232300_refrigerant_piping.pdf

CHICOPEE ARMORY REHABILITATION MMD PROJECT NO. 985101

CHICOPEE, MASSACHUSETTS ISSUED FOR BID - 05/20/11

10090 REFRIGERANT PIPING 232300-1

SECTION 232300

REFRIGERANT PIPING

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary

Conditions and Division 1 Specification Sections, apply to this Section.

B. The requirements of Section 230100, “Basic Mechanical Requirements” apply to work defined by this Section.

C. The requirements of Section 230500, “Basic Mechanical Materials and Methods” apply to work defined by the Section.

1.2 SUMMARY

A. This Section includes refrigerant piping used for air-conditioning applications.

B. Related Sections include the following:

1. Division 7, Section 078413 "Through-Penetration Firestop Systems" for materials and methods for sealing pipe penetrations through fire and smoke barriers.

2. Division 7, Section 079200 "Joint Sealants" for materials and methods for sealing pipe penetrations through exterior walls.

3. Division 23 Section "Hangers and Supports" for pipe supports and installation requirements.

4. Division 23 Section "Mechanical Identification" for labeling and identifying refrigerant piping.

5. Division 23 Section "Meters and Gages" for thermometers and pressure gages.

6. Division 23 Section "HVAC Instrumentation and Controls" for thermostats, controllers, automatic-control valves, and sensors.

1.3 SUBMITTALS

A. Product Data: For each type of valve and refrigerant piping specialty indicated. Include pressure drop, based on manufacturer's test data, for thermostatic expansion valves, solenoid valves, and pressure-regulating valves.

B. Shop Drawings: Show layout of refrigerant piping and specialties, including pipe, tube, and fitting sizes, flow capacities, valve arrangements and locations, slopes of horizontal runs, oil traps, double risers, wall and floor penetrations, and equipment connection details. Show interface and spatial relationship between piping and equipment.

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1. Refrigerant piping indicated is schematic only. Size piping and design the actual piping layout, including oil traps, double risers, specialties, and pipe and tube sizes, to ensure proper operation and compliance with warranties of connected equipment.

C. Welding Certificates: Copies of certificates for welding procedures and personnel.

D. Field Test Reports: Indicate and interpret test results for compliance with performance requirements.

E. Maintenance Data: For refrigerant valves and piping specialties to include in maintenance manuals specified in Division 1.

1.4 QUALITY ASSURANCE

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

Code: Section IX; "Welding and Brazing Qualifications."

B. ASHRAE Standard: Comply with ASHRAE 15, "Safety Code for Mechanical

Refrigeration."

C. ASME Standard: Comply with ASME B31.5, "Refrigeration Piping."

D. UL Standard: Provide products complying with UL 207, "Refrigerant-Containing

Components and Accessories, Nonelectrical"; or UL 429, "Electrically Operated Valves."

1.5 COORDINATION

A. Coordinate layout and installation of refrigerant piping and suspension system components with other construction, including light fixtures, HVAC equipment, fire-suppression-system components, and partition assemblies.

B. Coordinate pipe sleeve installations for foundation wall penetrations.

C. Coordinate installation of roof curbs, equipment supports, and roof penetrations. These items are specified in Division 7 Section "Roof Accessories."

D. Coordinate pipe sleeve installations for penetrations in exterior walls and floor assemblies.

Coordinate with requirements for firestopping specified in Division 7 Section "Through-

Penetration Firestop Systems" for materials and methods for sealing pipe penetrations through fire and smoke barriers.

E. Coordinate pipe fitting pressure classes with products specified in related Sections.

1.6 EXTRA MATERIALS

A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents.

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1. Refrigeration Oil Test Kits: Two each, containing everything required to conduct one test.

2. Refrigerant: Two containers each, with 20 lb of refrigerant.

3. Filter-Dryer Cartridges: Three of each type.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

B. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

1. Refrigerants:

a. Allied Signal, Inc./Fluorine Products; Genetron Refrigerants.

b. DuPont Company; Fluorochemicals Div.

c. Elf Atochem North America, Inc.; Fluorocarbon Div.

d. ICI Americas Inc./ICI KLEA; Fluorochemicals Bus.

