232213 Steam and Condensate Heating Piping.pdf

05-01-20 Correct Reusable Medical Equipment Storage Harry S. Truman Veterans Memorial Hospital, Columbia MO VA Project No. 589A4-24-101

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SECTION 23 22 13

STEAM AND CONDENSATE HEATING PIPING

PART 1 - GENERAL

1.1 DESCRIPTION

A. Steam, condensate, and vent piping inside buildings.

B. A complete listing of common acronyms and abbreviations are included in

Section 23 05 11, COMMON WORK RESULTS FOR HVAC.

1.2 RELATED WORK

A. Section 01 00 00, GENERAL REQUIREMENTS.

B. Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, AND SAMPLES.

C. Section 01 81 13, SUSTAINABLE CONSTRUCTION REQUIREMENTS.

D. Section 01 91 00, GENERAL COMMISSIONING REQUIREMENTS.

E. Section 09 91 00, PAINTING.

F. Section 13 05 41, SEISMIC RESTRAINT REQUIREMENTS FOR NON-STRUCTURAL

COMPONENTS.

G. Section 23 05 11, COMMON WORK RESULTS FOR HVAC.

H. Section 23 05 93, TESTING, ADJUSTING, AND BALANCING FOR HVAC.

I. Section 23 07 11, HVAC AND BOILER PLANT INSULATION.

J. Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

K. Section 23 09 23, DIRECT-DIGITAL CONTROL SYSTEM FOR HVAC.

1.3 APPLICABLE PUBLICATIONS

A. The publications listed below form a part of this specification to the extent referenced. The publications are referenced in the text by the basic designation only. Where conflicts occur these specifications and the VHA standards shall govern.

B. American Society of Mechanical Engineers (ASME):

B1.20.1-2013 (R2018) ...Pipe Threads, General Purpose (Inch)

B16.5-2024 .............Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard

B16.9-2021 .............Factory Made Wrought Buttwelding Fittings

B16.11-2021 ............Forged Fittings, Socket-Welding and Threaded

B16.42-2021 ............Ductile Iron Pipe Flanges and Flanged Fittings:

Classes 150 and 300

B31.1-2024 .............Power Piping

B31.9-2020 .............Building Services Piping

B40.100-2022 ...........Pressure Gauges and Gauge Attachments

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ASME Boiler and Pressure Vessel Code (BPVC) -

BPVC Section II-2023 Materials

BPVC Section VIII-2023 Rules for Construction of Pressure Vessels, Division 1

BPVC Section IX-2023Welding, Brazing, and Fusing Qualifications

C. American Society for Testing and Materials (ASTM):

A53/A53M-2022 ..........Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and

Seamless

A106/A106M-2019a .......Standard Specification for Seamless Carbon

Steel Pipe for High-Temperature Service

A216/A216M-2021 ........Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-

Temperature Service

A285/A285M-2017 ........Standard Specification for Pressure Vessel

Plates, Carbon Steel, Low-and Intermediate-

Tensile Strength

A193-2024 ..............Standard Specification for Alloy-Steel and

Stainless Steel Bolting for High Temperature or

High Pressure Service and Other Special Purpose

Applications

A516/A516M-2017 ........Standard Specification for Pressure Vessel

Plates, Carbon Steel, for Moderate- and Lower-

Temperature Service

A536-1984(2019)e1 ......Standard Specification for Ductile Iron

Castings

B62-2017 ...............Standard Specification for Composition Bronze or Ounce Metal Castings

D. American Welding Society (AWS):

B2.1/B2.1M-2014 ........Specification for Welding Procedure and

Performance Qualifications

Z49.1-2012 .............Safety in Welding and Cutting and Allied

Processes

E. Manufacturers Standardization Society (MSS) of the Valve and Fitting

Industry, Inc.:

SP-80-2019 .............Bronze Gate, Globe, Angle, and Check Valves

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F. Military Specifications (Mil. Spec.):

MIL-DTL-901E-2017 ......Shock Tests, H.I. (High Impact) Shipboard

Machinery, Equipment, and Systems

G. National Board of Boiler and Pressure Vessel Inspectors (NB):

Relieving Capacities of Safety Valves and Relief Valves

H. Tubular Exchanger Manufacturers Association (TEMA):

TEMA Standards-2019 ....10th Edition

1.4 SUBMITTALS

A. Submittals, including number of required copies, shall be submitted in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, AND

SAMPLES.

