232300_-_Refrigerant_Piping_0005.pdf

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REFRIGERANT PIPING

MAMMOTH CAVE NATIONAL PARK

MACA 258051

SECTION 232300 - REFRIGERANT PIPING

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Copper tube and fittings.

2. Valves and specialties.

3. Refrigerants.

1.2 ACTION SUBMITTALS

A. Product data: For the following:

1. Solenoid valves.

2. Thermostatic expansion valves.

3. Strainers.

4. Filter dryers.

5. Pressure-regulating valves.

B. Product Data Submittals: For each product.

1. Submit data for each type of refrigerant piping, fitting, valve, piping specialty, and refrigerant.

C. Delegated Design Submittals: For refrigerant piping size and layout, including oil traps, double risers, specialties, and pipe and tube sizes to accommodate, as a minimum, equipment provided, elevation difference between compressor and evaporator, and length of piping to ensure proper operation and compliance with warranties of connected equipment.

D. Shop Drawings:

1. Show piping size and piping layout, including oil traps, double risers, specialties, and pipe and tube sizes to accommodate, as a minimum, equipment provided, elevation difference between compressor and evaporator, and length of piping to ensure proper operation and compliance with warranties of connected equipment.

2. Show interface and spatial relationships between piping and equipment.

3. Shop Drawing Scale: 1/4 inch equals 1 foot (1:50).

1.3 INFORMATIONAL SUBMITTALS

A. Welding Certificates: For each welder performing shop or field welding on Project.

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B. Field Quality-Control Reports: For each field quality control test and inspection.

1.4 CLOSEOUT SUBMITTALS

A. Operation and maintenance data.

1.5 QUALITY ASSURANCE

A. Welding Qualifications: Qualify procedures and personnel according to ASME Boiler and

Pressure Vessel Code: Section IX, "Welding, Brazing, and Fusing Qualifications."

PART 2 - PRODUCTS

2.1 PERFORMANCE REQUIREMENTS

A. Physical: None

B. Functional: None

C. Performance:

1. Delegated Design: Engage a qualified professional engineer, as defined in

Section 014000 "Quality Requirements," for refrigerant piping size and layout, including oil traps, double risers, specialties, and pipe and tube sizes to accommodate, as a minimum, equipment provided, elevation difference between compressor and evaporator, and length of piping to ensure proper operation and compliance with warranties of connected equipment.

2. Comply with ASHRAE 15.

3. Comply with ASME B31.5.

4. Line Test Pressure for Refrigerant R-410A, R-32, or R-454B:

a. Suction Lines for Refrigeration and Air-Conditioning Applications Other than

Heat Pumps: 300 psig (2068 kPa).

b. Suction Lines for Heat-Pump Applications: 535 psig (3689 kPa).

c. Hot-Gas and Liquid Lines: 535 psig (3689 kPa).

2.2 COPPER TUBE AND FITTINGS

A. Physical: None

B. Functional:

1. Copper Tube: ASTM B280, Type ACR.

2. Wrought-Copper Fittings, Solder Joint: ASME B16.22.

3. Wrought-Copper Fittings, Brazed Joint: ASME B16.50.

4. Wrought-Copper Unions: ASME B16.22.

5. Solder Filler Metals: ASTM B32. Use 95-5 tin antimony or alloy HB solder to join copper socket fittings on copper pipe.

6. Brazing Filler Metals: AWS A5.8M/A5.8.

7. Flexible Connectors:

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a. Body: Tin-bronze bellows with woven, flexible, tinned-bronze-wire-reinforced protective jacket.

b. End Connections: Socket ends.

c. Offset Performance: Capable of minimum 3/4-inch (20-mm) misalignment in minimum 7-inch- (180-mm-) long assembly.

d. Working Pressure Rating: Factory test at minimum 500 psig (3450 kPa).

e. Maximum Operating Temperature: 250 deg F (121 deg C).

8. Copper-Tube, Pressure-Seal-Joint Fittings for Refrigerant Piping:

a. Standard: UL 207; certified by UL for field installation. Certification as a UL-recognized component alone is unacceptable.

b. Housing: Copper.

c. O-Rings: HNBR compatible with specific refrigerant.

d. Tools: Manufacturer's approved special tools.

e. Minimum Rated Pressure: 700 psig (48 bar).

