USACE / NAVFAC / AFCESA / NASA UFGS-43 32 76 (January 2008)
----------------------------
Preparing Activity: USACE Superseding
UFGS-43 32 76 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 43 32 76
CHLORINE-FEEDING MACHINES (AUTOMATIC, SEMIAUTOMATIC AND MANUAL)
01/08
NOTE: This guide specification covers the requirements for chlorine feeding
machines for the treatment of water or sewage.
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 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.
[ASME INTERNATIONAL (ASME)ASME B16.1(2005) Standard for Gray Iron Threaded Fittings; Classes 125 and 250ASME B16.11(2005) Forged Fittings, Socket-Welding and ThreadedASME B16.3(2006) Malleable Iron Threaded Fittings, Classes 150 and 300ASME B16.5(2003) Standard for Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24ASME BPVC SEC VIII D1(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section VIII, Pressure Vessels Division 1 - Basic Coverage][ASTM INTERNATIONAL (ASTM)ASTM A 106/A 106M(2008) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature ServiceASTM A 153/A 153M(2005) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel HardwareASTM A 53/A 53M(2007) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and SeamlessASTM A 587(1996; R 2005) Standard Specification for Electric-Resistance-Welded Low-Carbon Steel Pipe for the Chemical IndustryASTM B 88(2003) Standard Specification for Seamless Copper Water TubeASTM B 88M(2005) Standard Specification for Seamless Copper Water Tube (Metric)ASTM D 1785(2006) Standard Specification for Poly(Vinyl Chloride) (PVC), Plastic Pipe, Schedules 40, 80, and 120ASTM F 441/F 441M(2002) Standard Specification for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80][CHLORINE INSTITUTE (CI)CI Pamphlet 1(1997) Chlorine ManualCI Pamphlet 6(2005) Piping Systems for Dry Chlorine][U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)30 CFR 72Health Standards for Coal Mines]1.2 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.] The following shall be
submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Installation[; G][; G, [_____]]
Detail drawings containing complete wiring and schematic diagrams and any other details required
to demonstrate that the system has been coordinated and will properly function as a unit. Show
on the drawings proposed layout and anchorage of equipment and appurtenances, and equipment
relationship to other parts of the work including clearances for maintenance and operation.
SD-03 Product Data
Material and Equipment
A complete list of equipment and material, including manufacturer's descriptive data and technical
literature, performance charts and curves, catalog cuts, and installation instructions. Spare
parts data for each different item of material and equipment specified, after approval of the
detail drawings and not later than [_____] months prior to the date of beneficial occupancy.
Include in the data a complete list of parts and supplies, with current unit prices and source
of supply, and a list of the parts recommended by the manufacturer to be replaced after [1]
[and] [3] year(s) of service.
Diagrams, instructions, and other sheets, proposed for posting.
SD-06 Test Reports
Testing
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. Indicate in each test report the final position
of controls.
SD-10 Operation and Maintenance Data
Operating and Maintenance Instructions
[Six] [_____] complete copies of operating manuals outlining the step-by-step procedures required
for system startup, operation and shutdown. Include in the manuals the manufacturer's name,
model number, service manual, parts list, and brief description of all equipment and their basic
operating features. [Six] [_____] complete copies of maintenance manuals listing routine maintenance
procedures, possible breakdowns and repairs, and troubleshooting guides. Include in the instructions
gas pipe layout, liquid chlorine pipe layout, dilution liquid pipe layout, equipment layout,
and simplified wiring and control diagrams of the system as installed.
1.3 DELIVERY, STORAGE, AND HANDLING
Protect all equipment delivered and placed in storage from the weather, humidity and temperature variation, dirt
and dust, or other contaminants.
1.4 MAINTENANCE, EXTRA MATERIALS AND TOOLS
1.4.1 Auxiliary Equipment and Spare Parts
NOTE: Remove items not required in the project.
