing, provide such equipment, tools, and instruments as part of the work at no extra cost to City of Livingston; such equipment, tools, and instruments are to become the property of City of Livingston. D. Dataloggers: Independent equipment and software for monitoring flows, currents, status, pressures, etc. of equipment. 1. Dataloggers required to for Functional Tests will be provided by the Contractor and will not become the property of []. PART 3 3.01 PRODUCTS EXECUTION COMMISSIONING PLAN A. Engineer, Owner, and Contractor will develop the Commissioning Plan. 1. Engineer to attend meetings called by the Contractor for purposes of completing the commissioning plan. 2. Require attendance and participation of relevant subcontractors, installers, suppliers, and manufacturer representatives. B. Contractor is responsible for compliance with the Commissioning Plan. C. Commissioning Schedule: 1. Submit anticipated dates of startup of each item of equipment and system to Engineer within 60 days after award of Contract. 2. Re-submit anticipated startup dates monthly, but not less than 4 weeks prior to startup. 3. Prefunctional Checklists and Functional Tests are to be performed in sequence from components, to subsystems, to systems. Livingston WRF Upgrades Livingston, Montana 01 91 00 - 3 April 2017 Commissioning 4. 3.02 3.03 Provide sufficient notice to Engineer for delivery of relevant Checklists and Functional Test procedures, to avoid delay. STARTUP PLANS AND REPORTS A. Startup Plans: For each item of equipment and system for which the manufacturer provides a startup plan, submit the plan not less than 8 weeks prior to startup. B. Startup Reports: For each item of equipment and system for which the manufacturer provides a startup checklist (or startup plan or field checkout sheet), document compliance by submitting the completed startup checklist prior to startup, signed and dated by responsible entity. C. Submit directly to the Engineer. FUNCTIONAL TESTS A. Functional Test is required for each item of equipment, system, or other assembly specified to be commissioned, unless sampling of multiple identical or nearidentical units is allowed by the final test procedures. B. Contractor is responsible for execution of required Functional Tests, after completion of Prefunctional Checklist and before Substantial Completion. C. Engineer will witness Functional Tests, Contractor shall provide adequate notice to Engineer in advance of functional testing. D. Contractor is responsible for correction of deficiencies and re-testing at no extra cost to City of Livingston; if a deficiency is not corrected and re-tested immediately, the Engineer will document the deficiency and the Contractor's stated intentions regarding correction. 1. Deficiencies are any condition in the installation or function of a component, piece of equipment or system that is not in compliance with the Contract Documents or does not perform properly. 2. When the deficiency has been corrected, the Contractor completes the form certifying that the item is ready to be re-tested and returns the form to the Engineer; the Contractor will reschedule the test and the Contractor shall re-test. 3. Identical or Near-Identical Items: If 10 percent, or three, whichever is greater, of identical or near-identical items fail to perform due to material or manufacturing defect, all items will be considered defective; provide a proposal for correction within 2 weeks after notification of defect, including provision for testing sample installations prior to replacement of all items. 4. Contractor shall bear the cost of City of Livingston and Engineer's personnel time witnessing re-testing. E. Functional Test Procedures: 1. Some test procedures are included in the Contract Documents; where Functional Test procedures are not included in the Contract Documents, test procedures will be determined by the Engineer and Contractor. Livingston WRF Upgrades Livingston, Montana 01 91 00 - 4 April 2017 Commissioning 2. F. 3.04 Traditional air or water test and balancing (TAB) is not Functional Testing; spot checking of TAB by demonstration to the Engineer is Functional Testing. Deferred Functional Tests: Some tests may need to be performed later, after substantial completion, due to partial occupancy, equipment, seasonal requirements, design or other site conditions; performance of these tests remains the Contractor's responsibility regardless of timing. FUNCTIONAL TEST PROCEDURES – GENERAL A. Provide skilled technicians to execute starting of equipment and to execute the Functional Tests. Ensure that they are available and present during the agreed upon schedules and for sufficient duration to complete the necessary tests, adjustments and problem-solving. B. Provide all necessary materials and system modifications required to produce the flows, pressures, temperatures, and conditions necessary to execute the test according to the specified conditions. At completion of the test, return all affected equipment and systems to their pre-test condition. C. Manual Testing: Use hand-held instruments, immediate control system readouts, or direct observation to verify performance (contrasted to analyzing monitored data taken over time to make the “observation”). D. Simulating Conditions: Artificially create the necessary condition for the purpose of testing the response of a system; for example apply hot air to a space sensor using a hair dryer to see the response in a VAV box. E. Simulating Signals: Disconnect the sensor and use a signal generator to send an amperage, resistance or pressure to the transducer and control system to simulate the sensor value. F. Over-Writing Values: Change the sensor value known to the control system in the control system to see the response of the system; for example, change the outside air temperature value from 50 degrees F to 75 degrees F to verify economizer operation. G. Indirect Indicators: Remote indicators of a response or condition, such as a reading from a control system screen reporting a damper to be 100 percent closed, are considered indirect indicators. H. Monitoring: Record parameters (flow, current, status, pressure, etc.) of equipment operation using dataloggers or the trending capabilities of the relevant control systems; where monitoring of specific points is called for in Functional Test Procedures: 1. All points that are monitored by the relevant control system shall be trended by Contractor; at the Engineer's request, Contractor shall trend up to 20 percent more points than specified at no extra charge. 