B. Information and material submitted under this section shall be marked

“SUBMITTED UNDER SECTION 23 22 13, STEAM AND CONDENSATE HEATING

PIPING”, with applicable paragraph identification.

C. Manufacturer's Literature and Data including: Full item description and optional features and accessories. Include dimensions, weights, materials, applications, standard compliance, model numbers, size, and capacity.

1. Pipe and equipment supports. Submit calculations for variable spring and constant support hangers.

2. Pipe and tubing, with specification, class or type, and schedule.

3. Pipe fittings, including miscellaneous adapters and special fittings.

4. Flanges, gaskets and bolting.

5. Valves of all types.

6. Steam traps.

7. Strainers.

8. Pipe alignment guides.

9. Flexible ball joints: Catalog sheets, performance charts, schematic drawings, specifications and installation instructions.

10. All specified steam system components.

11. Gauges.

12. Thermometers and test wells.

13. Seismic bracing details for piping.

D. Manufacturer's certified data report, Form No. U-1, for ASME pressure vessels:

1. Heat Exchangers (Steam-to-Hot Water).

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E. Coordination Drawings: Refer to paragraph, SUBMITTALS of Section 23 05

11, COMMON WORK RESULTS FOR HVAC.

F. As-Built Piping Diagrams: Provide drawing as follows for steam and steam condensate piping and other central plant equipment.

1. One wall-mounted stick file for prints. Mount stick file in the chiller plant or adjacent control room along with control diagram stick file.

2. One set of reproducible drawings.

G. Complete operating and maintenance manuals including wiring diagrams, technical data sheets, information for ordering replacement parts, and troubleshooting guide:

1. Include complete list indicating all components of the systems.

2. Include complete diagrams of the internal wiring for each item of equipment.

3. Diagrams shall have their terminals identified to facilitate installation, operation and maintenance.

H. Completed System Readiness Checklist provided by the CxA and completed by the contractor, signed by a qualified technician and dated on the date of completion, in accordance with the requirements of Section 23

08 00, COMMISSIONING OF HVAC SYSTEMS.

I. Submit training plans and instructor qualifications in accordance with the requirements of Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

1.5 QUALITY ASSURANCE

A. Section 23 05 11, COMMON WORK RESULTS FOR HVAC, which includes welding qualifications.

B. The products and execution of work specified in this section shall conform to the referenced codes and standards as required by the specifications. Local codes and amendments shall be enforced, along with requirements of local utility companies. The most stringent requirements of these specifications, local codes, or utility company requirements shall always apply. Any conflicts shall be brought to the attention of the COR.

C. Welding Qualifications: Before any welding is performed, contractor shall submit a certificate certifying that welders comply with the following requirements:

1. Qualify welding processes and operators for piping according to ASME

BPVC Section IX, AWS Z49.1 and AWS B2.1/B2.1M.

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2. Comply with provisions in ASME B31.9.

3. Certify that each welder and welding operator has passed AWS qualification tests for welding processes involved and that certification is current and recent. Submit documentation to the

COR.

4. All welds shall be stamped according to the provisions of the

American Welding Society.

D. ASME Compliance: Comply with ASME B31.9 for materials, products, and installation. Safety valves and pressure vessels shall bear appropriate

ASME labels.

1.6 AS-BUILT DOCUMENTATION

A. Submit manufacturer’s literature and data updated to include submittal review comments and any equipment substitutions.

