3. PPW piping Specs.pdf

USDA AMES MODERNIZATION PROGRAM PHASE 1 CONTRACT 50-3K15-2-2707

CENTRAL PLANT, DISTR SYSTEM, SWITCHGEAR/GEN SUBSTATION & FUEL OIL STORAGE

SECTION 02533

DOUBLE WALL CONTAINMENT SANITARY SEWER FOR PRETREATMENT WASTE

PART 1 GENERAL

1.1 RELATED DOCUMENTS

Drawings and general provisions of Contract, including General and Supplementary Conditions and Division 1 Specifications sections, apply to work of this section.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B16.11 (1996) Forged Steel Fittings, Socket Welded and Threaded

AMERICAN PETROLEUM INSTITUTE (API)

API Spec 5L (2000) Line Pipe

API Spec 6D (2002) Specification for Pipeline Valves

API Std 594 (1997) Check Valves: Wafer, Wafer-Lug and Double-Flanged Type

API Std 609 (1997) Lug- and Wafer-Type Butterfly Valves

API RP 1110 (1997) Pressure Testing of Liquid Petroleum Pipelines

API BULL 2209 (1978) Pipe Plugging Practices

ASME INTERNATIONAL (ASME)

ASME B16.3 (1998) Malleable Iron Threaded Fittings

ASME B16.5 (1996) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24

ASME B16.9 (2001) Factory-Made Wrought Steel Buttwelding Fittings

ASME B16.11 (2002) Forged Fittings, Socket-Welding and Threaded

ASME B16.34 (1996) Valves - Flanged, Threaded, and Welding End

ASME B16.39 (1998) Malleable Iron Threaded Pipe Unions

ASME B31.3 (2002) Process Piping

ASTM INTERNATIONAL (ASTM)

ASTM A 36/A 36M (2001) Carbon Structural Steel

RMF NO.: 102118.A SECTION 02533 Page 1

CBM 52 - 07 JUL 05

ASTM A 53 (1999b) Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A 193/A 193M (2001b) Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service

ASTM A 194/A 194M (2001a) Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service or Both

ASTM D 229 (2001) Rigid Sheet and Plate Materials Used for Electrical Insulation

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (1993) Pipe Hangers and Supports - Materials, Design and Manufacture

MSS SP-69 (2002) Pipe Hangers and Supports - Selection and Application

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (1998) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 30 (2000) Flammable and Combustible Liquids Code

NFPA 70 (2002) National Electrical Code

1.2 SYSTEM DESCRIPTION

This Specification includes all underground PPW (Pumped Pretreatment Waste). For the PPW and related systems in the PPW manholes, refer to Section 15415, PUMPED PRETREATMENT WASTE PIPING.

All underground pumped pretreatment waste piping, as indicated on the contract drawings, shall be pre-fabricated, Class A testable, drainable and dryable, double containment piping systems. Conduits shall include two leak detection switches at the low end of each conduit as detailed (as opposed to continuous sensor cable) which shall be connected to a leak detector alarm system. Each system shall be contained in a single conduit.

The system supplier shall have fabricated systems of the composition herein for at least five years. All straight sections, fittings, and other accessories shall be factory prefabricated to job dimensions and designed to minimize the number of joints. The system design shall be in strict conformance with ASME B31.3, latest edition. Factory trained field technical assistance shall be provided for the critical periods of installation, i.e., unloading, field joint instruction and testing. The preapproved conduit system shall include all piping and components to a point twelve inches inside the building or manhole wall.

a. The system suppliers representative shall be responsible for directing the installation and testing of the conduit system. It shall be certified in writing by the supplier that the

RMF NO.: 102118.A SECTION 02533 Page 2 representative is technically qualified and experienced in the installation of the systems. The supplier's representative shall be present during the following work phases:

(1) Inspection and unloading

(2) Inspection of trench prior to laying of conduit

(3) Inspection of joining of system. As described in the paragraph "Quality Assurance", the service representative shall train all joint fitters on the joint procedure and then witness and approve the first joint assembly of each fitter.

(4) Hydrostatic Testing (piping)

(5) Air test (conduit)

(6) Repair of any patchwork

(7) Backfilling of conduit sections

The Contractor shall not perform any of the above stated work in the absence of the system supplier's representative. The contractor performing the work shall be responsible for the installation of the preapproved system and all other components of the conduit systems, including the piping equipment in the buildings. This responsibility shall include all site work and purchase of the preapproved system from the system supplier.

1.3 SUBMITTALS

Refer to Division 1 and Basic Mechanical Requirements for administrative and procedural requirements for submittals.

1.3.1 Product Data

Submit manufacturer's technical product data, including installation instructions, and dimensioned drawings for the type of manufactured piping specialty.

1.3.2 Shop Drawings

Submit for fabricated specialties, indicating details of fabrication, materials, and method of support. A complete engineering stress analysis indicating all fittings, dimensions in three axies, maximum anticipated stresses and maximum allowable stresses must be submitted.