2. Other points will be monitored by the Contractor using dataloggers. Livingston WRF Upgrades Livingston, Montana 01 91 00 - 5 April 2017 Commissioning 3. 4. 5. 6. 3.05 3.06 At the option of the Engineer, some control system monitoring may be replaced with datalogger monitoring. Provide hard copies of monitored data in columnar format with time down left column and at least 5 columns of point values on same page. Graphical output is desirable and is required for all output if the system can produce it. Monitoring may be used to augment manual testing. PERFORMANCE AND OPERATIONAL TESTING A. Contractor shall supervise, control, and be responsible for the operation and maintenance of the new equipment and/or system during a period of at least fifteen (15) days or until performance requirements are met, whichever is greater, after the written acceptance of the FT for each individual item that is placed into operation. The Contractor shall remain responsible for making required changes, repairs and replacements to the installation during this period. Final written acceptance of the equipment shall not be given until after fifteen (15) days of continuous successful operation. B. The POT test period will be used develop adequate process conditions to fully establish compliance with the performance requirements of the Contract Documents. Included in this requirement, but not limited to, are the following: 1. Establishing and maintaining an adequate microbial population in the aeration system to meet NPDES permit limits. 2. Developing sufficient waste activated sludge to operate biosolids treatment, thickening and dewatering equipment. 3. Generating sufficient materials to verify operation of materials handling equipment such as screenings conveyors and dewatered biosolids conveying equipment. C. During the POT, the Contractor shall provide supervisory and appropriately licensed personnel satisfactory to the Engineer. It is the intent that during the POT period, the Owner's personnel will become completely familiar with the operation and maintenance of the systems undergoing POT. See Section 01 79 00 Classroom and Demonstration Training for additional requirements. D. During the POT, the Owner will arrange to have a complement of operating personnel available, and these operators will be paid by the Owner. OPERATION AND MAINTENANCE MANUALS A. See Section 01 78 23 for additional requirements. B. Add design intent documentation furnished by AE2S to manuals prior to submission to City of Livingston. C. Submit manuals related to items that were commissioned to Engineer for review; make changes recommended by Engineer. D. Contractor will add commissioning records to manuals prior to submission to City of Livingston. END OF SECTION Livingston WRF Upgrades Livingston, Montana 01 91 00 - 6 April 2017 Commissioning Livingston WRF Upgrade Addendum 1 - Attachments Attachment 5: Section 26 32 13 - Engine Generators SECTION 26 32 13 - ENGINE GENERATORS PART 1 1.01 1.02 1.03 SUMMARY A. Section Includes: 1. Furnish and install a complete engine generator set, fully assembled as indicated on the Drawings, tested and ready to operate including fuel supply, exhaust system and cooling equipment. This unit shall be installed at the Reactor Control Building(RCB). Both engine and generator shall be the responsibility of a single manufacturer and be of a standard model or series in regular production at the manufacturers place of business. No unit assembled by anyone other than a recognized manufacturer will be accepted. B. Related Work: 1. Section 260502 – Electrical – General Conditions 2. Section 260534 - Conduit 3. Section 260519 – Low Voltage Electrical Power Conductors and Cables 4. Section 260537 – Boxes 5. Section 260553 – Labeling for Electrical Systems 6. Section 260526 – Grounding and Bonding for Electrical Systems 7. Section 263600 – Automatic Transfer Switch 8. Section 262416 – Panelboards DESCRIPTION OF SYSTEM A. After failure of normal power, the engine starts automatically, attains rated voltage and frequency and in conjunction with the automatic transfer switch, transfers power to the load in less than 10 seconds from the time of the power failure signal. Upon restoration of utility power, automatically retransfers load back to normal power, and then shuts down the generator (after programmable cool down period) and returns to readiness for another operating cycle. B. Generator shall meet most current and adopted emissions standards in project location. QUALITY ASSURANCE A. 1.04 GENERAL Built to NEMA Standards, U.L. 2200 listed ( generator set), and in accordance with NFPA 70. The engine generator set will be a packaged unit and will be the product of a single manufacturer, with all warranties for the complete unit provided by the factory. REQUIREMENTS OF REGULATORY AGENCIES A. The electric generating system consists of a prime mover, generator, governor, coupling and all controls. B. Conform to N.E.C. and applicable inspection authorities Livingston WRF Upgrades Livingston, Montana 26 32 13 - 1 April 2017 ENGINE GENERATORS 1.05 WARRANTY A. 1.06 OPTIONAL WARRANTIES A. 1.07 1.08 The manufacturer's and dealer's shall offer an extended warranty which shall be for a period of five (5) years (1500 operating hours) from date of initial startup of the system. 1. The extended warranty shall include repair parts, labor, reasonable travel expense necessary for repairs at the jobsite, and expendables (lubricating oil, filters, antifreeze, and other service items made unusable by the defect) used during the course of repair. 