Furnish auxiliary equipment and spare parts as follows:
a. One spare flow rate indicator for each machine.
b. One flexible tank connection for each machine, except where the machine is direct cylinder-mounted.
c. Three each of all special gaskets to fit all joints and unions.
d. One set of all necessary hose clamps to suit all hose connections.
e. Fifty cylinder valve gaskets.
f. One 118 mL 4 ounce bottle of ammonia.
g. Stationary metal platform scale without wheels, with a capacity of [_____] chloride containers of
[_____] kg pounds size and of the [dial] [beam] type.
h. [[_____] air-purifying respirators, with cartridges conforming to 30 CFR 72; Subpart 710.] [[_____]
self-contained air breathing units.]
i. [_____] residual-chlorine comparator of a type employing permanent color standards and 13- or 26-millimeter
viewing-depth sample tubes, with corrosion-resistant case, a color disk reading from 0.0 mg/L to [_____]
mg/L, and sufficient DPD tablets for 100 tests. The residual chlorine comparators shall meet EPA requirements.
j. [_____] emergency repair kit for chlorine cylinders.
k. [_____] emergency repair kit for chlorine [_____] metric ton ton containers.
1.4.2 Special Tools
For each type of equipment furnished provide:
a. Special tools necessary for adjustment, operation, maintenance, and disassembly.
b. A grease gun or other lubricating device for each type of grease required.
c. One or more steel cases mounted on the wall complete with flat key locks, two keys, and clips or
hooks to hold each tool in a convenient location. Tools shall be high-grade, smooth, forged, alloy tool
steel. Grease guns shall be lever type. Tools shall be delivered at the same time as the equipment and
handed over on completion of the work.
PART 2 PRODUCTS
2.1 GENERAL REQUIREMENTS
2.1.1 Standard Products
Provide material and equipment which are the standard products of a manufacturer regularly engaged in the manufacture
of the products and that 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 Nameplates
Major equipment items shall have the manufacturer's name, address, type or style, model or serial number, and
catalog number on a plate secured to the item of equipment.
2.1.3 Miscellaneous Supports
Bolts, nuts, anchors, washers, and all other types of supports necessary for the installation of the equipment
shall be galvanized steel, cadmium plated steel, or Type 316 stainless steel.
2.2 CHLORINE-FEEDING MACHINE
The machine shall be designed for the treatment of [water] [or] [sewage] by the application of chlorine [solution]
[gas] against a [positive] [negative] head of [_____] mm feet using the facility's [clarified sewage effluent]
[or] [water supply] system for operation of the machines under a variation in pressure from [_____] minimum to
[_____] maximum kPa psi. The chlorine-feeding system shall consist of controls and devices necessary for a complete
operating system including a chlorine pressure gauge or other device that indicates loss of chlorine pressure,
a chlorine pressure-reducing valve, a meter with rate-of-flow, injector, pressure-relief valves, water-pressure
gauges, water strainers, backflow preventer and water-pressure regulator if required. Each chlorine-feeding
machine shall be provided with means for [direct cylinder mounting] [wall mounting] [floor mounting on a panel
or in a cabinet] and shall be designed so that the chlorine gas feed rate control is under [a vacuum] [pressure]
when the machine is in operation. [Chlorine gas shall be mixed with liquid after being measured through the
meter.] The chlorine feeding machine shall function accurately regardless of normal variations in pressure in
the chlorine cylinders [and in the liquid pressure operating the machines]. In case of failure of the chlorine
supply, the machine shall be the type that is automatically protected against flooding or damage so that under
operating conditions it will not be possible for water to get back into the chlorine inlet line or dry-gas control
parts. Parts subject to contact with chlorine shall be made of materials resistant to the action of chlorine
at the pressures and concentrations that could be encountered. Construction shall be as simple as practicable
to provide reliable service and to be readily accessible for inspection, cleaning, adjustment, repairs, and replacements.
2.2.1 Capacity
Each chlorine-feeding machine shall be capable of delivering chlorine from a minimum of [_____] kg pounds to
a maximum of [_____] kg pounds in 24 hours and shall be capable of continuous operation at rated capacity.