B. Submit operation and maintenance data updated to include submittal review comments, VA approved substitutions and construction revisions shall be in electronic version on CD or DVD inserted into a three-ring binder. All aspects of system operation and maintenance procedures, including applicable piping isometrics, wiring diagrams of all circuits, a written description of system design, control logic, and sequence of operation shall be included in the operation and maintenance manual. The operations and maintenance manual shall include troubleshooting techniques and procedures for emergency situations.

Notes on all special systems or devices shall be included. A List of recommended spare parts (manufacturer, model number, and quantity) shall be furnished. Information explaining any special knowledge or tools the owner will be required to employ shall be inserted into the

As-Built documentation.

C. The installing contractor shall maintain as-built drawings of each completed phase for verification; and, shall provide the complete set at the time of final systems certification testing. Should the installing contractor engage the testing company to provide as-built or any portion thereof, it shall not be deemed a conflict of interest or breach of the ‘third party testing company’ requirement. Provide record drawings as follows:

1. Red-lined, hand-marked drawings are to be provided, with one paper copy and a scanned PDF version of the hand-marked drawings provided on CD or DVD.

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D. The as-built drawings shall indicate the location and type of all lockout/tagout points for all energy sources for all equipment and pumps to include breaker location and numbers, valve tag numbers, etc.

Coordinate lockout/tagout procedures and practices with local VA requirements.

E. Certification documentation shall be provided to COR 21 calendar days prior to submitting the request for final inspection. The documentation shall include all test results, the names of individuals performing work for the testing agency on this project, detailed procedures followed for all tests, and provide documentation/certification that all results of tests were within limits specified. Test results shall contain written sequence of test procedure with written test results annotated at each step along with the expected outcome or setpoint. The results shall include all readings, including but not limited to data on device (make, model and performance characteristics), normal pressures, switch ranges, trip points, amp readings, and calibration data to include equipment serial numbers or individual identifications, etc.

PART 2 - PRODUCTS

2.1 PIPE AND EQUIPMENT SUPPORTS, PIPE SLEEVES, AND WALL AND CEILING PLATES

A. Provide in accordance with Section 23 05 11, COMMON WORK RESULTS FOR

HVAC.

2.2 PIPE AND TUBING

A. Steam Piping: Steel, ASTM A53/A53M, Grade B, seamless or ERW; ASTM

A106/A106M Grade B, seamless; Schedule 40.

B. Steam Condensate and Pumped Condensate Piping: Steel, ASTM A53/A53M, Grade B, seamless or ERW; or ASTM A106/A106M Grade B, seamless, Schedule 80.

C. Vent Piping: Steel, ASTM A53/A53M, Grade B, seamless or ERW; ASTM

A106/A106M Grade B, seamless; Schedule 40, galvanized.

2.3 FITTINGS FOR STEEL PIPE

A. 50 mm (2 inches) and Smaller: Screwed or welded.

1. Cast iron fittings or piping is prohibited for steam and steam condensate piping. Bushing reduction or use of close nipples is prohibited.

2. Forged steel, socket welding or threaded: ASME B16.11, 13,790 kPa

(2000 psig) class with ASME B1.20.1 threads. Use Schedule 80 pipe

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23 22 13 - 7 and fittings for threaded joints. Lubricant or sealant shall be oil and graphite, or other compound approved for the intended service.

3. Unions: Forged steel, 13,790 kPa (2000 psig) class or 20,685 kPa

(3000 psig) class on piping 50 mm (2 inches) and less.

4. Steam line drip station and strainer quick-couple blowdown hose connection: Straight through, plug and socket, screw or cam locking type for 15 mm (1/2 inch) ID hose. No integral shut-off is required.

B. 65 mm (2-1/2 inches) and Larger: Welded or flanged joints.

1. Cast iron fittings or piping is prohibited for steam and steam condensate piping.

2. Butt welding fittings: ASME B16.9 with same wall thickness as connecting piping. Elbows shall be long radius type, unless otherwise noted.