2. Applicable deductible costs shall be specified in the manufacturer's warranty. 3. Submittals received without written warranties as specified will be rejected in their entirety. SHOP DRAWINGS AND PRODUCT DATA A. Submit in accordance with General Requirements B. Clearly indicate all connection points, installed weight, dimensions, clearance requirements, accessory description, fuel requirements, air quantity requirements, electrical rating, power factor, short circuit available amperes (R.M.S. value), voltage regulator type, temperature rise of the alternator, ambient air rating of the radiator, recommended pipe sizes and routing. C. Indicate the site value for kW and kVA. Note that the site altitude is approx. 4500' above MSL. DELIVERY, STORAGE AND HANDLING A. 1.09 The manufacturer’s and dealer’s warranty shall in no event be for a period of less than two (2) years from date of initial startup of the system. 1. The warranty shall include repair parts, labor, reasonable travel expense necessary for repairs at the jobsite, and expendables (lubricating oil, filters, antifreeze, and other service items made unusable by the defect) used during the course of the repair. 2. Running hours shall not be a limiting factor for the system warranty by either the manufacturer or servicing dealer. 3. Submittals received without written warranties as specified will be rejected in their entirety. Generator Supplier shall deliver generator set (FOB) to the Site , unload, and set in a location that will allow easy installation into the Reactor Control Building generator room. OPERATION AND MAINTENANCE DATA A. Include complete data in accordance with General Requirements for maintaining and operating the unit including fuel requirements, lubrication requirements, exercising, tests to be performed, spare parts list, troubleshooting guide, description of operation. Include a minimum of four hours for Owner instruction. Livingston WRF Upgrades Livingston, Montana 26 32 13 - 2 March 2017 ENGINE GENERATORS 1.10 MOTOR STARTING CAPABILITY A. Motor Starting Capability 1. The engine generator set shall have sufficient starting kVA to withstand the loading sequence listed below. The staggered start sequencing indicated will be provided from plant PLC SCADA system programming, separate from generator system. During motor starting, instantaneous voltage dip shall not exceed the limits indicated per individual step. The Contractor shall submit calculations with the shop drawing submittal that confirm the unit's conformance with this requirement. Starting Sequence: a. 2. 3. Step 1 Loads (15% Maximum Allowable Voltage and Frequency Dip per Step) 1) 15kW Lighting Loads. 2) 40kW Heating/AC Loads/Misc Load consisting of small horsepower motors, 5hp or less started across the line. 3) 25W Resistive Heating Loads 4) 3kVA System UPS 5) 40kW UV System b. Step 2 Loads (10% Maximum Allowable Voltage and Frequency Dip per Step) 1) (2) 100 HP NEMA motor – Blower – started via 6 pulse, variable frequency drive with 20 second nominal ramp from zero to full speed and 110% current limit. c. Step 3 Loads (10% Maximum Allowable Voltage and Frequency Dip per Step) 1) (3) 75 HP NEMA motor Blower – started via 6 pulse variable frequency drive with 20 second nominal ramp from zero to full speed and 110% current limit. d. Step 4 Loads (10% Maximum Allowable Voltage and Frequency Dip per Step) 1) (2) 60 HP NEMA motor - Jet Mix Pumps – started via 6 pulse variable frequency drive with 20 second nominal ramp from zero to full speed and 110% current limit. e. Step 5 Loads (10% Maximum Allowable Voltage and Frequency Dip per Step 1) (4) 25 HP NEMA motor – Effluent Pump – started via 6 pulse VFD with 20 second nominal ramp from zero to full speed and 110% current limit. The supplier shall provide a larger unit than the specified size if required to meet the motor starting requirements. 1000kW minimum (before derating due to elevation). The use of field "boost", or similar means, is not acceptable. Please note that some of the projected step loads are for future pump additions/revisions and that all loads listed may not be present at initial startup of the facility. Note this project is in livingston Montana, take note of the elevation when confirming loading and sizing requirements. Livingston WRF Upgrades Livingston, Montana 26 32 13 - 3 March 2017 ENGINE GENERATORS 1.11 SUPPLIER EXPERIENCE AND CAPABILITES A. It is the intent of this Specification that all equipment specified in this Section shall be furnished by a single source supplier who shall assume system responsibility along with the Contractor. B. The engine generator set supplier shall be normally engaged in the assembly, installation, repair, and maintenance of generation equipment. The supplier shall have provided at least three (3) systems of equal or greater complexity/size in the last year. C. The supplier shall be a factory authorized sales, parts, and service representative of the engine manufacturing company. The supplier shall demonstrate that it has spare parts in stock to service and maintain the engine and to repair the unit in 48 hours or less for most failures. D. The supplier shall have a service depot within a 100 mile radius of the project site. E. The supplier shall modify or supplement the supplier's "standard products" to meet these specifications. Standard products of a particular supplier that do not meet the functional and technical requirements of the specification are not acceptable. F. The supplier shall have qualified, trained service personnel on staff who are capable of maintaining and repairing the equipment. The supplier shall be capable of offering an extended service contract after completion of the warranty period, including 24 hour, 7 day per week emergency services. G. Upon request, the supplier shall submit: 1. List of three (3) projects referenced above, including customer's name, contact person, and phone number. 