2.2.2 Chlorinator Controls
Each chlorine-feeding machine shall be of the [fully automatic] [semiautomatic] [program control] [manually-adjusted]
type. [Fully automatic machines shall be capable of receiving standard 4-20 mA control signals.] [Fully automatic
controls shall consist of devices with accessories to adjust continuously the rate of chlorine feed automatically
in direct proportion to [flow] [and] [chlorine residual] [to compensate for changes in the chlorine demand] of
the [water] [or] [sewage] being chlorinated. The controls shall require no manual attention other than adjustment
of the required chlorine residual.] [Semiautomatic controls shall consist of devices with accessories to start
and stop the chlorine-feeding machine automatically with the starting and stopping of the [water] [or] [sewage]
being chlorinated or with a timer mechanism.] [Program control shall consist of a device with accessories to
change the chlorine feed rate of the machine automatically according to a predetermined cycle.] [Manual controls
shall consist of adjustment and indicating devices for regulating the chlorine dosage manually. Manually adjusted
types shall be capable of receiving standard 4-20 mA control signals by the addition of an automatic control
device.]
2.2.3 Cylinder Connections
Cylinder connections shall be provided for attaching standard chlorine cylinders to the chlorine-feeding machines.
Connections shall include flexible metal tubing, an auxiliary valve for each chlorine cylinder, a manifold for
connecting [_____] cylinders to each chlorine-feeding machine, and other necessary fittings, unless the machine
is direct cylinder-mounted.
2.2.4 Switchover Valves
Two or more mechanically operated or loss of chlorine supply-operated automatic gas switchover valves to automatically
regulate chlorine gas [pressure] [vacuum] shall be supplied and installed [in the gas header] [directly on the
chlorine cylinders]. The switchover valves shall be of suitable size and shall be equipped with filters [and
traps]. The switchover [pressure] [vacuum] shall be factory set.
2.2.5 Chlorine Pressure Gauges
Chlorine pressure gauges when supplied, shall be of the diaphragm type with the Bourdon tube and diaphragm compartments
filled completely with suitable oil. The gauge on the line from the chlorine tank shall be constructed to indicate
accurately the pressure of chlorine gas as supplied from the gas tank to the chlorine feeder.
2.2.6 Chlorine Pressure-Reducing Valves
Chlorine pressure-reducing valves shall function to reduce the pressure of the gas and maintain the pressure
constant for any given setting of rate of feed regardless of changes in the cylinder pressure.
2.2.7 Vacuum and Chlorine Relief
Vacuum and chlorine relief shall be provided to limit the vacuum within the chlorine-feeding machines and provide
for the release to a suitable vent to the outside atmosphere of any chlorine gas pressure build-up in the parts
of the machine, normally under vacuum, through improper functioning of the equipment. A vacuum sealing valve
which will seal off the system when excessive vacuum is present may be substituted for the vacuum relief valve.
2.2.8 Chlorine-Metering Devices
Chlorine-metering devices in sufficient number shall be furnished to cover properly the range specified. The
chlorine feed rate control system shall maintain the feed rate within 4 percent of the indicated rate.
2.2.9 Injectors
Injectors shall be provided with the chlorine-feeding machines to receive all chlorine and solution water and
to discharge the resulting solution to the points of application. The chlorine solution shall be introduced
into the [water] [or] [sewage] main by means [of a [ceramic] [hard rubber] [or] [plastic] injection nozzle] [of
a suitable diffuser tube inserted into the main through a corporation cock].
2.2.10 Alarm Actuators
Each chlorine-feeding machine shall be equipped with alarm actuators to indicate loss of vacuum and excess vacuum.
Alarm actuators shall be provided for low chlorine gas pressure and high chlorine gas pressure, unless the chlorine-feeding
machine is direct-cylinder mounted. [There shall also be a solution water low pressure alarm actuator.]
2.2.11 Pumps
A pump shall be provided for each chlorine-feeding machine when the minimum water pressure specified is below
that required for satisfactory operation of the machine. The pump shall be hydraulically operated or electric
motor-driven. The electric motor shall be rated for [_____] -volt, [_____] -phase, [_____] -Hz ac, and a maximum
speed of [_____] rpm. The pump shall be equipped with a suitable starter in accordance with the type of control
specified.
2.3 EVAPORATORS
NOTE: Delete this paragraph in its entirety for installations where chlorine
withdrawal rates will not exceed chlorine gasification rate.