1.3.3 Maintenance Data

Submit maintenance data and spare parts lists for each type of manufactured piping specialty. Include this data, product data, and shop drawings in maintenance manual; in accordance with requirements of Division 1.

1.3.4 Quality Control Submittals

a. Submit joint fitters certificates specified in Quality Assurance below.

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1.4 QUALITY ASSURANCE

1.4.1 Codes and Standards

Comply with the latest editions of the publications of the following Agencies to the extent referenced in this specification.

a. ANSI - American National Standards Institute

b. API - American Petroleum Institute.

c. ASME - American Society of Mechanical Engineers.

d. ASTM - American Society for Testing Materials.

e. AWS - American Welding Society.

f. FM - Factory Mutual

g. UL - Underwiter's Laboratories, Inc.

1.4.2 Joint Fitters On-Site Training

All joint fitters shall be trained by the system supplier's representative.

The first joint of each joint fitter shall be performed in the presence of the system supplier's representative which the person acknowledges in writing that the joint was made per the instructions.

1.5 DELIVERY, STORAGE, AND HANDLING

Provide factory-applied plastic end-caps on each length of pipe and tube.

Maintain end-caps through shipping, storage and handling to prevent pipe-end damage and prevent entrance of dirt, debris, and moisture. Ensure end caps are suitable for use when left in place and buried for future connection.

Protect stored pipes and tubes. Elevate above grade and enclose with durable, waterproof wrapping. When stored inside, do not exceed structural capacity of the floor.

Protect flanges, fittings, and specialties from moisture and dirt by inside storage and enclosure, or by packaging with durable, waterproof wrapping.

1.6 PROJECT CONDITIONS

1.6.1 Site Information

Perform site survey, and verify existing utility locations. Verify that piping is installed in compliance with the original design and referenced standards.

PART 2 PRODUCTS

2.1 PIPE MATERIALS AND FITTINGS

2.1.1 Service Pipe

The liquid that will be in the pipes mostly consists wastewater from animals, laboratory services, and related substances. The liquid also

RMF NO.: 102118.A SECTION 02533 Page 4 includes chemicals that decontaminate the waste from the biological toxins.

The liquid contains solids that tend to sludge and harden on rough surfaces. For design purposes,the specific gravity of the liquid shall be considered to be 1.15. The maximum design conditions shall be 225 PSIG at 225 degrees F. Normal operating conditions are 60 PSIG at 70 degrees F.

The install temperature shall be considered to be 60 degrees F. The maximum operating temperature for thermal expansion consideration shall be 105 degrees F. All piping shall be filament wound using an amine cured epoxy resin and fiberglass reinforced with surfacing viel for superior corrosion resistance. The basis of design for the service pipe is "Green Thread" manufactured by Smith Fibercast. The facility has a successful history with this piping system and it is therefore identified as the basis of design for this system. Any alternate will be closely scrutinized to the following design criteria:

a. ASTM D 2996 Designation Code: 1 to 1-1/2 inch NPS = RTRP-11FF1-3111, 2 to 4 inch NPS = RTRP-11F1-3112

b. Nominal Data for 4 inch NPS Pipe

1. Inside Diameter: 4.280 inches

2. Outside Diameter: 4.510 inches

3. Wall thickness: 0.030 inches

4. Weight: 1.2 pounds/foot

5. Capacity: 0.75 gallon/cubic foot

c. Pressure Ratings for 4 inch NPS Pipe

1. Maximum Internal Pressure at 225 degrees F: 225 PSIG

2. Maximum External Pressure at 75 degrees F: 77 PSIG

3. Maximum External Pressure at 225 degrees F: 56 PSIG

@75 degree F @225 degree F

PSI PSI

d. Axial Tensile per ASTM D2105:

1. Ultimate Stress 10,300 7,160

2. Design Stress 2,575 1,790

3. Modulus of Elasticity 1.80 x 106 1.03 x 106

e. Axial Compression per ASTM D695:

1. Ultimate Stress 33,300 17,800

2. Design Stress 8,300 4,450

3. Modulus of Elasticity 1.26 x 106 0.54 x 106

f. Beam Bending per ASTM D2925:

1. Ultimate Stress 23,000 16,000

2. Design Stress 2,900 2,000

3. Modulus of Elasticity 2.18 x 106 1.11 x 106

(long term)

g. Hydrostatic Burst per ASTM D1599:

1. Ultimate Hoop Tensile Stress 46,300 49,540

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@75 degree F @225 degree F

PSI PSI

h. Ring Tensile per ASTM D2290:

1. Minimum Hoop Tensile Stress 27,280 ----

i. Hydrostatic Design per ASTM D2992 Procedure A - Hoop Tensile Stress:

1. Cyclic 150 x 106 8,850 5,540 Cycles

j. Poisson's Ratio: 0.38

k. Coefficient of Linear Thermal Expansion per ASTM D696: 1.26 x 105 in./in/oF

l. Thermal Conductivity per ASTM D177: .23 BTU/(ft.)(hr.) (oF)

m. Specific Gravity per ASTM D792: 1.8

n. Flow Factor - SF Hazen-Williams Coefficient: 150

o. Surface Roughness: 1.7 x 10-5 Feet (0.00021 in.)

p. Manning's "n": 0.009 in.

