USACE / NAVFAC / AFCESA / NASA UFGS-44 11 33 (October 2007)
----------------------------
Preparing Activity: USACE Superseding
UFGS-44 11 33 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 44 11 33
THERMAL (CATALYTIC) OXIDATION SYSTEMS
10/07
NOTE: This guide specification covers the requirements for systems to destroy,
by thermal oxidation, organic contaminants contained in an off-gas stream; with
options to use concentration system, heat recovery and/or a catalyst to conserve
fuel.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
PART 1 GENERAL
1.1 UNIT PRICES
NOTE: Measurement and payment requirements will be specified for work subject
to extreme variation in estimated quantity when unit price bidding is required.
This paragraph is not used when quantities can be reasonably calculated from
information included in the contract.
Measurement and payment and unit prices for quantities of off-gas treated will be determined in accordance with
the Bid Schedule.
1.2 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[AMERICAN GAS ASSOCIATION (AGA)AGA B109.1(2000)Diaphragm-Type Gas Displacement Meters (Under 500 cubic ft./hour Capacity)AGA B109.2(2000)Diaphragm-Type Gas Displacement Meters (500 cubic ft./hour Capacity and Over)AGA B109.3(2000)Rotary-Type Gas Displacement MetersAGA Report No 3(2000) Orifice Metering of Natural Gas; PART 2: Specification and Installation Requirements][AMERICAN PETROLEUM INSTITUTE (API)API Spec 6D(2008; Errata 2008; Errata 2008) Specification for Pipeline Valves][AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)ASCE 25(2008) Standard for Earthquake-Activated Automatic Gas Shutoff Devices][AMERICAN WATER WORKS ASSOCIATION (AWWA)AWWA 10084(2005) Standard Methods for the Examination of Water and Wastewater][AMERICAN WELDING SOCIETY (AWS)AWS B2.1(2005; Errata 2006; Errata 2006) Welding Procedure and Performance QualificationAWS D1.1/D1.1M(2008) Structural Welding Code - Steel][ASME INTERNATIONAL (ASME)ASME B1.1(2003; R 2008) Unified Inch Screw Threads (UN and UNR Thread Form)ASME B16.33(2002; R 2007) Manually Operated Metallic Gas Valves for Use in Gas Piping Systems Up to 125 psi, Sizes NPS 1/2 - NPS 2ASME B40.100(2005) Pressure Gauges and Gauge AttachmentsASME BPVC SEC IX(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section IX, Welding and Brazing QualificationsASME PTC 19.3(1974; R 2004) Temperature Measurement Instruments and Apparatus][ASTM INTERNATIONAL (ASTM)ASTM A 123/A 123M(2008) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel ProductsASTM A 153/A 153M(2005) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware][CSA AMERICA, INC. (CSA/AM)CSA/AM Z21.15(1997; R 2003; A 2006) Manually Operated Gas Valves for Appliances, Appliance Connector Valves and Hose End Valves][FM GLOBAL (FM)FM P7825a(2005) Approval Guide Fire Protection][ISA - INTERNATIONAL SOCIETY OF AUTOMATION (ISA)ISA MC96.1(1982) Temperature Measurement Thermocouples][MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)MSS SP-25(2008) Standard Marking System for Valves, Fittings, Flanges and Unions][NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)NEMA ICS 1(2000; R 2005; R 2008) Standard for Industrial Control and Systems General RequirementsNEMA ICS 6(1993; R 2006) Standard for Industrial Controls and Systems EnclosuresNEMA MG 1(2007; Errata 2008) Standard for Motors and Generators][NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)NFPA 211(2006) Chimneys, Fireplaces, Vents, and Solid Fuel-Burning AppliancesNFPA 30(2007; Errata 2008) Flammable and Combustible Liquids CodeNFPA 31(2006; Errata 2006; Errata 2007) Installation of Oil Burning EquipmentNFPA 54(2008) National Fuel Gas CodeNFPA 58(2007; Amendment 1 2007; Amendment 2 2007; Amendment 3 2007; Amendment 4 2008) Liquefied Petroleum Gas CodeNFPA 70(2007; AMD 1 2008) National Electrical Code - 2008 EditionNFPA 82(2004) Incinerators and Waste and Linen Handling Systems and Equipment][NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)NIST SP 250(1991) Calibration Services Users Guide][U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)29 CFR 1910Occupational Safety and Health Standards40 CFR 60Standards of Performance for New Stationary Sources]1.3 SYSTEM DESCRIPTION
Provide a thermal (catalytic) oxidation system as a complete unit process for destruction of organic contaminants
carried in the [off-gas] [vapor phase]. Equipment shall include, but shall not be limited to, a complete and
operational thermal oxidation system, including supporting equipment and accessories.
1.3.1 Design Requirements
NOTE: Find the wind speed and seismic zone for the stack design in ASCE 7.
Provide the thermal oxidation system in conformance with section 60.18 of 40 CFR 60. Provide vertical and lateral
supports for the stack in accordance with NFPA 82 and NFPA 211, as applicable, for the wind forces indicated.
Design the system for the following parameters:
a. Altitude: [_____] m ft above mean sea level (MSL).
b. Stack discharge: [3] [_____] m [10] [_____] ft above [existing grade at the site] [MSL].
c. Minimum equipment [service] [design] life: [_____] years.
d. Oxidizer system dimensions:
(1) Maximum vertical projection, (excluding stack): [_____] m ft.
(2) Maximum ground surface coverage: [_____] x [_____] m [_____] x [_____] ft.
e. Soil bearing capacity: [_____] MPa psf.
f. Seismic zone: [_____].
g. Wind speed (maximum): [_____] km/h mph.
h. Ground snow load: [_____] kPa psf.
i. Ambient air temperature
(1) Maximum: [_____] degrees C F.
(2) Minimum: [_____] degrees C F.
j. Groundwater temperature
(1) Maximum: [_____] degrees C F.
(2) Minimum: [_____] degrees C F.
1.3.2 Inorganic Chemical Concentrations
NOTE: Indicate method in the first blank. The table is an example. Include
all identified site contaminants.
Volatile metals, chlorine, fluorine, phosphorus, sulfur or freon at low concentrations
will poison, foul or mask catalysts. More innovative technologies should be
strongly considered when freon is present.
a. Estimated influent inorganic chemical concentrations in the [off-gas] [vapor phase] shall be as determined
by [_____].
Influent Concentration Minimum Average Maximum
------------------------------------------------------------
Fluorides [_____] [_____] [_____]
Total Metals (as CaCO3) [_____] [_____] [_____]
Copper [_____] [_____] [_____]
Lead [_____] [_____] [_____]
Zinc [_____] [_____] [_____]
b. Chemical concentrations of entrained [water] [groundwater] [_____] shall be as determined by AWWA 10084
.