C. Performance: None

2.3 VALVES AND SPECIALTIES

A. Diaphragm Packless Valves:

1. Body and Bonnet: Forged brass or cast bronze; globe design with straight-through or angle pattern.

2. Diaphragm: Phosphor bronze and stainless steel with stainless steel spring.

3. Operator: Rising stem and hand wheel.

4. Seat: Nylon.

5. End Connections: Socket, union, or flanged.

6. Working Pressure Rating: 500 psig (3450 kPa).

7. Maximum Operating Temperature: 240 deg F (116 deg C).

B. Packed-Angle Valves:

1. Body and Bonnet: Forged brass or cast bronze.

2. Packing: Molded stem, back seating, and replaceable under pressure.

3. Operator: Rising stem.

4. Seat: Nonrotating, self-aligning polytetrafluoroethylene.

5. Seal Cap: Forged-brass or valox hex cap.

6. End Connections: Socket, union, threaded, or flanged.

7. Working Pressure Rating: 500 psig (3450 kPa).

8. Maximum Operating Temperature: 275 deg F (135 deg C).

C. Check Valves:

1. Body: Ductile iron, forged brass, or cast bronze; globe pattern.

2. Bonnet: Bolted ductile iron, forged brass, or cast bronze; or brass hex plug.

3. Piston: Removable polytetrafluoroethylene seat.

4. Closing Spring: Stainless steel.

5. Manual Opening Stem: Seal cap, plated-steel stem, and graphite seal.

6. End Connections: Socket, union, threaded, or flanged.

7. Maximum Opening Pressure: 0.50 psig (3.4 kPa).

8. Working Pressure Rating: 500 psig (3450 kPa).

9. Maximum Operating Temperature: 275 deg F (135 deg C).

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D. Service Valves:

1. Body: Forged brass with brass cap, including key end to remove core.

2. Core: Removable ball-type check valve with stainless steel spring.

3. Seat: Polytetrafluoroethylene.

4. End Connections: Copper spring.

5. Working Pressure Rating: 500 psig (3450 kPa).

6. Maximum Operating Temperature: 275 deg F (135 deg C).

E. Refrigerant Locking Caps:

1. Description: Locking-type, tamper-resistant, threaded caps to protect refrigerant-charging ports from unauthorized refrigerant access and leakage.

2. Material: Brass, with protective shroud or sleeve.

3. Refrigerant Identification: Universal design.

4. Special Tool: For installing and unlocking.

F. Solenoid Valves: Comply with AHRI 760 I-P (AHRI 761 SI) and UL 429; listed and labeled by an NRTL.

1. Body and Bonnet: Plated steel.

2. Solenoid Tube, Plunger, Closing Spring, and Seat Orifice: Stainless steel.

3. Seat: Polytetrafluoroethylene.

4. End Connections: Threaded.

5. Electrical: Molded, watertight coil in NEMA 250 enclosure of type required by location with 1/2-inch (16-mm) conduit adapter, and 24 V ac coil.