2. Description of service contract capability, including number of personnel, their location, and types of service contract available. PART 2 2.01 2.02 PRODUCTS MANUFACTURER A. The generator set shall be as manufactured by: 1. Caterpillar 2. Cummins N Power 3. Prior approved equal B. The engine, generator and all major items must be manufactured in the United States. RATINGS A. 277/480 VAC output voltage at 60Hz, 3 phase. B. 1000 Standby eKW @ .8PF, 1250 kVA 1. The standby (maximum or intermittent) rating of the unit shall not exceed the fuel rate limit of the engine based on two (2) hours of standby Livingston WRF Upgrades Livingston, Montana 26 32 13 - 4 March 2017 ENGINE GENERATORS 2. 3. C. 2.03 Type 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Diesel utilizing number 2 fuel Liquid cooled Four cycle 1800RPM Full pressure lubrication system; engine driven lube oil pump Lube oil filters Spring loaded by pass valve Lube oil cooler Lube oil Fuel transfer pump Fuel priming pump Fuel oil cooler Flexible fuel lines (labeled for fuel flow direction) Engine mounted fuel oil filter Engine driven water pump Dry type air cleaners with service indicators Closed Loop Crank Case breather system (No oil may be routed to dump on the floor, all must be recycled) GOVERNOR A. 2.05 Ambient temperature: -35Degrees F. minimum to +120 Degrees F. maximum ENGINE A. 2.04 operation out of any 24 hour period at rated speed and rated voltage. The ambient temperature is 120 degrees F. This is measured two (2) feet from the end bearing housing of the generator in line with the shaft. The standby rating shall be no greater than 10% above the prime rating. The rating must be adjusted for the elevation of the installation if necessary. The engine fuel rate must not be adjusted higher than the fuel rate recommended by the engine manufacturer. The submittal shall include the efficiency of a similar production generator and the fuel utilization of a similar production engine after 4 hours of continuous operation at prime rated load. This data shall be based on #2 diesel fuel with a cetane rating of 40. These ratings must be substantiated by the manufacturer's certified standard published curves. Special ratings or maximum ratings are not acceptable. Isochronous governor (electronic type with magnetic pickup) +/- ¼% speed regulation no load to full load GENERATOR (IN ACCORDANCE WITH NEMA STANDARD MG1-22.40) A. Type 1. 2. 3. 4. 5. 277/480 volt, 3 phase, wye connected Drip proof Permanent magnet excitation Brushless exciter with static regulator containing no moving parts Field circuit with inherent protection against excessive field currents or voltages Livingston WRF Upgrades Livingston, Montana 26 32 13 - 5 March 2017 ENGINE GENERATORS 6. 7. 8. 9. 10. 11. 12. 2.06 2.07 Heavy duty single ball bearing type Direct coupled to the engine through a semiflexible coupling NEMA Class “H” insulation NEMA Class “F” temperature rise (115o C maximum) Rating and voltage stamped on a permanent nameplate Voltage regulator (solid state), +/- 2% from no load to full load Voltage level adjustment, +/- 5% OUTPUT CIRCUIT BREAKER A. The generator output circuit breaker shall be mounted on the generator. The circuit breaker shall be molded case, provided with an adjustable electronic trip unit with adjustable LSIG functionality. In addition, the trip unit shall have a ground fault alarm function which is separately adjustable from the ground fault trip setting. The breaker shall have shunt-trip. B. Circuit breaker to be molded case, thermal magnetic, 1600amperes, 3 pole, 480 VAC, 65 KAIC minimum with shunt trip installed INSTRUMENTATION AND CONTROLS A. The generator control panel shall be generator mounted and shall provide all operating, monitoring and control functions for the generator set. B. The control panel shall include the following functional requirements: 1. LCD display with text based alarm/event descriptions. 2. Automatic and manual start/stop controls 3. Local run/off/auto control 4. Emergency stop pushbutton 5. Lamp test 6. Voltage control 7. Speed control 8. Password protected system programming 9. Spare relay - programmable C. Controls shall provide the following keypad accessible digital readouts for the engine and generator: 1. Engine a. Engine oil pressure b. Engine oil temperature c. Engine coolant temperature d. Engine RPM e. Battery Volts f. Hours Run 2. Generator a. AC Voltage (L-L & L-N) b. AC Amps c. Generator AC Frequency d. KW (total & per phase) e. KVA (total & per phase) f. KVAR (total & per phase) g. Power Factor (Average and per phase) Livingston WRF Upgrades Livingston, Montana 26 32 13 - 6 March 2017 ENGINE GENERATORS 3. h. KWhr (total) i. KVARhr (total) j. % of rated KW (total) Voltage Regulation a. DC voltage b. DC current D. Alarms and Shutdowns (Engine) 1. Low oil pressure alarm/shutdown 2. High coolant temperature alarm/shutdown 3. Loss of coolant shutdown 4. Overspeed shutdown 5. Overcrank shutdown 6. Low coolant level alarm 7. Low fuel level alarm 8. Emergency stop shutdown 9. Low coolant temperature alarm 10. Low battery voltage alarm 11. High battery voltage alarm 12. Control switch not in auto position alarm 13. Battery charger failure alarm E. Alarms and Shutdowns (Generator) 1. Generator over voltage 2. Generator under voltage 3. Generator over frequency 4. Generator under frequency 5. Generator reverse power 6. Generator overcurrent 7. Generator breaker open F. Alarms and Shutdowns (Voltage Regulation) 1. Loss of excitation alarm/shutdown 2. Instantaneous over excitation alarm/shutdown 3. Time over excitation alarm/shutdown 4. Rotating diode failure 5. Loss of sensing 6. Loss of PMG G. Auxiliary 1. Provide (6) programmable discrete inputs. 2. Provide (15) discrete outputs which shall be of the dry contact type rated for 120VAC. There outputs shall be configurable in the field but shall be initally configured to provide the following: a. Generator Running b. Generator not in auto c. Generator Pre-High Engine Temp d. Generator High Engine Temo e. Generator Overspeed f. Generator Low Engine Temp g. Generator Low Collant Level Livingston WRF Upgrades Livingston, Montana 26 32 13 - 7 March 2017 ENGINE GENERATORS 3. 