2. Refrigerant Valves and Specialties:

a. Climate & Industrial Controls Group; Parker-Hannifin Corp.; Refrigeration & Air

Conditioning Division.

b. Danfoss Electronics, Inc.

c. Emerson Electric Company; Alco Controls Div.

d. Henry Valve Company.

e. Sporlan Valve Company.

2.2 COPPER TUBE AND FITTINGS

A. Drawn-Temper Copper Tube: ASTM B 280, Type ACR .

B. Annealed-Temper Copper Tube: ASTM B 280, Type ACR .

C. Wrought-Copper Fittings: ASME B16.22.

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

E. Brazing Filler Metals: AWS A5.8/A5.8M, Classification BAg-1 (silver)

F. Flexible Connectors: 500-psig (3450-kPa) minimum operating pressure; seamless tin-bronze core, high-tensile bronze-braid covering, and solder-joint end connections; dehydrated, pressure tested, minimum 7 inches long http://www.specagent.com/LookUp/?ulid=3417&mf=04&src=wd http://www.specagent.com/LookUp/?uid=123456823994&mf=04&src=wd

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2.3 STEEL PIPE AND FITTINGS

A. Steel Pipe: ASTM A 53/A 53M, Schedule 40, seamless black steel.

B. Wrought-Steel Fittings: ASTM A 234/A 234M, for welded joints.

C. Steel Flanges and Flanged Fittings: ASME B16.5, steel, including bolts, nuts, and gaskets, butt-welded end connection, and raised face.

D. Flanged Unions: 400-psig working pressure, 330 deg F maximum operating temperature; 2 brass tailpiece adapters for solder-end connections to copper tubing; forged-steel flanges for

NPS 1 to NPS 1-1/2 and ductile iron for NPS 2 to NPS 3 with 4 plated-steel bolts, with silicon bronze nuts and fiber gasket; and having factory-applied, rust-resistant coating on flanges and bolts.

E. Flexible connectors: 500-psig minimum operating pressure; stainless-steel core and high-tensile stainless-steel-braid covering; dehydrated, pressure tested, minimum 7 inches long.

1. NPS 2 (DN 50) and Smaller: With thread-end connections.

2. NPS 2-1/2 (DN 65) and Larger: With flanged-end connections.

2.4 VALVES

A. Diaphragm Packless Valves: 500-psig working pressure and 275 deg F working temperature; globe design with straight-through or angle pattern; forged-brass or bronze body and bonnet, phosphor bronze and stainless-steel diaphragms, rising stem and handwheel, stainless-steel spring, nylon seat disc, and with solder-end connections.

B. Packed-Angle Valves: 500-psig working pressure and 275 deg F working temperature;

forged-brass or bronze body, forged-brass seal caps with copper gasket, back seating, rising stem and seat, molded stem packing, and with solder-end connections.

C. Check Valves Smaller Than NPS 1: 400-psig operating pressure and 285 deg F operating temperature; cast-brass body, with removable piston, polytetrafluoroethylene seat, and stainless-steel spring; globe design. Valve shall be straight-through pattern, with solder-end connections.

D. Check Valves, NPS 1 and Larger: 400-psig operating pressure and 285 deg F operating temperature; cast-bronze body, with cast-bronze or forged-brass bolted bonnet; floating piston with mechanically retained polytetrafluoroethylene seat disc. Valve shall be straight-through or angle pattern, with solder-end connections.

E. Service Valves: 500-psig pressure rating; forged-brass body with copper stubs, brass caps, removable valve core, integral ball check valve, and with solder-end connections.

F. Solenoid Valves: Comply with ARI 760 and UL 429; 250 deg F temperature rating and 400-psig working pressure; forged brass, with polytetrafluoroethylene valve seat, 2-way, straight-through pattern, and solder-end connections; manual operator; fitted with suitable

NEMA 250 enclosure of type required by location, with 1/2-inch conduit adapter and [24]

[120]-V, normally [closed] [open] holding coil.

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G. Pressure-Regulating Valves: Comply with ARI 770; direct acting, brass; with pilot operator, stainless-steel diaphragm, standard coil, and solder-end connection; suitable for refrigerant specified.

H. Pressure Relief Valves: Straight-through or angle pattern, brass body and disc, neoprene seat, and factory sealed and ASME labeled for standard pressure setting.