3. Welding flanges and bolting: ASME B16.5:

a. Steam service: Weld neck or slip-on, raised face, with non-asbestos gasket. Non-asbestos gasket shall either be stainless steel spiral wound strip with flexible graphite filler or compressed inorganic fiber with nitrile binder rated for saturated and superheated steam service 400 degrees C (750 degrees F) and 10,342 kPa (1500 psig).

b. Flange bolting: Carbon steel machine bolts or studs and nuts, ASTM A193, Grade B7.

C. Welded Branch and Tap Connections: Forged steel weldolets, or branchlets and threadolets may be used for branch connections up to one pipe size smaller than the main. Forged steel half-couplings, ASME

B16.11 may be used for drain, vent and gauge connections.

2.4 DIELECTRIC FITTINGS

A. Provide where dissimilar metal pipe are joined.

B. 50 mm (2 inches) and Smaller: Threaded dielectric union.

C. 65 mm (2-1/2 inches) and Larger: Flange union with dielectric gasket and bolt sleeves, ASME B16.42.

D. Temperature Rating, 121 degrees C (250 degrees F) for steam condensate and as required for steam service.

E. Contractor’s option: On pipe sizes 50 mm (2 inches) and smaller, screwed end steel gate valves or dielectric nipples may be used in lieu of dielectric unions.

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2.5 VALVES

A. Asbestos packing is prohibited.

B. All valves of the same type shall be products of a single manufacturer.

C. Provide chain operators for valves 150 mm (6 inches) and larger when the centerline is located 2.1 meter (7 feet) or greater above the floor or operating platform.

D. Shut-Off Valves:

1. Ball Valves:

a. 50 mm (2 inches) and smaller: Forged steel body, rated for 1380 kPa (200 psig) saturated steam, 2758 kPa (400 psig) WOG, bronze wedges and Monel or stainless-steel seats, threaded ends, rising stem, and union bonnet.

b. 65 mm (2-1/2 inches) and larger: Flanged, outside screw and yoke.

1) High pressure steam 110 kPa (16 psig) and above system: Cast steel body, ASTM A216/A216M grade WCB, 1035 kPa (150 psig) at

260 degrees C (500 degrees F), 11-1/2 to 13 percent chrome stainless steel solid disc and seats. Provide 25 mm (1 inch) factory installed bypass with globe valve on valves 100 mm (4 inches) and larger.

2) All other services: Forged steel body, Class B, rated for 850 kPa (123 psig) saturated steam, 1380 kPa (200 psig) WOG, bronze or bronze face wedge and seats, 850 kPa (123 psig) ASME flanged ends, OS&Y, rising stem, bolted bonnet, and renewable seat rings.

E. Ball Valves: Reduced port permitted for bypass (throttling) service;

full port required for all other services, one-fourth turn to open.

1. Type 501: Type 316 stainless steel body, ball and stem, rated for

1034 kPa at 185 degrees C (150 psig at 365 degrees F), 4137 kPa at

93 degrees C (600 psig at 200 degrees F); reinforced TFE seat, stem seal and thrust washer; end entry, threaded ends.

2. Type 502: Steel body, rated for 1034 kPa at 185 degrees C (150 psig at 365 degrees F), 1724 kPa at 121 degrees C (250 psig at 250 degrees F), reinforced TFE seat, stem seal and thrust washer; end entry, threaded ends, UL-listed for natural or LP gas shut off service when used on those services.

3. Type 503: Carbon steel body, steam service, rated for 1380 kPa at

200 degrees C (200 psig at 392 degrees F), stainless steel ball and

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23 22 13 - 9 stem, Polyfil seat, live-loaded or adjustable stem seal, threaded ends.