2.1.2 Fittings

Match piping, or be part of the piping system "family" as recommended by the manufacturer that meets or exceeds the properties of the piping system.

2.1.3 Joints

With the excepting of the flanged connections to the carbon steel piping in the manholes, pipe and fittings shall be joined using a bell and spigot method with epoxy adhesive applied to the joints to secure the system and maintain the rating of the piping system. The pipe manufacturer shall provide the epoxy. All joint fitters shall be factory trained by the pipe manufacturer on site. The flanges in the manholes shall be meet ANSI B16.5 Class 150 bolt hole standards. The piping system supplier shall provide clear direction as to the appropriate bolt and gasket recommendation and also the facing style of the flanges. Steel back-up plates shall be provided for all blind flanges if necessary to achieve pressure ratings equivalent to the pipe.

2.1.4 Sub-Assemblies

Gland seals and end seals shall be designed and factory prefabricated to prevent the ingress of moisture into the system. All sub-assemblies shall be designed to allow for complete draining and drying of the conduit system.

2.1.5 Carrier Pipe (Outer Conduit)

Shall be epoxy fiberglass as manufactued by A.O. Smith Red Thread II or approved equal.

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2.1.6 Pipe Supports

All pipes within the inner casing shall be supported as required. These supports shall be designed to allow for continuous airflow and drainage of the conduit in place. The straight supports shall be designed to occupy not more than 10 percent of the annular air space. No plastic types ofsupports will be allowed.

2.1.7 Field Closure

Field closures shall be made with a split fiberglass closure sleeve of the same diameter and thickness as the containment pipe. The sleeve shall be sealed and bonded to the containment pipe with double hand lay-ups over all seams.

2.1.8 Backfill

A 6 inch layer of sand or pea gravel shall be placed and tamped in the trench to provide a uniform bedding for the conduit. The entire trench shall be evenly backfilled with a similar material as the bedding in 6 inch compacted layers to a minimum height of 6 inches above the top of the insulated piping system. Bedding and backfill materials shall be as recommended by the manufacturer.

2.1.9 Leak Detection/Location System

a. The secondary containment system manufacturer shall furnish a leak detection system which shall consist of water detecting switches at the ends of the pipes in the manholes as shown on the Contract Drawings. For each low pipe in a valve vault, two switches are provided for redundancy and to determine the severity of the leak.

b. The leak detection system shall consist of one microprocessor based panel capable of continuous monitoring of the leak detection switches for leaks. Provide one single monitoring box that monitors all switches. The main microprocessor unit shall be provided under the base bid equipped with the capability for detection and indication for an additional 10 switches.

c. The liquid detection switch shall be explosion proof with 18V probes and shall have threaded connections. The switch shall detect water based, chemical, and hydrocarbon liquids.

d. The monitoring panel shall be provided with auxiliary contacts for remote alarm. Provide one contact for each piping system leak detection.

PART 3 EXECUTION

3.1 INSTALLATION

The installing contractor shall handle the system in accordance with the directions furnished by the manufacturer and as approved by the engineer.

The casing shall be air tested at 10 psig and the service piping shall be hydrostatically tested to 1 1/2 times the design pressure. Testing shall occur in the field after fabrication is complete or as specified in the contract documents. The test pressure shall be held for not less than one hour.

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3.2 BURIED UTILITY WARNING AND IDENTIFICATION TAPE

Polyethylene plastic tape shall possess a detectable metal core and be manufactured specifically for warning of and identifying buried utility lines and shall be supplied and installed by Contractor. Tape shall be buried above the pipe during the trench backfilling operation and shall be buried approximately 12 inches below grade.

3.3 CONDUIT AIR TEST

The Contractor shall furnish all necessary equipment and labor to perform the air test, including air compressor, gauges, conduit caps, temporary pipe and connections, etc. and complete the test to the satisfaction of the engineer.

3.4 VERIFICATION OF FINAL ELEVATIONS

Prior to covering the top of the casing with backfill material, but after all temporary supports have been removed and initial backfilling of the conduit systems have been accomplished, the contractor shall measure and record the elevation of the top of the casings in the trench. This measurement shall be checked against the contract drawings. These measurements shall confirm that the conduit system have been installed to the elevations shown on the contract drawings. These measurements shall be certified correct by the Contractor and provided to the Government for review prior to covering the casing with backfill material. The preapproved conduit system shall be installed, inspected, and tested in accordance with the contract drawings and specifications, the system supplier's Approved Brochure and any directions given by the system supplier's representative. All work pertaining to the preapproved system shall be performed in the presence of the system supplier's representative.

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