I. Thermostatic Expansion Valves: Comply with ARI 750; brass body with stainless-steel parts; thermostatic-adjustable, modulating type; size and operating characteristics as recommended by manufacturer of evaporator, and factory set for superheat requirements;

solder-end connections; with sensing bulb, distributor having side connection for hot-gas bypass line, and external equalizer line.

2.5 REFRIGERANT PIPING SPECIALITIES

A. Straight- or Angle-Type Strainers: 500-psig working pressure; forged-brass or steel body with stainless-steel wire or brass-reinforced Monel screen of 80 to 100 mesh in liquid lines up to 1-1/8 inches, 60 mesh in larger liquid lines, and 40 mesh in suction lines; with screwed cleanout plug and solder-end connections.

B. Moisture/Liquid Indicators: 500-psig maximum working pressure and 200 deg F operating temperature; all-brass body with replaceable, polished, optical viewing window with color-coded moisture indicator; with solder-end connections.

C. Replaceable-Core Filter-Dryers: 500-psig maximum working pressure; heavy gage protected with corrosion-resistant-painted steel shell, flanged ring and spring, ductile-iron cover plate with steel cap screws; wrought-copper fittings for solder-end connections; with replaceable-core kit, including gaskets and the following:

1. Filter Cartridge: Pleated media with integral end rings, stainless-steel support, ARI 730 rated for capacity.

2. Filter-Dryer Cartridge: Pleated media with solid-core sieve with activated alumina, ARI 730 rated for capacity.

3. Wax Removal Cartridge: Molded, bonded core of activated charcoal and desiccant with integral gaskets.

D. Permanent Filter-Dryer: 350-psig maximum operating pressure and 225 deg F maximum operating temperature; Comply with ARI 730; steel shell and wrought-copper fittings for solder-end connections; molded-felt core surrounded by desiccant.

2.6 RECEIVERS

A. Receivers, 6-Inch Diameter and Smaller: ARI 495, UL listed, steel, brazed, 400-psig pressure rating, with tappings for inlet, outlet, and pressure relief valve.

2.7 REFRIGERANTS

A.

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

PART 3 - EXECUTION

3.1 PIPING APPLICATIONS

A. Aboveground, within Building: Type ACR drawn-copper tubing [Steel pipe].

B. Belowground for NPS 2 and Smaller: Type L annealed-copper tubing.

3.2 VALVE APPLICATIONS

A. Install diaphragm packless or packed-angle valves in suction and discharge lines of compressor, for gage taps at hot-gas bypass regulators, on each side of strainers.

B. Install check valves in compressor discharge lines and in condenser liquid lines on multiple condenser systems.

C. Install packed-angle valve in liquid line between receiver shutoff valve and thermostatic expansion valve for system charging.

D. Install diaphragm packless or packed-angle valves on each side of strainers and dryers, in liquid and suction lines at evaporators, and elsewhere as indicated.

E. Install a full-sized, three-valve bypass around each dryer.

F. Install solenoid valves upstream from each expansion valve and hot-gas bypass valve.

1. Install solenoid valves in horizontal lines with coil at top.

2. Electrical wiring for solenoid valves is specified in Division 26 Sections. Coordinate electrical requirements and connections.

G. Install thermostatic expansion valves as close as possible to evaporator.

1. If refrigerant distributors are used, install them directly on expansion-valve outlet.

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

3. 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.

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

H. Install pressure regulating and pressure relief valves as required by ASHRAE 15. Pipe pressure relief valve discharge to outside.

3.3 SPECIALTY APPLICATIONS

A. Install liquid indicators in liquid line leaving condenser, in liquid line leaving receiver, and on leaving side of liquid solenoid valves.

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B. Install strainers immediately upstream from each automatic valve, including expansion valves, solenoid valves, hot-gas bypass valves, and compressor suction valves.

C. Install strainers in main liquid line where multiple expansion valves with integral strainers are used.

D. Install strainers in suction line of steel pipe.

E. Install moisture-liquid indicators in liquid lines between filter-dryers and thermostatic expansion valves and in liquid line to receiver.

F. Install pressure relief valves on ASME receivers; pipe discharge to outdoors.

G. Install replaceable-core filter-dryers in vertical liquid line adjacent to receivers and before each solenoid valve.

H. Install permanent filter-dryers in low-temperature systems, in systems using hermetic compressors, and before each solenoid valve.