Concentration Minimum Average Maximum
------------------------------------------------------------
pH [_____] [_____] [_____]
Conductivity (mho) [_____] [_____] [_____]
Total hardness (mg/L as CaCO3) [_____] [_____] [_____]
Calcium (mg/L) [_____] [_____] [_____]
Magnesium (mg/L) [_____] [_____] [_____]
Total iron (mg/L) [_____] [_____] [_____]
Ferric iron (mg/L) [_____] [_____] [_____]
Ferrous iron (mg/L) [_____] [_____] [_____]
Manganese (mg/L) [_____] [_____] [_____]
Sodium (mg/L) [_____] [_____] [_____]
Potassium (mg/L) [_____] [_____] [_____]
Copper (mg/L) [_____] [_____] [_____]
Total alkalinity [_____] [_____] [_____]
(mg/L as CaCO3)
Hydroxide alkalinity [_____] [_____] [_____]
(mg/L as CaCO3)
Carbonate (mg/L as CaCO3) [_____] [_____] [_____]
Bicarbonate (mg/L as CaCO3) [_____] [_____] [_____]
Nitrate (mg/L) [_____] [_____] [_____]
Nitrite (mg/L) [_____] [_____] [_____]
Sulfate (mg/L) [_____] [_____] [_____]
Sulfide (mg/L) [_____] [_____] [_____]
Phosphate (mg/L) [_____] [_____] [_____]
Chloride (mg/L) [_____] [_____] [_____]
Fluoride (mg/L) [_____] [_____] [_____]
Free carbon dioxide [_____] [_____] [_____]
mg/L as CaCO3)
Dissolved oxygen (mg/L) [_____] [_____] [_____]
Free chlorine residual (mg/L) [_____] [_____] [_____]
Silica (mg/L) [_____] [_____] [_____]
Total solids (mg/L) [_____] [_____] [_____]
Total dissolved solids (mg/L) [_____] [_____] [_____]
Suspended solids (mg/L) [_____] [_____] [_____]
Turbidity in nephelometric [_____] [_____] [_____]
turbidity units (NTU)
Color by platinum standard [_____] [_____] [_____]
comparison
1.3.3 Performance Requirements
NOTE: Coordinate controls with the blower specified in Section 43 11 00 FANS/BLOWERS/PUMPS;
OFF-GAS.
Select the retention time appropriate for the oxidation device considering any
regulated compounds.
Minimum retention time in the combustion chamber shall be [0.5] [1.0] [1.5] [2.0] [2.5] [_____] seconds at [1095]
[982] [820] [760] [400] [260] degrees C [2,000] [1,800] [1,500] [1,400] [750] [500] degrees F minimum at maximum
flow. The flow rate shall be [constant at [_____] cu m/second scfm] [off and on at [_____] cu m/second scfm
maximum, with a turndown range of four to one (4:1)] [variable between [_____] cu m/second scfm minimum and [_____]
cu m/second scfm maximum]. Flow rates shall be based on measurement at standard temperature and pressure (STP),
101.3 kPa at 15.5 degrees C 14.7 psia at 60 degrees F. Influent gauge pressure shall vary between [_____] Pa
inch H2O minimum, [_____] Pa inch H2O average, and [_____] Pa inch H2O maximum. Inlet temperature shall vary
between [_____] degrees C degrees F minimum, [_____] degrees C degrees F average and [_____] degrees C degrees
F maximum. Materials of construction shall be compatible with the ambient and operating temperatures and long
term exposure to untreated and treated gas constituents.
1.3.4 Off-Gas Composition
NOTE: Reduce the dew point to below 50 degrees C (120 degrees F) ahead of the
thermal oxidizer.
If the unit will be classified as a hazardous waste incinerator, required emission
limits for specific compounds are given in the National Emission Standard for
Hazardous Air Pollutants (NESHAP) Maximum Achievable Control Technology (MACT)
Standard. The MACT standard is scheduled to be finalized the end of 1998 and
will not appear in hard copies of the 40 CFR 63 until the July 1999 edition
is issued by EPA. Until the 1999 CFR is available, it will be necessary for
designers to obtain the Federal Register in which the new standard is given.
Establishing and enforcing air regulations is primarily done at the State level;
therefore, it is critical that designers research State specific requirements
applicable to the unit.
The BDT control device is a combustion device capable of reducing NMOC emissions
by 98 weight-percent or an outlet NMOC concentration of 20 ppmv or less. The
EPA 98 percent DRE requirement applies to total emissions as determined by stack
gas analysis (to include aerosols, particulates, VOCs, etc.), not individual
contaminants, and may not be attainable on individual contaminants in long term
performance.
Include appropriate off-gas discharge requirements (or DRE) and products of
incomplete combustion (if appropriate). Use energy conservation/recovery on
long term or high volume devices.
The system shall be capable of oxidation of the organic components of gaseous, solid and aerosol type emissions
, as follows:
Off-Gas Constituent Influent Effluent Destruction
Estimate Requirement Requirement
------------------------------------------------------------------------
Total Maximum [_____] [_____] NA
Hydrocarbon Average [_____] [_____] NA
(ppmv) Minimum [_____] NA [98*] [_____]%
Methane Maximum [_____] [_____] NA
(ppmv) Average [_____] NA NA
Minimum [_____] NA [98] [_____]%
Non methane Maximum [_____] [20**] [_____] NA
organic Average [_____] NA NA
compounds Minimum [_____] NA [98] [_____]%
(NMOC) (ppmv)
[_____] Maximum [_____] [_____] NA
Average [_____] NA NA
Minimum [_____] NA [95] [_____]%
Carbon Maximum [_____] [_____] NA
Monoxide Average [_____] NA NA
(ppmv) Minimum [_____] NA [98] [_____]%
Nitrogen, Maximum [_____] [_____] NA
NOX (ppmv) Average [_____] NA NA
Minimum [_____] NA [_____]
Total Sulfur, Maximum [_____] NA NA
as SO2 Average [_____] NA NA
(ppmv) Minimum [_____] NA NA
Sulfur, Maximum [_____] [_____] NA
SOX (ppmv) Average [_____] NA NA
Minimum [_____] NA [_____]
Total Chlorine, Maximum [_____] [_____] NA
as HCl Average [_____] NA NA
(ppmv) Minimum [_____] NA [_____]
HCl (ppmv) Maximum [_____] [_____] NA
Average [_____] NA NA
Minimum [_____] NA [_____]
Water Vapor Maximum 100% NA NA
(% saturation) Average [_____] NA NA
Minimum [_____] NA NA
Particulates Maximum [_____] [_____] NA
(mg/m3 Average [_____] NA NA
gr/dscf)Minimum [_____] NA [_____]
Opacity (%) Maximum [_____] [_____] NA
Average [_____] NA NA
Minimum [_____] NA NA
Oxygen (%) Maximum [_____] NA NA
Average [_____] NA NA
Minimum [_____] [_____] NA
* Destruction percentage will be determined as follows:
100% x ((Influent mass - Effluent mass)/(Influent mass)).