6. Working Pressure Rating: 400 psig (2760 kPa).

7. Maximum Operating Temperature: 240 deg F (116 deg C).

G. Safety Relief Valves: Comply with ASME Boiler and Pressure Vessel Code; listed and labeled by an NRTL.

1. Body and Bonnet: Ductile iron and steel, with neoprene O-ring seal.

2. Piston, Closing Spring, and Seat Insert: Stainless steel.

3. Seat: Polytetrafluoroethylene.

4. End Connections: Threaded.

5. Working Pressure Rating: 400 psig (2760 kPa).

6. Maximum Operating Temperature: 240 deg F (116 deg C).

H. Thermostatic Expansion Valves: Comply with AHRI 750 I-P (AHRI 751 SI).

1. Body, Bonnet, and Seal Cap: Forged brass or steel.

2. Diaphragm, Piston, Closing Spring, and Seat Insert: Stainless steel.

3. Packing and Gaskets: Non-asbestos.

4. Capillary and Bulb: Copper tubing filled with refrigerant charge.

5. Suction Temperature: 40 deg F (4.4 deg C).

6. Superheat: Adjustable.

7. Reverse-flow option (for heat-pump applications).

8. End Connections: Socket, flare, or threaded union.

9. Working Pressure Rating: 700 psig (4820 kPa).

I. Straight-Type Strainers:

1. Body: Welded steel with corrosion-resistant coating.

2. Screen: 100-mesh stainless steel.

3. End Connections: Socket or flare.

4. Working Pressure Rating: 500 psig (3450 kPa).

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5. Maximum Operating Temperature: 275 deg F (135 deg C).

J. Angle-Type Strainers:

1. Body: Forged brass or cast bronze.

2. Drain Plug: Brass hex plug.

3. Screen: 100-mesh monel.

4. End Connections: Socket or flare.

5. Working Pressure Rating: 500 psig (3450 kPa).

6. Maximum Operating Temperature: 275 deg F (135 deg C).

K. Moisture/Liquid Indicators:

1. Body: Forged brass.

2. Window: Replaceable, clear, fused glass window with indicating element protected by filter screen.

3. Indicator: Color-coded to show moisture content in parts per million (ppm).

4. Minimum Moisture Indicator Sensitivity: Indicate moisture above 60 ppm.

5. End Connections: Socket or flare.

6. Working Pressure Rating: 500 psig (3450 kPa).

7. Maximum Operating Temperature: 240 deg F (116 deg C).

L. Replaceable-Core Filter Dryers: Comply with AHRI 730 I-P (AHRI 731 SI).

1. Body and Cover: Painted-steel shell with ductile-iron cover, stainless steel screws, and neoprene gaskets.

2. Filter Media: 10 micron, pleated with integral end rings; stainless steel support.

3. Desiccant Media: Activated alumina.

4. Design: Reverse flow (for heat-pump applications).

5. End Connections: Socket.

6. Access Ports: NPS 1/4 (DN 8) connections at entering and leaving sides for pressure differential measurement.

7. Maximum Pressure Loss: 2 psig (14 kPa).

8. Working Pressure Rating: 500 psig (3450 kPa).

9. Maximum Operating Temperature: 240 deg F (116 deg C).

M. Permanent Filter Dryers: Comply with AHRI 730 I-P (AHRI 731 SI).

1. Body and Cover: Painted-steel shell.

2. Filter Media: 10 micron, pleated with integral end rings; stainless steel support.

3. Desiccant Media: Activated alumina.

4. Design: Reverse flow (for heat-pump applications).

5. End Connections: Socket.

6. Access Ports: NPS 1/4 (DN 8) connections at entering and leaving sides for pressure differential measurement.

7. Maximum Pressure Loss: 2 psig (14 kPa).

8. Working Pressure Rating: 500 psig (3450 kPa).

9. Maximum Operating Temperature: 240 deg F (116 deg C).

2.4 REFRIGERANTS

A. R-410A, ASHRAE 34: Pentafluoroethane/Difluoromethane.

B. R-32, ASHRAE 34: Difluoromethane.

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C. R-454B, ASHRAE 34: R-32 (68.9 percent by mass) and R-1234yf (31.1 percent by mass).

PART 3 - EXECUTION

3.1 PIPING APPLICATION SCHEDULES R-410A, R-32, AND/OR R-454B

A. Suction, Hot-Gas, and Liquid Tubing for Heat-Pump Applications, NPS 1-1/2 (DN 40) and

Smaller: Copper, Type ACR, annealed-temper tubing and wrought-copper fittings with brazed or soldered joints.

B. Safety-Relief-Valve Discharge Tubing for Heat-Pump Applications, Copper: Type ACR tubing and wrought-copper fittings with brazed or soldered joints.

3.2 VALVE AND SPECIALTY APPLICATIONS

A. Install diaphragm packless valves in suction and discharge lines of compressor.

B. Install service valves for gauge taps at inlet and outlet of hot-gas bypass valves and strainers if they are not an integral part of valves and strainers.