I. Install solenoid valves in liquid line of systems operating with single pump-out or pump-down compressor control, in liquid line of single or multiple evaporator systems, and in oil bleeder lines from flooded evaporators to stop flow of oil and refrigerant into suction line when system shuts down.

J. Install receivers, sized to accommodate pump-down charge, on systems 5 tons and larger and on systems with long piping runs.

K. Install flexible connectors at or near compressors.

3.4 PIPING INSTALLATION

A. Install refrigerant piping according to ASHRAE 15.

B. Basic piping installation requirements are specified in Division 23 Section "Basic

Mechanical Materials and Methods."

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

D. Arrange piping to allow inspection and service of compressor and other equipment. Install valves and specialties in accessible locations to allow for service and inspection.

E. Install piping with adequate clearance between pipe and adjacent walls and hangers or between pipes for insulation installation. Use sleeves through floors, walls, or ceilings, sized to permit installation of full-thickness insulation.

F. Belowground, install copper tubing in protective conduit. Vent conduit outdoors.

G. Install copper tubing in rigid or flexible conduit in locations where copper tubing will be exposed to mechanical injury.

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H. 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.

I. Install bypass around moisture-liquid indicators in lines larger than NPS 2.

J. Install unions to allow removal of solenoid valves, pressure-regulating valves, and expansion valves and at connections to compressors and evaporators.

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

L. Hanger, support, and anchor products are specified in Division 23 Section "Hangers and

Supports."

M. Install the following pipe attachments:

1. Adjustable steel clevis hangers for individual horizontal runs less than 20 feet long.

2. Roller hangers and spring hangers for individual horizontal runs 20 feet or longer.

3. Pipe rollers for multiple horizontal runs 20 feet or longer, supported by a trapeze.

4. Spring hangers to support vertical runs.

N. Install hangers for copper tubing with the following maximum spacing and minimum rod sizes:

1. NPS 1/2: Maximum span, 60 inches; minimum rod size, 1/4 inch.

2. NPS 5/8: Maximum span, 60 inches; minimum rod size, 1/4 inch.

3. NPS 1: Maximum span, 72 inches; minimum rod size, 1/4 inch.

O. Install hangers for steel piping with the following maximum spacing and minimum rod sizes:

1. NPS 1/2: Maximum span, 84 inches; minimum rod size, 1/4 inch.

2. NPS 3/4: Maximum span, 84 inches; minimum rod size, 1/4 inch.

3. NPS 1: Maximum span, 84 inches; minimum rod size, 1/4 inch.

P. Support vertical runs at each floor.

3.5 PIPE JOINT CONSTRUCTION

A. Braze joints according to Division 23 Section "Basic Mechanical Materials and Methods."

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B. Fill pipe and fittings with an inert gas (nitrogen or carbon dioxide) during brazing to prevent scale formation.

3.6 FIELD QUALITY CONTROL

A. Test and inspect refrigerant piping according to ASME B31.5, Chapter VI.

1. Test refrigerant piping, specialties, and receivers. Isolate compressor, condenser, evaporator, and safety devices from test pressure.

2. Test high- and low-pressure side piping of each system at not less than the lower of the design pressure or the setting of pressure relief device protecting high and low side of system.

a. System shall maintain test pressure at the manifold gage throughout duration of test.

b. Test joints and fittings by brushing a small amount of soap and glycerine solution over joint.

c. Fill system with nitrogen to raise a test pressure of 150 psig or higher as required by authorities having jurisdiction.

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

3.7 ADJUSTING

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

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

C. Adjust set-point temperature of the conditioned air 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. Check compressor oil level above center of sight glass.

3. Open compressor suction and discharge valves.

4. Open refrigerant valves, except bypass valves that are used for other purposes.

5. Check compressor-motor alignment, and lubricate motors and bearings.

3.8 CLEANING

A. Before installing copper tubing other than Type ACR, clean tubing and fittings with trichloroethylene.

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

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3.9 SYSTEM CHARGING

A. Charge system using the following procedures:

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

2. Evacuate entire refrigerant system with a vacuum pump to a vacuum of 500 micrometers.

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.

4. Charge system with a new filter-dryer core in charging line. Provide full-operating charge.

END OF SECTION 232300