** Dry basis, as hexane at 3% oxygen.
1.4 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.][information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] Submit the following in
accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings[; G][; G, [_____]]
Detail drawings containing complete flow diagrams, piping, wiring, schematic, and any other
details required to demonstrate that the system has been coordinated and will properly function
as a unit. Drawings shall show capacities and pressure drop; heat and material balances; make
and model; complete list of equipment and materials. Drawings shall show proposed layout and
anchorage of equipment and appurtenances, and equipment relationship to other parts of the work
including clearances for installation, maintenance and operation.
SD-03 Product Data
Emissions
Reports for permit compliance.
Temperature Sensors, Transmitters and Controllers[; G][; G, [_____]]
Detailed manufacturer's data on the overall controls, sensors, process controllers, control
operators, ladder diagrams, timers, sequence of controls, valves, alarms, signals, interlocks
and cut off systems. Data describing in detail the equipment used to monitor emissions, including
the sampling probe, filters, off-gas transport tubing, sampling pump, moisture removal system,
analyzer calibration systems, and data recorder. Process and instrumentation diagrams (P&IDs).
Thermal Oxidation System[; G][; G, [_____]]
Manufacturer's descriptive data and technical literature, performance charts, catalog cuts,
and installation instructions.
Field Training
Training course curriculum and training instructions, [14] [_____] days prior to the start
of training.
SD-06 Test Reports
Factory Tests[; G][; G, [_____]]
Printout of factory test results.
Field Quality Control/Tests[; G][; G, [_____]]
Test reports, in booklet form, showing all field tests performed to adjust each component
and all field tests performed to prove compliance with the specified performance criteria, upon
completion and testing of the installed system. Each test report shall indicate the final position
of controls.
SD-07 Certificates
Motors
Manufacturer's certificates attesting that the motors meet the NFPA 70 requirements for the
hazardous area classification.
Manufacturer's Field Representative
Names and qualifications of each manufacturer's field representative and training engineer
with written certification from the manufacturer that each representative and trainer is technically
qualified.
SD-10 Operation and Maintenance Data
Thermal Oxidation System
Maintenance
[Six] [_____] complete copies of detailed operating instructions with step-by-step procedures
and sequences for system startup, operation and shutdown. The instructions shall include the
manufacturer's name, model number, service manual, parts list, and brief description of all
equipment and the operating features of each element. The instructions shall include as-built
drawings of the piping layout, equipment layout, and simplified wiring and control diagrams
of the system as installed. Describe automatic controls, functional logic, control loops, set
points and alarm signals. Include flow diagrams in the instructions.
[Six] [_____] complete copies of maintenance instructions listing maintenance procedures,
possible breakdowns and repairs, and trouble shooting guides.
1.5 QUALIFICATIONS
1.5.1 Contractor
Contractor shall have had a minimum of [2] [3] [5] [_____] years of experience in the construction of industrial
air pollution control systems, sanitary wastewater sludge digestion gas systems, landfill off-gas or vapor extraction
off-gas handling systems.
1.5.2 Single Source Supplier
Assign to a single supplier full responsibility for the furnishing of the adsorption system. The designated
single supplier, however, need not manufacture the system but shall coordinate the selection, assembly, installation,
and testing of the entire specified system.
1.5.3 Manufacturer's Field Representative
Provide the.services of a manufacturer's field representative, who is experienced in the installation, adjustment,
and operation of the equipment furnished, and who has complete knowledge of the proper operation and maintenance
of the system.
1.5.4 Welders
[Welders shall have passed qualification tests using procedures covered in AWS B2.1 or ASME BPVC SEC IX and have
the appropriate certification.] [Qualifications of welders, and welding and nondestructive testing procedures
for piping shall be as specified in Section 43 02 00 WELDING PRESSURE PIPING.] [Structural members shall be welded
in accordance with Section 05 05 23 WELDING, STRUCTURAL.] Require any welder to retake the test when, in the
opinion of the Contracting Officer, the work of the welder creates reasonable doubt as to proficiency.
1.6 REGULATORY REQUIREMENTS
NOTE: Add applicable regional, state, or local requirements. Section
01 57 20.00 10 ENVIRONMENTAL PROTECTION includes basic requirements.
Abide by the following requirements: [_____].
1.7 PARTNERING OR PRE-INSTALLATION CONFERENCE
[Partnering] [Pre-installation] conference [may] [will] be [requested] [required]. Ensure that involved subcontractors,
suppliers, and manufacturers are [notified] [represented]. Submit the date and time of the conference to the
Contracting Officer for approval.
1.8 DELIVERY, STORAGE, AND HANDLING
Protect from the weather, excessive humidity, excessive temperature variation, and dirt, dust, or other contaminants
all equipment delivered and placed in storage. Catalyst material shall be protected in accordance with the manufacturer's
recommendations.
1.9 SEQUENCING AND SCHEDULING
NOTE: Testing of the thermal oxidation system should be concurrent with the
start of gas flow from the landfill, vapor extraction system, or other source.
Section 01 35 45.00 10 CHEMICAL DATA QUALITY CONTROL should be included even
if the project is not concerned with HTRW.
Installation of the thermal oxidizer shall be complete and the system operational prior to completion of the
[gas collection system] [vapor extraction system] [landfill cap]. Point source release of untreated off-gas
shall be avoided to the maximum extent consistent with completion of the contract. Sampling and analyses to
demonstrate system performance and emission compliance shall be performed in accordance with Section
01 35 45.00 10 CHEMICAL DATA QUALITY CONTROL.
1.10 EXTRA MATERIALS
NOTE: Include items needed for future maintenance and repair, items that might
be difficult to obtain and spare parts needed to ensure continued operation
of critical equipment. Consider whether an initial operating period is included
in the contract.
[An inventory of all equipment, tools, and items shall be provided to the Contracting Officer at the start of
the operating period. The inventory shall be updated monthly. A current inventory shall be delivered to the
Contracting Officer when the operating period is complete.] [Concurrent with delivery and installation of the
specified equipment, auxiliary equipment and spare parts shall be furnished.] Furnish the following:
a. [Spare parts for each different item of material and equipment specified including all of the parts
recommended by the manufacturer to be replaced after [1 year] [1 year and 3 years] service.] [Spare parts,
replacement parts and other items duplicated or replaced during the operating period.]
b. For each type of grease, one lever type grease gun or other lubricating device.
c. [One set of special tools for each type of equipment including calibration devices, and instruments
required for adjustment, calibration, disassembly, operation, and maintenance of the equipment.] [One
set of special tools, calibration devices, and instruments required for operation, calibration, and maintenance
of the equipment.]
d. One or more steel tool cases mounted on the wall in a convenient location complete with flat key
locks, two keys, and clips or hooks to hold each special tool.
e. A [three] [six] month supply of lubricants, [fuel,] [and] [consumable items] at the end of the contract.
f. [_____].