C. Install a check valve at the compressor discharge and a liquid accumulator at the compressor suction connection.

D. Except as otherwise indicated, install diaphragm packless valves on inlet and outlet side of filter dryers.

E. Install a full-size, three-valve bypass around filter dryers.

F. Install solenoid valves upstream from each expansion valve and hot-gas bypass valve. Install solenoid valves in horizontal lines with coil at top.

G. Install thermostatic expansion valves as close as possible to distributors on evaporators.

1. Install valve so diaphragm case is warmer than bulb.

2. Secure bulb to clean, straight, horizontal section of suction line using two bulb straps. Do not mount bulb in a trap or at bottom of the line.

3. If external equalizer lines are required, make connection where it will reflect suction-line pressure at bulb location.

H. Install safety-relief valves where required by ASME Boiler and Pressure Vessel Code. Pipe safety-relief-valve discharge line to outside in accordance with ASHRAE 15.

I. Install moisture/liquid indicators in liquid line at the inlet of the thermostatic expansion valve or at the inlet of the evaporator coil capillary tube.

J. Install strainers upstream from and adjacent to the following unless they are furnished as an integral assembly for the device being protected:

1. Solenoid valves.

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2. Thermostatic expansion valves.

3. Compressor.

K. Install filter dryers in liquid line between compressor and thermostatic expansion valve.

L. Install flexible connectors at compressors.

M. Provide refrigerant locking caps on refrigerant charging ports that are located outdoors unless otherwise protected from unauthorized access by a means acceptable to authority having jurisdiction.

3.3 INSTALLATION OF PIPING, GENERAL

A. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems; indicated locations and arrangements were used to size pipe and calculate friction loss, expansion, pump sizing, and other design considerations. Install piping as indicated unless deviations to layout are approved on Shop Drawings.

B. Install refrigerant piping in accordance with ASHRAE 15.

C. Install piping in concealed locations unless otherwise indicated and except in equipment rooms and service areas.

D. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise.

E. Install piping above accessible ceilings to allow sufficient space for ceiling panel removal.

F. Install piping adjacent to machines to allow service and maintenance.

G. Install piping free of sags and bends.

H. Install fittings for changes in direction and branch connections.

I. Select system components with pressure rating equal to or greater than system operating pressure.

J. Refer to Section 230923 "Direct Digital Control (DDC) System for HVAC" and

Section 230993.11 "Sequence of Operations for HVAC DDC" for solenoid valve controllers, control wiring, and sequence of operation.

K. Install piping as short and direct as possible, with a minimum number of joints, elbows, and fittings.

L. Arrange piping to allow inspection and service of refrigeration equipment. Install valves and specialties in accessible locations to allow for service and inspection. Install access doors or panels as specified in Section 083113 "Access Doors and Frames" if valves or equipment requiring maintenance is concealed behind finished surfaces.

M. Install refrigerant piping in protective conduit where installed belowground.

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N. Install refrigerant piping in rigid or flexible conduit in locations where exposed to mechanical injury.

O. Slope refrigerant piping as follows:

1. Install horizontal hot-gas discharge piping with a uniform slope downward away from compressor.

2. Install horizontal suction lines with a uniform slope downward to compressor.

3. Install traps and double risers to entrain oil in vertical runs.

4. Liquid lines may be installed level.

P. When brazing or soldering, remove solenoid-valve coils and sight glasses; also remove valve stems, seats, packing, and accessible internal parts of refrigerant specialties. Do not apply heat near expansion-valve bulb.

Q. Install piping with adequate clearance between pipe and adjacent walls and hangers or between pipes for insulation installation.

R. Identify refrigerant piping and valves in accordance with Section 230553 "Identification for

HVAC Piping and Equipment."

S. Install sleeves for piping penetrations of walls, ceilings, and floors. Comply with requirements for sleeves specified in Section 230517 "Sleeves and Sleeve Seals for HVAC Piping."

T. Install escutcheons for piping penetrations of walls, ceilings, and floors. Comply with requirements for escutcheons specified in Section 230518 "Escutcheons for HVAC Piping."