Evaporators will be required whenever gas withdrawal rates would exceed the rate at which liquid chlorine gasifies
at the operating temperature. Evaporators shall be water immersed tank heat-exchanger type specifically designed
to evaporate liquid chlorine. The evaporators shall be complete with controls and devices for a complete operating
system including: Vaporizing chamber, electric water heaters, water temperature thermostat and indicator, high
and low water temperature alarm actuators, water-level gauge, automatic make-up water control system, low water
alarm actuator, chlorine gas temperature, and pressure gauges, [make-up water visual flow-indicator], ammonia-type
flanged connections for chlorine inlet and outlet, drain and vent line connections, and cathodic protection system
with ammeter. Parts subject to contact with chlorine shall be made of materials resistant to the action of chlorine
at pressure and concentrations that could be encountered. Construction shall be as simple as practicable to
provide reliable service and to be readily accessible for inspection, cleaning, adjustment, repair and replacement.
2.3.1 Capacity
Evaporators shall have a capacity to convert [_____] kg pounds per day of liquid chlorine into gaseous state.
2.3.2 Vaporizing Chamber
The vaporizing chamber shall be constructed of steel and shall be designed to conform to ASME BPVC SEC VIII D1
. The chamber shall be hydrostatically tested at 5.5 MPa 800 psig minimum. The gas chamber and water bath tank
shall be cathodically protected. The tank shall be galvanized to conform to ASTM A 153/A 153M and insulated.
2.3.3 Water Heaters
The water heaters shall be designed for operation on a 3-phase, 60-Hz current of the voltage indicated. A vapor-sealed
magnetic contactor shall be included for handling the current to the heaters. The holding coil shall be suitable
for single-phase, 60-Hz current.
2.3.4 Switchover System
A liquid chlorine automatic switchover system shall automatically change to a reserve supply when the on-line
liquid chlorine supply runs out.
2.3.5 Pressure-Relief System
Each evaporator shall also be equipped with a chlorine pressure relief system located downstream of the gas outlet.
The relief system shall have the following features:
a. Rupture disk with 1.7 MPa 250 psig minimum rating.
b. Pressure switch protected by a diaphragm seal and actuated at 137.9 kPa 20 psig.
c. Self-reseating pressure relief valve with manufacturer's standard pressure rating, set for a pressure
compatible with the respective rupture disk rating figure.
2.4 PIPING
2.4.1 Water Piping
Water piping shall be galvanized steel conforming to ASTM A 53/A 53M or copper tubing conforming to ASTM B 88M
ASTM B 88. Malleable-iron unions and fittings for installation of steel pipe shall conform to ASME B16.3.
2.4.2 Chlorine Piping
Chlorine solution piping smaller than 40 mm 1-1/2 inches in diameter shall be [PVC pipe conforming to ASTM D 1785
or CPVC pipe conforming to ASTM F 441/F 441M] [or] [rubber hose]. Piping of 40 mm 1-1/2 inches in diameter
or larger shall be [plastic pipe] [or] [rubber hose] [rubber-lined] [or] [plastic-lined] [steel pipe]. Linings
for steel pipe smaller than 150 mm 6 inches shall be not less than 3.2 mm 1/8 inch thick, and for steel pipe
larger than 150 mm 6 inches, it shall be not less than 4.8 mm 3/16 inch thick. Fittings for plastic pipe shall
be of plastic with [flanged] [or] [threaded] joints. Joints for rubber hose shall be made using a clamp-type
mechanical coupling. Steel pipe shall have [threaded] [or] [flanged integral with the pipe] [or] [forged-steel
flanges screwed to the pipe barrel]. Fittings for steel pipe shall be [flanged conforming to ASME B16.1 or ASME B16.5
] [or] [forged-steel threaded conforming to ASME B16.11].
2.4.2.1 Piping for Dry Chlorine
NOTE: Selection of chlorine-gas piping is dependent on the service for which
the system is designed. The designer must consult the Chlorine Manual and CI
Pamphlet 6, Piping Systems for Dry Chlorine for applicable piping system.
Piping for dry chlorine shall conform to CI Pamphlet 1 and CI Pamphlet 6. [Steel pipe 19 through 40 mm 3/4 through
1-1/2 inches in diameter shall conform to [ASTM A 106/A 106M, Schedule 80, Grade A or B] [or] [ASTM A 587].