PART 2 PRODUCTS
NOTE: A life cycle cost analysis should be performed before selection of the
equipment option: flare, enclosed combustor, thermal oxidizer, catalytic thermal
oxidizer, regenerative thermal oxidizer, recuperative thermal oxidizer or catalytic
recuperative thermal oxidizer.
2.1 MATERIALS AND EQUIPMENT
2.1.1 Standard Products
Materials and equipment shall be the standard products of a manufacturer regularly engaged in the manufacture
of such products and shall essentially duplicate items that have been in satisfactory use for at least 2 years
prior to bid opening. Equipment shall be supported by a service organization that is, in the opinion of the
Contracting Officer, reasonably convenient to the site.
2.1.2 General Requirements
Equipment and appurtenances shall be as specified and as shown on the detail drawings, and shall be suitable
for the service intended. Materials and equipment shall be new and unused, except for testing equipment. Components
that serve the same function and are the same size shall be identical products of the same manufacturer. The
system will be rejected upon failure to achieve both the minimum temperature and the minimum retention time specified
in paragraph Performance Requirements.
2.1.3 Nameplates
Each major item of equipment shall have the manufacturer's name, address, type or style, model or serial number,
and catalog number on a plate secured to the item of equipment. Each piece of equipment shall bear the approval
designation and the markings required for that designation. Valves shall be marked in accordance with MSS SP-25
and shall bear a securely attached tag with the manufacturer's name, catalog number and valve identification
permanently displayed.
2.1.4 Equipment Guards [and Access]
Belts, chains, couplings, and other moving parts shall be completely enclosed by guards, to prevent accidental
personal injury, in accordance with 29 CFR 1910, Subpart O, Machinery and Machine Guarding. Guards shall be
removable and arranged to allow access to the equipment for maintenance. Thermal insulation shall enclose high
temperature components to prevent ignition of combustible materials and to preclude personnel contact.
2.2 FLARE
NOTE: See 40 CFR 60.18 for shroud requirements; edit this paragraph if shroud
is not needed.
The [candlestick] [open] [ground] flare shall be composed of an open combustion chamber without enclosure or
shroud.
2.3 ENCLOSED COMBUSTOR
NOTE: Enclosed combustors must demonstrate either 98 percent NMOC reduction
or outlet NMOC concentration of 20 ppmv or less.
The enclosed combustor shall be composed of a vertical enclosed combustion chamber that maintains a constant
temperature by controlling fuel and combustion air.
2.4 THERMAL OXIDIZER
NOTE: Catalytic oxidation operates at a reduced temperature and should be considered
when the organic carbon is between 150 ppmv and 2,000 ppmv. Review the anticipated
off-gas analysis for substances that mask or poison catalysts. Edit this paragraph
as required.
The thermal oxidizer shall be composed of a horizontal enclosed combustion chamber, with catalyst, that maintains
a constant temperature by controlling fuel and combustion air. Catalyst shall be suitable for use under the
conditions listed in paragraph SYSTEM DESCRIPTION and shall be fabricated in modules for ease of installation
in the combustion chamber. Thermal oxidizer shall be compatible reduced temperature operation with the catalyst
in place and high temperature operation without using the modular catalyst unit.
2.5 REGENERATIVE THERMAL OXIDIZER
NOTE: This system is a high temperature operation that recovers energy by cycling
exhaust and inlet gases through regenerative heat exchange media.
The thermal oxidizer shall be composed of a horizontal enclosed combustion chamber that maintains a constant
temperature by controlling fuel and combustion air.
2.6 RECUPERATIVE THERMAL OXIDIZER
NOTE: This system consists of a high temperature operation, without catalyst,
or low temperature operation, with catalyst, that recovers energy by counter
current passing of the exhaust and inlet gases through the heat exchanger.
Edit this paragraph as required for job conditions.
The thermal oxidizer shall be composed of a horizontal enclosed combustion chamber, with catalyst modules, that
maintains a constant temperature by controlling fuel and combustion air. The thermal oxidizer shall be compatible
with the temperatures of operation with or without using the modular catalyst unit.
2.7 CONTAMINANT CONCENTRATION SYSTEM
NOTE: Fuel costs for dilute or wet off-gas streams are substantially reduced
by using a concentration system. Consider a concentration system if the organic
carbon is less than 2,000 ppmv.
Inlet gas concentration of [total hydrocarbon] [methane] [non methane organic compounds (NMOC)] [_____] shall
be increased by a minimum of [ten] [five] [two] times the initial concentration.
2.8 HEAT RECOVERY SYSTEM
NOTE: Use media for regenerative systems or heat exchanger for recuperative
systems.
2.8.1 Media Chambers
Exhaust flow through media chambers shall recycle a minimum of [50] [_____] percent of the heat input at maximum
operating conditions (maximum flow and temperature).
2.8.2 Heat Exchanger
The multiple pass, or single pass plate heat exchanger, or tube and shell heat exchanger shall recycle a minimum
of [80] [_____] percent of the heat input at maximum operating conditions (maximum flow and temperature).
2.9 FLAME TRAP/ARRESTER
NOTE: This is a safety requirement that must be implemented.
Flame arrester, in accordance with FM P7825a, shall be provided at the inlet to the oxidation system. The pressure
drop across the flame arrester shall be a maximum of [_____] [1.5] kPa [_____] [6] in W.C. at maximum flow.
The flame arrester shall have a clean-out cover to facilitate maintenance.
2.10 INLET PROTECTION
NOTE: The system should be protected by moisture reduction.
2.10.1 Knock-Out Pot
Knock out pot, with a minimum collection efficiency of [98] [98.5] [99] percent, shall be provided.
2.10.2 Mist Eliminator
A mist eliminator, with a minimum collection efficiency of [85] [98] [98.5] [99] [_____] percent of the impinging
mist shall be provided.
2.11 IGNITION SYSTEM/BURNER ASSEMBLY
2.11.1 Pilot
NOTE: ASCE 25 applies to earthquake actuated systems.
Automatic gas shutoff system conforming to ASCE 25 shall be provided on the pilot supply. The pilot assembly
shall be removable and shall be provided with pressure indicator, pressure regulator, solenoid valve, manual
shutoff valve and pilot gas pressure manometer port. Pilot inlet nozzle shall be 150# ANSI, stainless steel,
flanged.
2.11.2 Igniter
Electronic spark ignition shall be provided. The igniter assembly shall be removable from outside the combustion
chamber without disconnecting conduit or wiring.