3.4 PIPE JOINT CONSTRUCTION

A. Ream ends of pipes and tubes and remove burrs.

B. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly.

C. Soldered Joints: Construct joints in accordance with ASTM B828 or CDA's "Copper Tube

Handbook."

D. Brazed Joints: Construct joints in accordance with AWS BRH, "Brazing Handbook," Ch. 35, "Pipe and Tubing."

1. Use Type BCuP (copper-phosphorus) alloy for joining copper socket fittings with copper pipe.

2. Use Type BAg (cadmium-free silver) alloy for joining copper with bronze or steel.

E. Threaded Joints: Thread steel pipe with tapered pipe threads in accordance with ASME B1.20.1.

Cut threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and to restore full ID. Join pipe fittings and valves as follows:

1. Apply appropriate tape or thread compound to external pipe threads unless dry-seal threading is specified.

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2. Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or damaged. Do not use pipe sections that have cracked or open welds.

3.5 INSTALLATION OF HANGERS AND SUPPORTS

A. Comply with Section 230529 "Hangers and Supports for HVAC Piping and Equipment" for hangers, supports, and anchor devices.

B. Install the following pipe attachments:

1. Adjustable steel clevis hangers for individual horizontal runs less than 20 ft. (6 m) long.

2. Roller hangers and spring hangers for individual horizontal runs 20 ft. (6 m) or longer.

3. Pipe Roller: MSS SP-58, Type 44 for multiple horizontal piping 20 ft. (6 m) or longer, supported on a trapeze.

4. Spring hangers to support vertical runs.

5. Copper-clad hangers and supports for hangers and supports in direct contact with copper pipe.

C. Install hangers for copper tubing with maximum horizontal spacing and minimum rod diameters, to comply with MSS SP-58, locally enforced codes, and authorities having jurisdiction requirements, whichever are most stringent.

D. Support horizontal piping within 12 inches (300 mm) of each fitting.

E. Support vertical runs of copper tubing to comply with MSS SP-58, locally enforced codes, and authorities having jurisdiction requirements, whichever are most stringent.

3.6 FIELD QUALITY CONTROL

A. Testing Agency: Engage a qualified testing agency to perform tests and inspections.

B. Tests and Inspections:

1. Comply with ASME B31.5, Chapter VI.

2. Test refrigerant piping, specialties, and receivers. Isolate compressor, condenser, evaporator, and safety devices from test pressure if they are not rated above the test pressure.

3. Test high- and low-pressure side piping of each system separately at not less than the pressures indicated in "Performance Requirements" Article.

a. Fill system with nitrogen to the required test pressure.

b. System must maintain test pressure at the manifold gauge throughout duration of test.

c. Test joints and fittings with electronic leak detector or by brushing a small amount of soap and glycerin solution over joints.

d. Remake leaking joints using new materials, and retest until satisfactory results are achieved.

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C. Prepare test and inspection reports.

3.7 SYSTEM CHARGING

A. Charge system using the following procedures:

1. Install core in filter dryers after leak test but before evacuation.

2. Evacuate entire refrigerant system with a vacuum pump to 500 micrometers (67 Pa). If vacuum holds for 12 hours, system is ready for charging.

3. Break vacuum with refrigerant gas, allowing pressure to build up to 2 psig (14 kPa).

4. Charge system with a new filter-dryer core in charging line.

3.8 ADJUSTING

A. Adjust thermostatic expansion valve to obtain proper evaporator superheat.

B. Adjust high- and low-pressure switch settings to avoid short cycling in response to fluctuating suction pressure.

C. Adjust set-point temperature of air-conditioning or chilled-water controllers to the system design temperature.

D. Perform the following adjustments before operating the refrigeration system, according to manufacturer's written instructions:

1. Open shutoff valves in condenser water circuit.

2. Verify that compressor oil level is correct.

3. Open compressor suction and discharge valves.

4. Open refrigerant valves but not bypass valves that are used for other purposes.

5. Check open compressor-motor alignment and verify lubrication for motors and bearings.

E. Replace core of replaceable filter dryer after system has been adjusted and after design flow rates and pressures are established.

END OF SECTION 232300