4. 2.08 2.09 h. Generator Pre-Low Oil Pressure i. Generator Low Oil Pressure j. Generator Fuel Tank Leak k. Generator Battery Charger Fault l. Four (4) Spares Provide (1) programmable analog output (4-20mAdc): a. One analog (4-20mAdc) output to indicate continuous fuel level to SCADA Panel. Provide (1) AllenBradley Ethernet IP protocol communication network connection to SCADA. Provide conversion gateway module for AllenBradley Ethernet IP protocol as required: H. Enclosure 1. None, to be mounted in generator room as an open enclosure I. Indicating Lights 1. Low oil pressure 2. High coolant temperature 3. Overspeed 4. Overcrank 5. Emergency stop 6. Fault shutdown 7. Fault alarms 8. 3 Spare lights/4 spare inputs 9. Customer programmable (shutdown or alarm) to spare alarm or fault LEDs J. Pre-alarm and LED indicators for 1. Approach high coolant temperature 2. Low coolant temperature (70 degrees F.) 3. Approach low oil pressure 4. Low DC volts 5. System not in “automatic” 6. Low fuel level 7. Fuel in rupture basin REMOTE COMMUNICATIONS A. Generator control shall include an external Ethernet communication port for connecting to the plant SCADA. B. Remote serial annunciator panel (RSA) shall be furnished loose for installation at the site by the Electrical Contractor. The RSA shall enable the operator to monitor the status of the generator set from a remote location. The RSA shall be connected via RS-485 Serial Communication using Modbus or other industry standard protocol and a Belden data cable. STARTING SYSTEM A. 24 volt DC starter motor(s) B. Automatic reset circuit breaker to protect against butt engagement of starter motor(s) Livingston WRF Upgrades Livingston, Montana 26 32 13 - 8 March 2017 ENGINE GENERATORS 2.10 2.11 2.12 2.13 C. Batteries, low maintenance, lead acid type (low antimony) adequately sized per the ambient temperatures stated D. Corrosion resistant or coated steel battery rack E. Required battery cables BATTERY CHARGER A. Automatic mode switching type. 10 ampere minimum rating. B. Rating of at least 1/20 of the ampere hour rating of the batteries C. Factory preset ranges – not field adjustable D. DC output +/- 0.2% with AC input variation of +/- 10% E. DC voltmeter F. DC ammeter G. NFPA malfunction alarm contacts JACKET WATER HEATER(S) A. 208 volts, three phase, sized to manufacturer’s recommendations B. Adjustable thermostatic control C. Isolation valves D. Sized to maintain engine jacket water temperature at a minimum of 120 degrees F. when the engine is idle. COOLING SYSTEM, ENGINE MOUNTED (AMBIENT RATING OF -35 F TO +120F) A. Vertical core with built in expansion tank B. Flanged for direct duct connection C. Engine driven blower fan D. OSHA type fan and belt guards E. Low coolant level contactor F. 50% ethylene glycol inhibited antifreeze liquid with additives EXHAUST SYSTEM A. Critical type silencer B. Silencer configuration shall be for horizontal installation with a bottom inlet, to be mounted to the roof of the generator room. C. Mechanical contractor to construct roof support and connect silencer to generator as required. Livingston WRF Upgrades Livingston, Montana 26 32 13 - 9 March 2017 ENGINE GENERATORS 2.14 2.15 FUEL TANK SYSTEM A. 12 hour fuel supply at 100% load (1000 gallon minimum) B. Mounted under the generator, double walled with leak detention to meet PCA requirements. C. Coordinate foot print during submittal phase. The intent is to allow the generator manufacturer the freedom to provide a tank that best meets the site requirements. Note: any tank size must fit inside the building and allow for the generator to also fit in the space, pay special attention to the installation method for the site to ensure the generator will be able to be placed in the space without issues. D. Inlet - exterior mounted fuel fill box E. Vents top of tank, Normal, Emergency, & Rupture Basin shall be extended through the building wall & include non corrosive aluminum vent extensions & vent caps. F. Engine return line top of tank G. Low level fuel alarm with contacts for remote annunciation, prewired to generator control panel. H. Visual Level Indicator I. Leak detection alarm. J. Fuel level gauge (4-20mA analog output). K. Drain petcock at bottom of tank L. Utilize flexible metal hose for final connections of fuel supply and return lines M. A (4) point lifting means for the total weight of the system less fuel shall be designed into the base. N. Provide a fuel fill box and all connecting lines for fueling of the tank from the exterior of the building. Fuel fill box shall have level indication lights for 75% and 95% filled. Additionally shall have a continuous electronic analog gauge to monitor fuel level while filling. Engine manufacturer to provide fuel fill box per requirements in the drawings. ACCESSORIES A. Glycol coolant mixture (50%) B. Initial fuel fill (blended). See Part 3 for additional information. C. OSHA approved ear protectors (four sets). Livingston WRF Upgrades Livingston, Montana 26 32 13 - 10 March 2017 ENGINE GENERATORS 2.16 LUBE OIL SYSTEM A. 2.17 Forced-feed lubrication system with piston cooling, lube oil circulating pump with safety valve, lube oil filter, lube oil heat exchanger, filler neck, dip stick, and closed crankcase breather system. PROVIDE AN ELEVATED MAINTENANCE PLATFORM WHICH MEETS THE FOLLOWING MINIMUM REQUIREMENTS: A. The intent is for the generator supplier to provide an elevated maintenance platform only as required to maintain code compliance with the main breaker height, and also ease of access for the main controller on the engine. If the fuel tank height allows to the breaker to meet the NEC requirements without the use of an access platform this is acceptable; if however, it does not meet the NEC requirements then an access platform must be provided in accordance to this subsection. B. The platform shall be cantilever supported off of