2.11.3 Burner Assembly
The primary air mixed burner shall be compatible with the specified fuel, shall have multiple small gas ports
or jets, and shall be constructed of 304L/316L stainless steel, heat and corrosion resistant alloy steel, ceramic
and/or castable refractory. The burner shall be of adequate capacity to maintain the required combustion temperature
at the maximum flow with no fuel value in the off-gas.
2.11.4 Refractory Insulation
Removable, cast venturi burner lining assemblies shall be provided with a [1500] [_____] degrees C [2,700] [_____]
degrees F rating. Refractory insulation shall be continuous, a minimum of 50 mm 2 inches of ceramic fiber insulation
blanket surrounding the combustion cylinder, attached to the wall and floor with Inconel studs and washers, with
plate retainers installed around all open edges of the blanket. The refractory insulation shall be coated with
a high temperature, surface sealer protectant.
2.12 EXHAUST TREATMENT
2.12.1 Adsorber
NOTE: Adsorbers are not commonly required.
Exhaust gas shall be treated by an activated carbon adsorption system in accordance with Section 43 13 13.13
VAPOR PHASE ACTIVATED CARBON ADSORPTION UNITS.
2.12.2 Scrubber
NOTE: Scrubber is used only for high acid concentrations resulting from chlorine
or sulfur in the feed or combustion of nitrogen.
Scrubber shall remove [85] [90] [95] [_____] percent of the acid gas formed.
2.13 STACK
2.13.1 Minimum Exit Velocity
The stack exit velocity shall be not less than [_____] m/sec ft/sec.
2.13.2 Minimum Elevation
The stack elevation shall be not less than stated in paragraph Design Requirements.
2.13.3 Lining
Stack shall be lined with ceramic and/or castable refractory.
2.13.4 Lightning Protection
An engineered lightning protection system with grounding shall be provided.
2.13.5 Lugs
Lifting lugs shall be provided at the top of the stack for ease of installation; each lug shall be capable of
supporting the entire weight of the stack.
2.13.6 Access
Access to the interior of the stack shall be provided by an insulated, [hinged or supported 0.6 x 0.6 m 24 x
24 inch square or 0.6 m 24 inch diameter, manway] [150 x 150 mm 6 x 6 inch square or 150 mm 6 inch diameter,
hand hole] located above the burners.
2.13.7 Ladder
An aluminum or galvanized steel fixed ladder shall be mounted to allow access for removal or replacement of each
of the thermocouples. The ladder furnished with the system shall have side rails. Individual rung ladders
are not acceptable. Ladder shall conform to 29 CFR 1910, Part 27 Fixed Ladders, except as specified herein.
The safety cage shall be provided with locking device to prevent unauthorized access.
2.14 PROVISIONS FOR OBSERVATION AND SAMPLING
2.14.1 Observation Ports
Observation ports or sight glasses with removable tempered glass covers and cooling holes shall be provided.
View port diameter shall be a minimum of [75] [50] mm [3] [2] inch. Ports shall be located to allow viewing
the pilot flame, the base of the main flame, and a view of each of the thermocouples.
2.14.2 Inlet Sample Port
Inlet sample port [50] [_____] mm [2] [_____] inch minimum diameter, with cap and cooling holes, shall be located
upstream of all contributing flows, with the exception of the off-gas.
2.14.3 Outlet Sample Port
Outlet sample port [50] [_____] mm [2] [_____] inch minimum diameter, with cap and cooling holes, shall be located
[upstream of the cooling or dilution air inlet] [and] [two stack diameters from the top of stack].
2.14.4 Sampling Equipment
NOTE: Add sampler requirements.
Provide the following equipment: [_____].
2.15 CONTROLS
NOTE: Blower controls are in Section 43 11 00 FANS/BLOWERS/PUMPS; OFF-GAS.
Omit last sentence if not applicable to the project.
Set points, signals and control functions and dampers shall be linked by a central programmable logic controller
(PLC) located in the control panel. Control signals shall be 4-20 ma or 0-10 Vdc, compatible with the controller
and sensor or control device. Burner control diagnostics shall be included. For parameters specified to be
continuously recorded, digital data shall be recorded at intervals not exceeding one minute. Sensors shall be
calibrated with standards traceable to NIST and in conformance with NIST SP 250. Each alarm shall be connected
to an [auto-dialer] [or] [telemetry] system.
2.15.1 Ultraviolet (UV) Flame Scanner
Ultraviolet scanner shall be furnished, installed and calibrated to provide for safety shutdown on the absence
of flame. The signal from each scanner shall incorporate a time delay appropriate to the control sequence.
The burner flame scanner shall monitor the burner flame. The pilot flame scanner shall monitor the pilot flame.
2.15.2 Timers
Automatic timers shall provide independent adjustment of the start and duration of each step in the control sequence.
2.15.2.1 Purge Timer
The minimum purge cycle shall be set at four changes of [air] [or] [inert gas]. Purge cycle shall have both
automatic and manual start.
2.15.2.2 Igniter Timer
NOTE: The spark duration adjustment extends the life of the plug, transformer
and other pilot components.
An igniter timer, with [manual] [automatic] adjustment of the spark duration, shall be provided to set the time
and duration of the igniter spark during the ignition cycle, and to compensate for the distance of the pilot
gas supply from the oxidizer.
2.15.2.3 Pilot Timer
At the end of the purge, the pilot timer shall begin automatic ignition. If the UV sensor fails to sense the
pilot flame, the pilot solenoid valve shall close, the pilot flame shall be extinguished, the system shall shut
down and the pilot fail alarm shall be activated.
2.15.2.4 Main Flame Timer
The main flame timer shall extend beyond the pilot timer cycle. When the burner flame lights and the temperature
exceeds the low temperature set point on the temperature controller, the pilot flame shall be shut off. The
system shall shut down, and the main flame fail alarm shall be activated, if the UV sensor fails to sense the
pilot flame or the flame temperature does not reach the low temperature set point by the end of the main flame
step.
2.15.3 Temperature Sensors, Transmitters and Controllers
2.15.3.1 Thermocouples
NOTE: Narrow temperature ranges are more responsive than broad ranges because
the sensitivity is a percentage of the range.
Thermocouples shall conform to ISA MC96.1, Type K, suitable for continuous operation and control at temperatures
up to [50] [100] [150] [_____] degrees C [80] [180] [260] [_____] degrees F above the temperature specified in
the performance requirements and accurate to 0.75 percent of the maximum temperature. Each thermocouple used
for control shall be provided with high and low set points and an adjustable time delay before initiation of
each control action. A thermocouple located in or immediately downstream of the combustion chamber shall control
burner operation and shall [indicate] [and] [record] combustion chamber temperatures. [Three] [_____] additional
thermocouple ports shall be spaced at vertical intervals equal to the stack diameter, starting two stack diameters
from the top of the stack. Compensating lead wire connecting the thermocouple to the read out shall be 16 gauge
with a weatherproof braid.