F. Globe and Angle Valves:

1. Globe Valves:

a. 50 mm (2 inches) and smaller: Forged steel body, rated for 1380 kPa (200 psig) saturated steam, 2758 kPa (400 psig) WOG, hardened stainless steel disc and seat, threaded ends, rising stem, union bonnet, and renewable seat rings.

b. 65 mm (2-1/2 inches) and larger:

1) Globe valves for high pressure steam 110 kPa (16 psig): Cast steel body, ASTM A216/A216M grade WCB, flanged, OS&Y, 1035 kPa

(150 psig) at 260 degrees C (500 degrees F), 11-1/2 to 13 percent chrome stainless steel disc and renewable seat rings.

2) All other services: Steel body, rated for 850 kPa (123 psig) saturated steam, 1380 kPa (200 psig) WOG, bronze or bronze-faced disc (Teflon or composition facing permitted) and seat, 850 kPa (123 psig) ASME flanged ends, OS&Y, rising stem, bolted bonnet, and renewable seat rings.

2. Angle Valves:

a. 50 mm (2 inches) and smaller: Cast steel 1035 kPa (150 psig), union bonnet with metal plug type disc.

b. 65 mm (2-1/2 inches) and larger:

1) Angle valves for high pressure steam 110 kPa (16 psig): Cast steel body, ASTM A216/A216M grade WCB, flanged, OS&Y, 1035 kPa

(150 psig) at 260 degrees C (500 degrees F), 11-1/2 to 13 percent chrome stainless steel disc and renewable seat rings.

2) All other services: 861 kPa (125 psig), flanged, cast steel body, and bronze trim.

G. Gate Valves:

1. 50 mm (2 inches) and smaller:

a. Brass or bronze valve, Class 125, rising stem, union bonnet threaded ends, ASME B1.20.1.

2. 65mm (2-1/2 inches) and larger:

a. Iron valve, Class 125, OS&Y, bolted bonnet, threaded or flanged ends, ASME B16.1.

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H. Swing Check Valves:

1. 50 mm (2 inches) and smaller: Cast steel, 1035 kPa (150 psig), 45-degree swing disc.

2. 65 mm (2-1/2 inches) and Larger:

a. Check valves for high pressure steam 110 kPa (16 psig) and above system: Cast steel body, ASTM A216/A216M grade WCB, flanged, OS&Y, 1035 kPa (150 psig) at 260 degrees C (500 degrees F), 11-

1/2 to 13 percent chrome stainless steel disc and renewable seat rings.

b. All other services: 861 kPa (125 psig), flanged, cast steel body, and bronze trim.

2.6 STRAINERS

A. Basket or Y Type. Tee type is acceptable for gravity flow and pumped steam condensate service.

B. High Pressure Steam: Rated 1035 kPa (150 psig) saturated steam.

1. 50 mm (2 inches) and smaller: Cast steel, rated for saturated steam at 1034 kPa (150 psig) threaded ends.

2. 65 mm (2-1/2 inches) and larger: Cast steel rated for 1034 kPa (150 psig) saturated steam with 1034 kPa (150 psig) ASME flanged ends or forged steel with 1724 kPa (250 psig) ASME flanged ends.

C. All Other Services: Rated 861 kPa (125 psig) saturated steam.

1. 50 mm (2 inches) and smaller: Cast steel body.

2. 65 mm (2-1/2 inches) and larger: Flanged, cast steel body.

D. Screens: Bronze, Monel metal or 18-8 stainless steel, free area not less than 2-1/2 times pipe area, with perforations as follows:

1. 75 mm (3 inches) and smaller: 20 mesh for steam and 1.1 mm (0.045 inch) diameter perforations for liquids.

2. 100 mm (4 inches) and larger: 1.1 mm (0.045) inch diameter perforations for steam and 3.2 mm (1/8 inch) diameter perforations for liquids.

2.7 PIPE ALIGNMENT

A. Guides: Provide factory-built guides along the pipe line to permit axial movement only and to restrain lateral and angular movement.