the engine generator sub-base with formed steel frame, structural members, toe plates, railing posts, rails and floor assemblies, Platform shall be constructed with 2 "walk" assemblies (outside of all generator set service doors). C. A "ship's ladder" shall be used to access the platform. D. Design of platform shall permit inspection of all serviceable components. E. Platform height shall be no greater than 1.5" above the bottom of the generator base frame. The platform shall be wide enough to allow full extension of the generator doors but be a minimum width of 42”. F. The platform frame shall be of 0.125 gauge formed steel. G. Frame design shall be pre-drilled to accept handrail mounting vertical supports. Structural frame members shall serve as the walkway toe-board supports. H. Compression members shall be predrilled to connect the ladder assembly and frame to the platform. I. No connection to the sub-base tank is permitted but rather all connections shall be through the engine base. J. The walkway tread shall utilize 0.125 gauge 1 inch thick minimum galvanized tread plate to provide sufficient cross section to resist vertically applied loads. K. Platform shall provide for 180 degree "full swing opening" of all side service doors. L. Handrails shall be a nominal 42" from the walkway surface. M. The platform shall have a galvanized finish. N. The walkway (ladder and platform) shall meet standards of OSHA 3124 Stairways and Ladders. The platform shall be installed by the generator set supplier.” Livingston WRF Upgrades Livingston, Montana 26 32 13 - 11 March 2017 ENGINE GENERATORS O. PART 3 3.01 3.02 3.03 Platform shall be located on two sides of the generator, the main breaker side, and the engine end side. Coordinate exact requirements during submittal phase as required. EXECUTION INSTALLATION A. Coordinate with Electrical Contractor the unloading and proper placement of the engine generator set inside the generator room. B. Provide all power feeders per Drawings and connect. C. Tighten all lugs and bolts to manufacturer's recommendations. D. Neatly dress conductors and bundle with nylon cable ties. E. Provide all required control connections between generator control panel and ATS, between generator control panel and SCADA, and between SCADA and ATS. F. Use touch-up paint, as recommended by the manufacturer, to repair scratches and other surface defects. CHECKOUT & STARTUP A. Electrical Contractor shall contract with manufacturer of the electric generating plant and associated items covered herein to provide factory trained technicians to checkout the completed installation and to perform an initial startup inspection to include: 1. Ensuring the engine starts (both hot and cold) within the specified time. 2. Verification of engine parameters are within manufacturer’s recommendations. 3. Set no load frequency and voltage. 4. Single step load pickup per NFPA 110-1985, Paragraph 5-13.2. 5. Transient and voltage dip responses and steady state voltage and speed (frequency) checks. 6. Test all automatic shutdowns of the engine generator. B. Furnish to engineer, a report indicating that installation has been tested by a manufacturer’s representative and is installed and operating properly. TRAINING A. Training for the Owner's personnel shall be for not less than eight (8) hours on the power generation system. The eight hours shall consist of up to two (2) separate four (4) hour sessions on Site. B. All training sessions shall be at times that are preapproved with the Owner (7 days minimum advance notice). C. Training shall be in accordance Division 1 requirements. Livingston WRF Upgrades Livingston, Montana 26 32 13 - 12 March 2017 ENGINE GENERATORS 3.04 WIRING A. 3.05 Wiring of the engine generator set, switchgear, lighting, outlets, panelboard, transformer, ventilation and other components of the integrated generation system shall meet all State requirements. These requirements shall include, but are not limited to: 1. Applying and paying for an electrical construction permit. 2. Installation by an electrician appropriately licensed by the State of Minnesota. 3. Inspection and approval by an electrical inspector recognized by the State of Minnesota. TESTING A. Testing During Fabrication 1. Engine Generator. The power generation system manufacturer or fabricator shall have: a. The power generation system is to be tested as a complete unit including engine, generator, excitation system, together with all subsystems in the enclosure and cooled by the engine radiator and fan. b. The manufacturer shall provide all equipment for the test including, but not limited to, ammeters, voltmeters, fuel supply, frequency meter, and load banks capable of 10% maximum steps to 100% of the engine generator's continuous standby rating; and the addition, in one step, of 50% of the continuous standby rating from a 50% continuous standby rating load point, or removal of the total load from the generator in one step. The load banks shall be connected through the switchgear. The load bank shall be connected to the power generation system's load terminals. The test program will cover the following items: 1) Extended operation at 100% of continuous-standby rating, 2 (two) hours minimum. 2) 50% load to 100% load test with a +10%-15% from nominal voltage dip, maximum, permitted with frequency fluctuation measurement. Code F motor inrush characteristics. Frequency deviation shall not exceed 3 cycles for 2 seconds. 3) Engine protective device evaluation. 4) No load operation with an addition of load to 50% of rating with 15% voltage dip maximum and frequency fluctuation not exceeding 2 cycles for 2 seconds. 5) Various 10% load additions and subtractions. 