2.15.3.2 Thermometers
Thermometers shall conform to ASME PTC 19.3, with wells and temperature range suitable for the use encountered.
2.15.3.3 Combustion Chamber Temperature Controller
The combustion temperature control shall [record the combustion chamber temperature] [and] [maintain the temperature
between the adjustable high temperature and low temperature set points]. The controller shall control the [damper
actuator motors] [blowers]. Control logic shall include auto position signal and automatic switch over capabilities.
a. The system shall shut down and not attempt to restart if the temperature exceeds the allowable combustion
chamber temperature range. A high temperature shutdown shall activate the high temperature alarm.
b. During operation, the system shall shut down and not attempt to restart if the temperature falls
below the allowable combustion chamber temperature range. During the ignition cycle, if the temperature
does not reach or exceed the low temperature shutdown setting, the system shall shut down and not attempt
to restart. A low temperature shutdown during operation or during the ignition cycle shall activate
the low temperature alarm.
2.15.3.4 Primary Combustion Air Control
NOTE: For this and the following paragraph, refer to Section 43 11 00 FANS/BLOWERS/PUMPS;
OFF-GAS for combustion air control.
Fully adjustable air dampers on each burner shall be furnished with remote operation by external lever control,
sized to provide a minimum of [100] [115] percent of theoretical stoichiometric air as primary air. Dampers
shall allow the operator to adjust the primary air/fuel ratio while burner is in operation.
2.15.3.5 Total Combustion Air Control
[Motor operated louver dampers shall be provided. Actuators shall cause louvers to fail open on loss of signal
or power.] [Two multistage centrifugal blower trains, each with a suction valve, discharge valve, and discharge
check valve shall be provided.]
2.15.3.6 Quenching/Dilution Air Control
Motor operated louver dampers shall be provided. Actuators shall cause louvers to fail open on loss of signal
or power.
2.16 FLOW METERS, TRANSMITTERS AND FLOW CONTROLLER
The flow control system shall include an automatically actuated main fuel valve with fail-closed feature and
limit switches for position indication. The flow rate metering system shall include recording, totaling and
alarm capabilities.
2.16.1 Off-Gas Flow Meter
Flow metering for the off-gas shall conform to AGA Report No 3.
2.16.2 Supplemental Fuel Flow Meter
NOTE: Supplemental fuel meters should be sized on peak requirement. Off-gas
meters should be based on blower size.
Gas meters shall conform to [AGA B109.1] [AGA B109.2] [AGA B109.3].
2.17 PRESSURE MEASUREMENT AND CONTROL
One differential pressure sensor with large diameter sensing holes shall be furnished. A differential pressure
transmitter shall be provided and shall be mounted within 1 m 3 feet of the sensor. A compound vacuum/pressure
gauge shall be installed on each blower. The compound gauges shall be furnished with a differential pressure
range of [0.1 to 100] [_____] kPa [0.015 to 15] [_____] psig. The piping from the sensor to the transmitter
shall be 3 mm 1/8 inch stainless steel tubing with stainless steel drain valves on each pipe, at low points.
Piping shall be plumbed so that condensate will drain back into the pipe. The transmitter shall be equipped
with zero and span adjustment, and shall provide a standard volumetric output rate reading to the chart recorder
(included with the control system) without the need for separate compensating pressure or temperature transducers.
A pressure gauge shall be installed on the discharge side of each blower. The pressure gauges shall be furnished
with a range of 0 to 34 kPa 0 to 5 psi. The gauges shall be weatherproof, with 113 mm 4-1/2 inch dials and Type
316 stainless steel Bourdon tubes. The gauges shall be furnished with pressure snubbers and diaphragm seals
and valves. Isolation valves shall be installed between the process pipe and the seal. Diaphragm seals shall
be furnished with top and bottom housings and diaphragms of Type 316 SS. The diaphragm cavities shall be liquid
filled with silicone.
2.17.1 Draft Gauges
Draft gauges shall be Type I, Class 1 or 2, as applicable, conforming to ASME B40.100 with a diaphragm or bellows
actuating system and a circular scale. The gauges shall have a zero adjustment screw. Suitable shutoff cocks
shall be provided.
2.17.2 Pressure Gauges
Pressure gauges shall conform to ASME B40.100 and be of pressure detecting Class, single Bourdon tube style,
and suitable for detecting air pressure.
2.17.3 Pressure Switches
Pressure switches shall be provided to activate the blowers.
2.17.4 Pressure Release
A pressure release valve shall be located on the off-gas line upstream of the oxidizer.
2.18 EXPLOSIMETER
NOTE: The fuel concentration should be greater than 30 percent of LEL. Combustion
air should be less than 30 percent of LEL.
A combustible gas analyzer, with a minimum of four in-line sensors, calibrated to methane shall be located in
the control panel.
2.18.1 Lower Explosive Limit (LEL)
The lower explosive limit of the fuel and of the off-gas shall be continuously indicated. The lower explosive
limit of the off-gas shall be continuously recorded.
2.18.2 Upper Explosive Limit (UEL)
The upper explosive limit of the combustion air and of the off-gas shall be continuously indicated.
2.19 OXYGEN METERING AND MAKE-UP AIR CONTROL
2.19.1 Oxygen Meter
The upper oxygen level of the combustion air and of the off-gas shall be continuously indicated.
2.19.2 Methane Monitor
The methane level of the combustion air and of the off-gas shall be continuously indicated.
2.20 OPERATING INDICATORS AND ALARMS
Simulated running lights to indicate normal operating conditions and alarms shall be displayed at the control
panel.
2.20.1 Visible Alarms
Each visible alarm shall be indicated at the control panel and by a red light at the device.
2.20.2 Audible Alarms
Each audible alarm shall be located at the device.
2.20.3 Remote Alarms
NOTE: The Contractor should respond to alarms for the duration of the contract.
Remote alarms shall activate the programmable auto dialer. A prerecorded message shall provide specific information
to the operator about the alarm condition. At contract close out, the dialer shall be reprogrammed to the number
indicated by the Contracting Officer.
2.21 ELECTRICAL WORK
NOTE: Hazard classifications in accordance with NFPA 70 should be indicated
on the drawings.
All electrical equipment, wiring and controls shall comply with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM
and with NFPA 70, with proper consideration given to environmental considerations such as moisture, dirt, corrosive
agents and proper NFPA 70 hazardous area classification. Lightning and surge protection shall be provided.
2.21.1 Motors
Electric motor driven equipment shall be provided complete with starters and alternating current motors conforming
to NEMA MG 1. Fractional horsepower motors shall be 115-volt, single-phase, 60 cycle. Integral horsepower motors
shall be three-phase, 60 cycle. Motor starters shall be provided complete with properly sized thermal overload
protection and other appurtenances necessary for the motor specified. Each motor shall be designed for operation
in ambient temperatures up to 40 degrees C 104 degrees F.