Steel pipe over 40 mm 1-1/2 inches in diameter shall conform to ASTM A 53/A 53M, Schedule [40] [80], Grade [E]
[or] [S]. Fittings for steel pipe shall conform to CI Pamphlet 6]. [Copper tubing shall be seamless conforming
to ASTM B 88M ASTM B 88 in the annealed state with Type K wall thickness or heavier. Fittings for copper tubing
shall be in accordance with CI Pamphlet 6.] If moisture may be present, piping smaller than 40 mm 1-1/2 inches
in diameter shall be [polyvinylidene fluoride] [polyvinylidene fluoride lined steel pipe]; piping larger than
40 mm 1-1/2 inches in diameter shall be polyvinylidene fluoride lined steel pipe. Piping for dry or moist chlorine
gas under vacuum shall be chlorinated polyvinyl chloride.
2.4.2.2 Piping for Liquid Chlorine
Piping for liquid chlorine free of moisture shall be as specified for dry chlorine gas under pressure. Whenever
a portion of the liquid chlorine piping can be isolated between two closed valves, that portion shall be protected
with a liquid chlorine expansion chamber.
2.4.3 Cylinder Connections
Cylinder connections shall be flexible metal tubing of required size cadmium-plated copper. Flexible cylinder
connector assembly shall be installed with lead-gasketed, naval-bronze fittings.
2.5 ELECTRICAL WORK
Electric motor-driven equipment, and wiring shall be in accordance with Section 26 20 00 INTERIOR DISTRIBUTION
SYSTEM. Ratings shall be as indicated. Motor starters shall be provided complete with thermal-overload protection
and other appurtenances necessary for motor controls specified. Manual or automatic control and protective or
signal devices required for controls and devices shall be provided. All electrical connections at junction terminal
boxes and at contactor-starter unit enclosures shall be prewired.
2.6 FACTORY PAINTING
Factory painting shall conform to manufacturer's standard factory finish.
PART 3 EXECUTION
3.1 EXAMINATION
After becoming familiar with all details of work, verify all dimensions in the field, and advise the Contracting
Officer of any discrepancy before performing the work.
3.2 INSTALLATION
3.2.1 Chlorine-Feeding Equipment
The chlorine feeding machines, [the evaporators] and all equipment appurtenances shall be installed in accordance
with CI Pamphlet 1 and CI Pamphlet 6 so as to provide a complete and integrated system in accordance with the
instructions of the manufacturer [and under the direct supervision of the manufacturer's representative].
3.2.2 Pipe, Tubing, Hangers, and Supports
The installation of pipes and tubes shall be in accordance with Section 22 00 00 PLUMBING, GENERAL PURPOSE.
3.3 MANUFACTURER'S FIELD SERVICE
3.3.1 Manufacturer's Supervision
Provide the services of a manufacturer's representative who is experienced in the installation, adjustment, and
operation of the equipment specified. The representative shall supervise the installation, adjustment, and testing
of the equipment.
3.3.2 Field Training
Conduct a field training course for designated operating staff members. 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 final acceptance tests. Field training shall cover all of the items contained in the operating and
maintenance instructions.
3.4 FRAMED INSTRUCTIONS
Post framed operating instructions under glass or in laminated plastic, including wiring and control diagrams
showing the complete layout of the entire system, where directed. Condensed operating instructions explaining
preventive maintenance procedures, methods of checking the system for normal safe operation, and procedures for
safely starting and stopping the system shall be prepared in typed form, framed as specified and posted beside
the diagrams. The framed instructions shall be posted before acceptance testing of the systems.
3.5 TESTING
After installation of the chlorine-feeding machine [and evaporators] is complete, operating tests shall be carried
out to assure that the chlorine-feeding installation operates properly. All piping shall be tested hydrostatically
and for leaks. If any deficiencies are revealed during any tests, such deficiencies shall be corrected and the
tests shall be reconducted.
3.6 FIELD PAINTING
Equipment which did not receive a factory finish shall be painted as specified in Section 09 90 00 PAINTS AND
COATINGS. Factory painted items requiring touching up in the field, shall be thoroughly cleaned of all foreign
material and shall be primed and topcoated with the manufacturer's standard factory finish provided it does not
discolor in the presence of hydrogen sulfide fumes, high water vapor atmosphere, alkaline water vapor, and concentrated
chlorine (oxidizing) conditions. Coating shall be not less than 0.05 mm 1.78 mils thick.