Guides shall be designed to withstand a minimum of 15 percent of the axial force which will be imposed on the expansion joints and anchors.

Field-built guides may be used if detailed in the contract documents.

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2.8 FLEXIBLE BALL JOINTS

A. Design and Fabrication: One-piece component construction, fabricated from steel with welded ends, designed for a working steam pressure of

1725 kPa (250 psig) and a temperature of 232 degrees C (450 degrees F).

Each joint shall provide for 360 degrees rotation in addition to a minimum angular flexible movement of 30 degrees for sizes 6 mm (1/4 inch) to 150 mm (6 inch) inclusive, and 15 degrees for sizes 65 mm (2-

1/2 inches) to 762 mm (30 inches). Joints through 355 mm (14 inches) shall have forged pressure retaining members, while size 406 mm (16 inches) through 762 mm (30 inches) shall be of one-piece construction.

B. Material:

1. Cast or forged steel pressure containing parts and bolting in accordance with ASME BPVC Section II or ASME B31.1. Retainer may be ductile iron ASTM A536, Grade 65-45-12, or ASME BPVC Section II SA

515, Grade 70.

2. Gaskets: Steam pressure molded composition design for a temperature range of from minus 10 degrees C (50 degrees F) to plus 274 degrees

C (525 degrees F).

C. Certificates: Submit qualifications of ball joints in accordance with the following test data:

1. Low pressure leakage test: 41 kPa (6 psig) saturated steam for 60 calendar days.

2. Flex cycling: 800 Flex cycles at 3447 kPa (500 psig) saturated steam.

3. Thermal cycling: 100 saturated steam pressure cycles from atmospheric pressure to operating pressure and back to atmospheric pressure.

4. Environmental shock tests: Forward certificate from a recognized test laboratory, that ball joints of the type submitted has passed shock testing in accordance with Mil. Spec MIL-S-901.

5. Vibration: 170 hours on each of three mutually perpendicular axes at

25 to 125 Hz; 1.3 mm to 2.5 mm (0.05 inch to 0.10 inch) double amplitude on a single ball joint and 3 ball joint off set.

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2.9 STEAM SYSTEM COMPONENTS

A. Heat Exchanger (Steam to Hot Water): Shell and tube type, U-bend removable tube bundle, steam in shell, water in tubes, equipped with support cradles.

1. Maximum tube velocity: 2.3 meter/second (7.5 feet/second).

2. Tube fouling factor: TEMA Standards, but not less than 0.00018 square meters K/W (0.001 square foot/hour degrees F/Btu).

3. Materials:

a. Shell: Steel.

b. Tube sheet and tube supports: Steel or brass.

c. Tubes: 20 mm (3/4 inch) OD copper.

d. Head or bonnet: Steel.

4. Construction: In accordance with ASME Pressure Vessel Code for 861 kPa (125 psig) working pressure for shell and tubes. Provide manufacturer's certified data report, Form No. U-1.

B. Optional Heat Transfer Package: In lieu of field erected individual components, the Contractor may provide a factory or shop assembled package of heat exchangers, pumps, and other components, pre-piped and pre-wired and supported on a welded steel frame or skid.

C. Steam Pressure Reducing Valves in PRV Stations:

1. Type: Single-seated, diaphragm operated, spring-loaded, external or internal steam pilot-controlled, normally closed, adjustable set pressure. Pilot shall sense controlled pressure downstream of main valve.

2. Service: Provide controlled reduced pressure to steam piping systems.

3. Pressure control shall be smooth and continuous with maximum drop of

10percent deviation from set pressure. Maximum flow capacity of each valve shall not exceed capacity of downstream safety valve(s).

4. Main valve and pilot valve shall have replaceable valve plug and seat of stainless steel, Monel, or similar durable material.

a. Pressure rating for high pressure steam: Not less than 1035 kPa

(150 psig) saturated steam.

b. Connections: Flanged for valves 65 mm (2-1/2 inches) and larger;

flanged or threaded ends for smaller valves.