2.21.2 Control Panels
A complete control panel with options for various control schemes and control wiring shall be included. Manual
or automatic controls, protective or signal devices and control wiring for the controls and devices required
for the operation specified shall be provided. Motor controls shall conform to NEMA ICS 1. Enclosures for power
and control panels shall conform to NEMA ICS 6. Panels located outdoors shall be [NEMA 4X] [NEMA 4] and shall
be weatherproof.
2.21.3 Resistance Heaters
NOTE: The designer should select the most cost effective heat source for the
application.
Electric resistance pre-heaters and dryers shall be used where indicated on the drawings.
2.22 AUXILIARY FUEL SYSTEM
NOTE: The designer should select the most cost effective heat source for the
location.
2.22.1 Feed Capability
The auxiliary fuel system shall have direct feed capability to the thermal destruction system with meters, pressure
gages and controls to maintain the specified operating conditions. Design shall be in conformance with the applicable
requirements of NFPA 30 and NFPA 31, NFPA 54 or NFPA 58, as appropriate to the fuel type.
2.22.2 Auxiliary Fuel Regulator
Auxiliary fuel rate shall be controlled by the temperature of the combustion chamber.
2.22.3 Secondary Containment
Fuel storage tanks shall be provided with secondary containment as required by NFPA 30, paragraph 2-3.4 Control
of Spillage from Aboveground Tanks.
2.23 VALVES
Design of valve operators and mechanisms shall avoid initial surges and sudden inrushes by gradually allowing
flows to increase.
2.23.1 Butterfly Valves
Butterfly valve shall be cast iron body with resilient seat, 316 stainless steel disc and shaft and actuator.
Valve shall have fail-safe closing in ease of a power failure. Valve shall have location limit switch for use
in the control system.
2.23.2 Other Valves
Other valves shall conform to API Spec 6D, CSA/AM Z21.15 or ASME B16.33 as appropriate for the type.
2.24 JOINTS
2.24.1 Dielectric Fittings
Dielectric fittings shall be installed between threaded ferrous and nonferrous metallic pipe, fittings and valves.
Dielectric fittings shall prevent metal-to-metal contact of dissimilar metallic piping elements and shall be
suitable for the required working pressure.
2.24.2 Isolation Joints
Isolation joints shall be installed between non-threaded ferrous and nonferrous metallic pipe, fittings and valves.
Isolation joints shall consist of a dielectric sandwich type flange isolation gasket with isolation washers and
isolation sleeves for flange bolts. Isolation gaskets shall be full faced with outside diameter equal to the
flange outside diameter. Bolt isolation sleeves shall be full length. Units shall be of a shape to prevent
metal-to-metal contact of dissimilar metallic piping elements.
2.24.2.1 Sleeve Type Couplings
Sleeve type couplings shall be used for joining plain end pipe sections. Each coupling shall consist of a steel
middle ring, two steel followers, two gaskets, and the necessary steel bolts and nuts to compress the gaskets.
2.24.2.2 Split Sleeve Couplings
Split sleeve type couplings may be used in aboveground installations, when approved in special situations, and
shall consist of gaskets and housing in two or more sections with the necessary bolts and nuts.
2.24.3 Bolts, Nuts, and Fasteners
Bolts, anchor bolts, nuts, washers, plates, bolt sleeves, and all other types of supports necessary for the installation
of the equipment shall be furnished with the equipment and shall be galvanized unless otherwise indicated. Anchor
bolts shall be provided with square plates at least 100 by 100 by 9 mm 4 by 4 by 3/8 inch or shall have square
heads and washers and be set in the concrete forms with suitable sleeves. Expansion bolts shall have malleable-iron
and lead composition elements. Unless otherwise specified, stud, tap, and machine bolts shall be of refined
bar iron. All threads shall conform to ASME B1.1. Bolts, anchor bolts, nuts, and washers specified to be galvanized,
shall be zinc coated, after being threaded, by the hot-dip process in conformance with ASTM A 123/A 123M or ASTM A 153/A 153M
. Bolts, anchor bolts, nuts, and washers indicated to be stainless steel shall be Type 316 stainless steel.
2.25 FACTORY TESTS
The thermal oxidation system equipment shall be skid mounted and assembled in the shop, to the maximum practical
extent, in the configuration outlined in the detail drawings and specifications. A factory pressure test shall
be made at [125] [250] [_____] percent of the rated pressure of the equipment. Continuity check and process
simulation shall be performed at the factory before shipping the control panel. The system shall be test fired
with the specified fuel and air and maintained at the temperature specified in paragraph Performance Requirements
for [two] [_____] hours. Test reports shall be furnished [with the equipment] [to the Contracting Officer prior
to shipment of the equipment].
PART 3 EXECUTION
3.1 EXAMINATION
After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Contracting
Officer of any discrepancy before performing the work.
3.2 PREPARATION
All equipment and products shall be inspected for defects in workmanship and material. Debris and foreign matter
shall be cleaned out of valve openings and seats. Each operating mechanism shall be operated to check proper
functioning. Each nut shall be checked for tightness. Valves and other equipment that do not operate easily
or are otherwise defective shall be repaired or replaced.
3.3 FOUNDATIONS AND SKID BASES
Foundations for the thermal oxidizer and appurtenances, and pads for skid bases, shall be constructed of concrete,
reinforced where necessary, in conformance with the applicable requirements of Section [03 31 00.00 10 CAST-IN-PLACE
STRUCTURAL CONCRETE][03 30 00 CAST-IN-PLACE CONCRETE], except as otherwise shown or specified. Concrete surface
shall be [75] [_____] mm [3] [_____] inch above grade in outdoor locations. Mounting feet shall be provided
so that appropriate anchorage can be provided. Anchor embedment depth and spacing shall be sufficient for seismic
attachment to the foundation and for prevention of overturning. Concrete pad shall extend [150] [_____] mm [6]
[_____] inch beyond the equipment.
3.4 ERECTION
3.4.1 Welding
NOTE: Use second set of brackets when critical pipe welding is required.
[Welding procedures shall be as specified in AWS D1.1/D1.1M] [Welding and nondestructive testing procedures for
piping shall be as specified in Section 43 02 00 WELDING PRESSURE PIPING] [Structural members shall be welded
in accordance with Section 05 05 23 WELDING, STRUCTURAL].
3.4.2 Painting/Corrosion Prevention
All ferrous surfaces shall be coated or painted. Exposed ferrous surfaces shall be painted in accordance with
Section 09 90 00 PAINTS AND COATINGS. Color shall be as indicated on the paint schedule or as otherwise approved.
3.4.2.1 Factory Primed Surfaces
Factory primed surfaces shall be solvent-cleaned before painting.