6) Evaluation of subsystems, noise, component installation and interconnections, workmanship, quality, engine and generator performance, etc. 7) The test program will not start without all required equipment, including but not limited to load banks and voltmeter as required. B. Site Testing Livingston WRF Upgrades Livingston, Montana 26 32 13 - 13 March 2017 ENGINE GENERATORS 1. After installation, but prior to acceptance for substantial completion, the system shall undergo formal onsite testing. This testing will be witnessed by representatives of the Owner and the Engineer. The testing will include, but not be limited to: a. Demonstration of system features and functions. b. Machine performance. c. Use project loads and a separate resistive load bank equal to the generator capacity for testing purposes. Unit shall be tested as follows: 1) With generator in a “cold start” condition and load at normal operating level, initiate a normal power failure by opening all switches or breakers supplying normal power to the facility. Test load shall be that load which is served by the generator. 2) Observe and record the time delay on start. 3) Observe and record the cranking time until the generator starts and runs. 4) Observe and record the time required to come up to operating speed. 5) Record voltage and frequency overshoot. 6) Observe and record time required to achieve steady-state condition with all switches transferred to the emergency/standby position. 7) Record voltage, frequency and amperes. 8) Continue load test with building load for one (1) hour, observing and recording load changes and the resultant effect on voltage and frequency. 9) Return normal power to the facility, record the time delay on retransfer to normal (set to 15 minutes minimum) and the time delay on the generator cool down period and shutdown. 10) Confirm and record the time delays associated with the delayed transition feature of the switch and the “pre-transfer” signal to SCADA. 11) Perform a crank cycle test. Utilize any method recommended by the manufacturer to prevent the generator from running. Put the control switch into the “run” position to cause the generator to crank. Observe the complete crank/rest cycle specified and record. 12) After successful testing with the available facility loads, provide a resistive load bank to test the generator at full specified load at 1.0 power factor. Run generator at full load for two (2) hours. Record generator oil pressure, water temperature, and battery charge rate, voltage, frequency, and amperes at 5 minute intervals for the first 15 minutes and at fifteen minute intervals thereafter. 13) Test all safeties specified, as recommended by the manufacturer. d. Perform testing at time pre approved by Owner and Engineer (7 day prior notice, minimum). Livingston WRF Upgrades Livingston, Montana 26 32 13 - 14 March 2017 ENGINE GENERATORS e. 2. 3.06 3.07 Submit record of site test procedures and results and include a copy in the O&M manuals. If the system is not accepted or does not perform satisfactorily, repairs shall be completed and the unit retested until it performs to the Owner, Utility, and the Engineer's satisfaction. FUEL A. Provide all diesel fuel for initial start up, training and testing procedures. B. Provide $1500 worth of fuel in the fuel tank (winter blend diesel fuel) at project completion. Intent is to leave the tank filled to at least half full capacity prior to leaving site. Provide copies of all fuel receipts to the Engineer to confirm quantity of fuel provided. Demonstrate fuel tank level to the Engineer and Owner prior to leaving site at project completion. SUPPLIES AND SPARE PARTS A. Provide all supplies, spare parts, expendable items and related equipment for initial startup, training and testing procedures. B. At project completion, provide Owner with a complete set of spare parts for the equipment, including, but not limited to lamps, fuses, etc. Provide twenty (20) percent spare fuses and lamps of each type furnished under this Section, but not less than six (6) of each type. END OF SECTION Livingston WRF Upgrades Livingston, Montana 26 32 13 - 15 March 2017 ENGINE GENERATORS Livingston WRF Upgrade Addendum 1 - Attachments Attachment 6: Temporary Construction Sign for Rural Development Projects Lettering (Green, PMS 343) Black Lettering Financed by : Donald J. Trump, President of the United States White Background Sonny Perdue, Secretary of Agriculture PLYWOOD PANEL (APA RATED A-B GRADE-EXTERIOR) SIGN DIMENSIONS: 1200mm x 2400mm x 19mm (approx.. 4’ x 8’ x ¾”) Black Lettering USDA provider, employer, and lender. USDA is is an an equal equalopportunity opportunity provider and employer. (RRGL) Montana DNRC Renewable Resource Grant and Loan Program Montana Department of Commerce Treasure State Endowment Program Montana Water Pollution Control State Revolving Fund (WPCSRF) Program (DEQ & DNRC) United States Department of Agriculture (USDA) Rural Development Contractor Engineer Owner Project RURAL DEVELOPMENT PROJECTS TEMPORARY CONSTRUCTION SIGN FOR Symbol & Letters (Teal, PMS 322) Symbol Letters (Black) Symbol (Light Green, PMS 359) With Black Outline Symbol Fields (Green, PMS 343) Signature Letters (Black) Symbol Letters (Blue, PMS 288) Livingston WRF Upgrade Addendum 1 - Attachments Attachment 7: Sheet GEN-P4 ADDENDUM 1 b. C. a. b. D. a. b. E. a. b. F. a. b. APPR MGD MGD MGD MGD MGD 1.21 2.18 2.57 3.33 3.42 MGD MGD MGD MGD MGD 1,919 2,348 3,685 LB/DAY LB/DAY LB/DAY 2,770 3,389 5,319 LB/DAY LB/DAY LB/DAY 2,135 3,088 4,948 LB/DAY LB/DAY LB/DAY 3,071 3,389 5,319 LB/DAY LB/DAY LB/DAY 261 320 502 LB/DAY LB/DAY LB/DAY 415 507 796 LB/DAY LB/DAY LB/DAY 65 80 125 LB/DAY LB/DAY LB/DAY 104 127 199 LB/DAY LB/DAY LB/DAY b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. B. a. b. C. d. e. f. 2. EFFLUENT DISCHARGE LIMITS A. B. C D. E. F. C. BOD5 - 30 CONSECUTIVE DAY AVERAGE TSS - 30 CONSECUTIVE DAY AVERAGE pH E-COLI (APRIL 1 - OCTOBER 31) E-COLI (NOVEMBER 1 - MARCH 31) TOTAL RESIDUAL CHLORINE TOTAL AMMONIA, as N (EFFECTIVE NOVEMBER 1, 2021) 30 30 6.0 - 9.0 126 630 74 6.2 MG/L MG/L S.U. CFU/100 ML CFU/100 ML mG/L MG/L g. a. a. B. a. b. Plotted: By: Randy Leppala Date: Tuesday, June 06, 2017 Last Saved: By: Randy Leppala Date: Tuesday, June 06, 2017 7:17:09 AM c. d. CAPACITIES FULL PUMPING CAPACITY (ALL UNITS IN SERVICE) FIRM PUMPING CAPACITY (LARGEST UNIT OUT OF SERVICE) INFLUENT PUMPS IPS-IP1 TYPE MOTOR HORSEPOWER (HP) MAXIMUM CAPACITY PRESSURE HEAD SPEED CONTROL IPS-IP2 TYPE MOTOR HORSEPOWER (HP) MAXIMUM CAPACITY PRESSURE HEAD SPEED CONTROL IPS-IP3 TYPE MOTOR HORSEPOWER (HP) MAXIMUM CAPACITY PRESSURE HEAD SPEED CONTROL IPS-IP4 TYPE MOTOR HORSEPOWER (HP) MAXIMUM CAPACITY PRESSURE HEAD SPEED CONTROL 3,600 3,200 A. a. b. c. d. e. f. GPM GPM g. DRY-PIT SUBMERSIBLE 25 1760 35 VARIABLE FREQUENCY DRIVE HP GPM FT DRY-PIT SUBMERSIBLE 25 1750 35 VARIABLE FREQUENCY DRIVE HP GPM FT DRY-PIT SUBMERSIBLE 25 1750 35 CONSTANT SPEED HP GPM FT DRY-PIT SUBMERSIBLE 10 750 30 VARIABLE FREQUENCY DRIVE HP GPM FT h. B. a. b. c. d. 4. ICEAS SEQUENCING BATCH REACTOR A. a. b. c. d. e. f. g. SBR BASIN DESIGN NUMBER OF BASINS FLOW SPLITTING BASIN VOLUME (EACH OF 2) TOP WATER LEVEL BASIN WIDTH (INSIDE) BASIN LENGTH (INSIDE) BOTTOM WATER LEVEL 2 DOWNWARD OPENING WEIR GATES 911,244 18 48 141 13.9 2 GAL FT FT FT FT 2 QTY 40 FT 2 QTY HP 0.5 3 QTY ROTARY SCREW 3 QTY 4 QTY HP 100 8.8 PSIG 1550 SCFM 3010 SCFM 4560 SCFM 2,470 DISC DIFFUSERS/BASIN 0.50 0.98 FINE BUBBLE EPDM FT 13 TO 17.25 0.7 TO 2.5 SCFM/DIFFUSER 28 TO 35 % 2 QTY 2 QTY 306 GPM DRY PIT SUBMERSIBLE 2 QTY 20 HP 5. UV Disinfection 3. INFLUENT PUMP STATION A. SBR EQUIPMENT DECANTER MECHANISM WEIR LENGTH DECANTER DRIVE UNIT MOTOR SBR BLOWERS TYPE NUMBER FUTURE CAPACITY (SPACE ALLOWED) MOTOR SIZE MAXIMUM DISCHARGE PRESSURE (HWL) CAPACITY (PER BLOWER) FIRM (ONE UNIT OUT OF SERVICE) CAPACITY FULL (ALL UNITS IN SERVICE) CAPACITY DIFFUSERS DESIGN ALPHA FACTOR DESIGN BETA FACTOR TYPE AND MATERIAL DIFFUSER DEPTH (RANGE BASED ON WATER LEVEL RANGES) AIRFLOW RATE PER DIFFUSER SOTE (RANGE FOR SUBMERGENCE AND AIRFLOW RATE) AIR CONTROL VALVES WASTE ACTIVATED SLUDGE PUMP PUMPING CAPACITY TYPE SUBMERSIBLE MIXER MOTOR e. UV Disinfection Design Criteria PEAK MONTH FLOW PEAK UV FLOW UV TRANSMITTANCE TOTAL SUSPENDED SOLIDS (30 DAY AVERAGE) DISINFECTION LIMIT (E. COLI) DESIGN DOSE MS2 T1 VALIDATION FACTORS END OF LAMP LIFE FACTOR (LOW-PRESSURE AMALGAM LAMPS) SLEEVE FOULING FACTOR EFFLUENT TEMPERATURE EFFLUENT REUSE SYSTEM PUMP 1 TYPE MOTOR MAXIMUM CAPACITY PRESSURE SPEED CONTROL PUMP 2 TYPE MOTOR MAXIMUM CAPACITY PRESSURE SPEED CONTROL PUMP 3 TYPE MOTOR MAXIMUM CAPACITY PRESSURE SPEED CONTROL HYDROPNEUMATIC TANK TYPE SIZE MAX PRESSURE SETTING MIN PRESSURE SETTING CHLORINATION SYSTEM TANK SIZE MATERIAL FEED PUMPS TYPE PUMP 1 CAPACITY PUMP 1 DISCHARGE PRESSURE PUMP 2 PUMP 2 DISCHARGE PRESSURE 6.85 6.85 55% 30 126 30 15 0.87 0.95 8-25 MGD MGD MG/L CFU / 100 ML mJ/cm2 mJ/cm2 °c SUBMERSIBLE - VERTICAL TURBINE 5 70.00 80 VARIABLE FREQUENCY DRIVE HP GPM PSI SUBMERSIBLE - VERTICAL TURBINE 5 70.00 80 VARIABLE FREQUENCY DRIVE HP GPM PSI SUBMERSIBLE - VERTICAL TURBINE 25 390.00 80 VARIABLE FREQUENCY DRIVE HP GPM PSI Advanced Engineering and Environmental Services, Inc. l 1050 E Main St Ste 2 Bozeman, MT 59715 l (t) 406-219-2633 (f) 406-219-2635 l www.ae2s.com BLADDER 80 85 75 DESCRIPTION 0.78 1.49 1.75 2.42 2.49 5 QTY 4.8 HR 1.2 HR 1.6 HR 1.0 HR 1.0 HR 6.7 QTY HR 3.6 HR 0.9 HR 1.2 0.6 HR 0.9 HR 24 TO 17 HOURS 8 TO 20 DAYS 5,000 MG/L 6,179 MG/L 0.055 TO 0.134 LB BOD5 / LB MLSS / DAY 150 ML/G 1,840 LB/DAY 2,000 LB/DAY 28,212 GPD 4,283 GPM 4,759 GPM 2 MG/L 7,678 LB/DAY 12,054 LB/DAY 819 LB/HR DATE a. PEOPLE PEOPLE SYM B. 7,245 11,500 SBR PROCESS DESIGN SUMMARY NORMAL CYCLES PER DAY NORMAL CYCLE TIME (TOTAL) ANOXIC REACT (PER CYCLE) AERATION TIME (PER CYCLE) MINIMUM SETTLING TIME (PER CYCLE) MAXIMUM DECANT TIME (PER CYCLE) STORM MODE - CYCLES PER DAY STORM CYCLE TIME (TOTAL) ANOXIC REACT (PER CYCLE) AERATION TIME (PER CYCLE) MINIMUM SETTLING TIME (PER CYCLE) MAXIUM DECANT TIME (PER CYCLE) HYDRAULIC RETENTION TIME (AA - 1 BASIN TO PD - 2 BASINS) SOLIDS RETENTION TIME (MIN AND MAX DESIGN) PEAK MLSS AT AVERAGE WATER LEVEL PEAK MLSS AT LOWEST WATER LEVEL F/M (VARIES FROM AA TO PEAK DAY, 1 BASIN VS. 2 BASINS) SVI (AFTER 30 MINUTES SETTLING) ESTIMATED AAF WAS PRODUCTION ESTIMATED MM WAS PRODUCTION VOLUME OF SLUDGE PRODUCED (APPROX., 0.85% SOLIDS) NORMAL DECANT RATE PEAK DECANT RATE TARGET DISSOLVED OXYGEN CONCENTRATION MAXIMUM MONTH AOR PEAK DAY AOR MAXIMUM MONTH AVERAGE SOTR LIVINGSTON, MONTANA a. b. a. EQUIVALENT POPULATION EXISTING 2035 DESIGN WASTEWATER FLOW RATE EXISTING i. AVERAGE ANNUAL (AA) ii. MAXIMUM MONTH (MM) iii. PEAK DAY (PD) iv. PEAK HOUR (PH) v. PEAK INSTANTANEOUS (PI) 2035 DESIGN i. AVERAGE ANNUAL (AA) ii. MAXIMUM MONTH (MM) iii. PEAK DAY (PD) iv. PEAK HOUR (PH) v. PEAK INSTANTANEOUS (PI) BIOLOGICAL OXYGEN DEMAND EXISTING AVERAGE ANNUAL i. ii. MAXIMUM MONTH iii. PEAK DAY 2035 DESIGN i. AVERAGE ANNUAL ii. MAXIMUM MONTH iii. PEAK DAY TOTAL SUSPENDED SOLIDS EXISTING AVERAGE ANNUAL i. ii. MAXIMUM MONTH iii. PEAK DAY 2035 DESIGN i. AVERAGE ANNUAL ii. MAXIMUM MONTH iii. PEAK DAY TOTAL KJELDAHL NITROGEN EXISTING i. AVERAGE ANNUAL ii. MAXIMUM MONTH iii. PEAK DAY 2035 DESIGN AVERAGE ANNUAL i. ii. MAXIMUM MONTH iii. PEAK DAY TOTAL PHOSPHORUS EXISTING i. AVERAGE ANNUAL ii. MAXIMUM MONTH iii. PEAK DAY 2035 DESIGN i. AVERAGE ANNUAL ii. MAXIMUM MONTH iii. PEAK DAY PROCESS LIQUID BASIS OF DESIGN A. CITY OF LIVINGSTON B. 1. DESIGN FLOWS AND LOADS LIVINGSTON WRF UPGRADES Layout: LIQUID File: W:\Livingston\05613-2015-001\040 Final Design\Drawings\04-Process\Sheets\Process Basis of Design.dwg LIVINGSTON WRF UPGRADES - LIQUIDS BASIS OF DESIGN DRAWING TYPE CONST PREPARED BY RCL CHECKED / APPROVED GAL PSI PSI BJV / SLB DATE APRIL 2017 1,000 HDPE PERISTALTIC 1.6 60 0.45 20 PROJECT NUMBER GAL 05613-2015-001 FACILITY GPM PSI GPM PSI GEN ADDENDUM 1 DRAWING P4 Livingston WRF Upgrade Addendum 1 - Attachments Attachment 8: Record Drawings of Existing Sludge Drying Beds Sheet No. C-3 of 4 from record drawings labelled "As Constructed 4-8-83" Project: City of Livingston Wastewater Treatment Facility Expansion Sheet Title: "Sludge Drying Beds, Modifications, & Additions." Prepared By: Christian, Springs, Sielbach & Associates ADDENDUM 1 - FOR INFORMATION ONLY

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