5. Select pressure reducing valves to develop less than 85 dBA at 1.5-meter (5 feet) elevation above adjacent floor, and 1.5 meter (5

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23 22 13 - 13 feet) distance in any direction. Inlet and outlet piping for steam pressure reducing valves shall be Schedule 80 minimum for required distance to achieve required levels or sound attenuators shall be applied.

D. Safety Valves and Accessories: Comply with ASME BPVC Section VIII.

Capacities shall be certified by National Board of Boiler and Pressure

Vessel Inspectors, maximum accumulation 10 percent. Provide lifting lever. Provide drip pan elbow where shown. Valve shall have stainless steel seats and trim.

E. Steam PRV for Individual Equipment: Cast steel body, screwed or flanged ends, rated 861 kPa (125 psig), or 20 percent above the working pressure, whichever is greater. Single-seated, diaphragm operated, spring loaded, adjustable range, all parts renewable.

F. Moisture Separator: Shall be of the high efficiency internal baffle type, with a pressure drop that does not exceed an equivalent length of straight pipe. Body shall be iron, steel or cast steel with screwed, socket weld or flanged connections as detailed on drawing schedule.

Steel construction shall be in accordance with Section VIII, Division 1 of the ASME Boiler and Pressure Vessel Code with ASME Class 150, 300 or

600 RF flange connections. A bottom drain connection shall be provided for the installation of a trap to discharge any accumulated liquid.

Separators shall be installed before steam PRV and Control Valves.

G. Steam Trap: Each type of trap shall be the product of a single manufacturer. Provide trap sets at all low points and at 61 meter (200 feet) intervals on the horizontal main lines.

1. Floats and linkages shall provide sufficient force to open trap valve over full operating pressure range available to the system.

Unless otherwise indicated in the contract documents, traps shall be sized for capacities indicated at minimum pressure drop as follows:

a. For equipment with modulating control valve: 1.7 kPa (1/4 psig), based on a condensate leg of 300 mm (12 inches) at the trap inlet and gravity flow to the receiver.

b. For main line drip trap sets and other trap sets at steam pressure: Up to 70 percent of design differential pressure.

Condensate may be lifted to the return line.

2. Trap bodies: Steel and stainless-steel, constructed to permit ease of removal and servicing working parts without disturbing connecting

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23 22 13 - 14 piping. The use of raised face flange is required on pipe sizes 1-

1/2 inch and greater. The use of unions is acceptable for pipe sizes less than 1─1/2 inches. For systems without relief valve traps shall be rated for the pressure upstream of the steam supplying the system.

3. Balanced pressure thermostatic elements: Phosphor bronze, stainless steel or Monel metal.

4. Valves and seats: Suitable hardened corrosion resistant alloy.

5. Mechanism: Brass, stainless steel or corrosion resistant alloy.

6. Floats: Stainless steel.

7. Inverted bucket traps: Provide bi-metallic thermostatic element for rapid release of non-condensables.

8. Thermodynamic steam traps: Shall have tight shut-off with no steam loss allowed either by bleed or “controlled leak” and shall have an integral seat design with hardened disc and seating surfaces.

Thermodynamic traps for steam pressures below 600 psi shall be all stainless-steel construction with threaded, socket weld or flanged connections on a common centerline, and shall be capable of operating in any position. Traps shall be capable of operating with up to 80% back pressure and shall be standard with insulating cover to reduce heat loss. Thermodynamic traps for steam pressures 600 psi or higher shall be of alloy steel construction with threaded, socket weld or flanged connections on a common centerline, and will operate in any position. Steam trap shall be capable of operating with up to

80% back pressure with operating pressure up to 900 psi.

Thermodynamic trap shall have three equidistant discharge ports between seat land surfaces to minimize disc and seat wear.