3.4.2.2 Touch-Up Painting
Factory painted items shall be touched up as needed. Factory painted items requiring touching up in the field
shall be thoroughly cleaned of foreign material, primed and top coated with the factory finish.
3.4.2.3 Field Painting
Equipment which did not receive a factory finish shall be prepared, primed and painted, as specified in Section
09 90 00 PAINTS AND COATINGS.
3.4.2.4 Corrosion Resistant Metals
Painting of corrosion resistant materials such as copper, brass, bronze, copper-nickel, and stainless steel is
not required unless otherwise specified.
3.5 INSTALLATION
3.5.1 Insulation
Equipment and piping shall be insulated in accordance with Section 23 07 00 THERMAL INSULATION FOR MECHANICAL
SYSTEMS.
3.5.2 Utilities
NOTE: Points of connection are normally shown on the drawings. Occasionally,
the name, address and telephone number of each utility company is shown on the
drawings. Delete the following paragraphs if the information is shown elsewhere.
Fuel and utilities shall be provided at locations shown on the drawings. Verify availability and locations of
utilities and compensate the utility company for connection and usage. Fuel, water, sewer, power and any other
utility bills shall be paid on receipt.
3.5.2.1 Electricity
The power [utility] [company] is [_____], telephone number [_____].
3.5.2.2 Water
The water [utility] [company] is [_____], telephone number [_____].
3.5.2.3 Natural Gas
The natural gas [utility] [company] is [_____], telephone number [_____].
3.5.3 Fuel System
NOTE: Coordinate requirements for the fuel source specified in paragraph Feed
Capability.
Fuel system installation and testing shall comply with the applicable requirements of NFPA 30 and NFPA 31, NFPA 54
or NFPA 58, as appropriate to the type of fuel.
3.6 POSTING FRAMED INSTRUCTIONS
NOTE: If the user preference is known, show the location on the drawings and
edit this paragraph.
Wiring and control diagrams and typed condensed operating instructions framed under glass or in laminated plastic
shall be posted where directed. Diagrams shall show the complete layout, wiring and control of the entire system.
Condensed operating instructions shall explain preventive maintenance procedures, methods of checking the system
for normal safe operation and procedures for safely starting and stopping the system. The diagrams and instructions
shall be posted before acceptance testing of the system.
3.7 FIELD QUALITY CONTROL/TESTS
3.7.1 Pressure and Leakage Test
NOTE: Testing of pipe and fittings should be specified in the pipe specification.
The test pressure for vessels should not exceed the rated pressure.
After installation, all piping, equipment, joints and connections shall be tested for gas tightness. Connections
and piping shall be tested by subjecting the complete system to pneumatic pressure of not less than [[105] [_____]
kPa [15] [_____] psi] [the pressure indicated in the schedule] for 6 hours. During the test, the system shall
be disconnected from the source of pressure and, with corrections made for barometric and temperature changes,
the pressure shall remain constant for the test period, as indicated by a test gauge. Joints shall be tested
using a soapy water solution to detect leaks.
3.7.2 Operational/Performance Tests
NOTE: Coordinate with the blower specification and the design sequence of operation.
Testing requirements should be edited to fit the intended mode of operation
for the system. Flow rates for operating capacity tests will be inserted in
the blank spaces provided.
After installation and pressure testing, the entire off-gas system shall be subjected to [an operational test]
[a performance test] to demonstrate satisfactory functional efficiency. Results of the tests shall be used in
determining the capacity and performance of the oxidation unit. Any deficiencies revealed during the tests shall
be corrected and the tests repeated.
3.7.2.1 Constant Flow Tests
NOTE: This procedure is appropriate for a system without blowers or with a
single constant speed blower.
Each unit shall be operated at a constant flow rate of approximately [_____] cubic m/second cubic feet/second
(actual) for the capacity test. Samples shall be taken of the influent and effluent at [[1] [8] hour] [1 day]
[1 week] intervals for analysis.
3.7.2.2 Variable Flow Tests
NOTE: This procedure is appropriate for a system with variable speed blowers
regulated by a pressure controller.
Each unit shall be operated at flow rates varying between [_____] and [_____] cubic m/second [_____] and [_____]
cubic feet/second (actual). Samples shall be taken of the influent and effluent at the high flow rate and [1
intermediate rate] [[2] [3] [_____] intermediate rates] for analysis.
3.7.2.3 Cyclic Flow Tests
NOTE: This procedure is appropriate for a system with constant speed blowers
operated by on/off control.
Each unit shall be put through a complete cycle of operation [at a constant flow rate of approximately [_____]
cubic m/second cubic feet/second (actual)] [through the complete range of flows]. Samples shall be taken of
the influent and effluent at the beginning and end of each cycle and at [1 intermediate time] [[2] [3] [_____]
intermediate times] for analysis.
3.7.3 Sampling and Analyses
NOTE: Verify that analyses are included in Paragraph Process Gas and Particulate
Emission Sample Methods of Section 01 35 45.00 10 CHEMICAL DATA QUALITY CONTROL.
Samples of influent and effluent off-gas shall be collected and analyzed for the parameters listed in Paragraph
Off-Gas Composition in accordance with the Sampling and Analysis Plan developed to conform with Section
01 35 45.00 10 CHEMICAL DATA QUALITY CONTROL.
3.7.4 Test Logs
A complete log of each test shall be made, giving the following data: date, time of each reading and each sampling
event, fuel use, and total off-gas treated.
3.8 MANUFACTURER'S FIELD SERVICE
3.8.1 Representative's Services
Services of a manufacturer's representative who is experienced in the installation, adjustment, and operation
of the equipment specified shall be provided. The representative shall supervise the installation, adjustment,
calibration, commissioning, start-up and operational/performance testing of the equipment.
3.8.2 Field Training
NOTE: Complexity of the system and experience of the user operators should
be taken into consideration.
A field-training course shall be provided for designated operating and maintenance personnel. Training shall
be provided for a total period of [_____] hours of normal working time and shall start after the system is functionally
complete but prior to the [performance] [operational] test. Field training shall cover each item contained in
the operating and maintenance manuals, as well as demonstrations of routine maintenance operations.
3.9 MAINTENANCE
NOTE: Select the option that is compatible with the Bid Schedule.
Manage, operate, maintain, and monitor the off-gas control system [until contract close out] [for at least [one
year] [_____] after construction, startup and performance testing are complete]. At a minimum, an operator shall
be on site [eight] [_____] hours per week to operate, maintain, and calibrate the equipment and instruments,
and to collect samples for analyses. A qualified person shall be on call to respond to emergencies and alarm
conditions at the off-gas system within two hours of alarm conditions. Compliance and monitoring records and
reports shall be prepared and maintained for the Contracting Officer and regulatory agencies. The operator shall
maintain a log of the actions taken.