H. Factory-Packaged Trap Station: As an option for drip points requiring isolation valves, strainer, trap, check-valve, valved test ports, and monitoring provide factory packaged trap station including all these features:

1. Shall consist of compact stainless steel design comprising upstream and downstream isolation valves, a quick- fit universal trap connector, strainer, and check valve. The trap station shall be single-piece construction. Once installed, the station remains permanently in the line. Steam traps shall be installed and removed

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23 22 13 - 15 from the station by two bolts, facilitating simple and rapid installation and replacement.

2. Isolation valves, check valve, and strainer shall be maintainable.

3. Steam trap station shall be suitable for use with and shall include thermodynamic, inverted bucket, float & thermostatic, or thermostatic steam traps fitted with universal connectors. The selected steam trap shall be attached to the connector by bolts.

4. Steam Trap Station shall be designed for maximum operating pressure

(PMO) with saturated steam of 1751 kPa (254 psig). For ANSI 150 connections PMO shall be 1379 kPa (200 psig).

5. All components of the packaged trap station shall meet specified requirements for individual components specified in this section.

I. Pressure Driven Condensate Pump Trap:

1. Unit shall automatically trap and pump condensate from process and heating equipment under all operating conditions including vacuum.

2. Body shall be constructed of cast iron with all stainless-steel internals. The mechanism shall incorporate stainless steel springs.

3. Motive Force: The pump trap shall utilize steam, to remove condensate from the receiving vessel.

4. Pumps shall require no electricity for operation.

5. Check valves at inlet and outlet shall be stainless steel.

6. ASME BPVC Section VIII.

J. Thermostatic Air Vent (Steam): Steel body, balanced pressure bellows, stainless steel (renewable) valve and seat, rated 861 kPa (125 psig) working pressure, 20 mm (3/4 inch) screwed connections. Air vents shall be balanced pressure type that responds to steam pressure-temperature curve and vents air at any pressure.

K. Clean Steam Generator for HVAC Humidification: Factory fabricated; UL listed heat exchanger for the generation of low-pressure clean steam to be used in HVAC humidification. Compatible with softened water .

1. Steam to steam humidifier: Steam to steam humidifier, 304 stainless steel tank with removable 304 stainless steel cover with gasketed flanges, steam outlet connection on top of tank for hose or pipe.

a. Tank: Stainless steel.

b. Enclosed cabinet, coated steel construction and air gap between cabinet and insulated tank

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c. Steam control valve, steam inlet strainer and steam trap furnished and installed at factory.

d. Steam outlet on top of tank configured to connect to hose, pipe, or flange connection.

e. Stainless steel evaporator tank with flat surfaces.

f. Mounting: Humidifier shall be mounted on painted legs.

2. Controls: Control subpanel shall be factory-attached to humidifier with all wiring between subpanel and humidifier completed at factory. A wiring diagram shall be included. The controller shall be microprocessor based and shall have the following features or functions:

a. Redundant low water safety control.

b. Fully modulating (0 to 100 percent) control of humidifier outputs.

c. Water level control: Automatic refill, low water cut-off, field adjustable skimmer bleed-off functions, and automatic drain-down of humidifier.

d. Temperature sensor: A factory mounted sensor, with a temperature range of -40 to 121 degrees C (-40 to 250 degrees F) mounted on the humidifier to enable the following functions:

1) Maintain the evaporating chamber water temperature above freezing.

2) Maintain a user-defined preset evaporating chamber water temperature.

3) Allow rapid warm-up of water in evaporating chamber after a call for humidity, providing 100% operation until steam production occurs.

e. USB port on the control board for software updates, data backups, and data restoration.

f. Up-time optimizer function to keep humidifier(s) operating through conditions such as fill, drain, or run-time faults, as long as safety conditions are met, minimizing production down-time.

g. Real-time clock to allow time-stamped alarm/message tracking, and scheduled events.

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h. Factory commissioning of humidifier and control board, including system configuration as-ordered, factory unit testing, and operation with water before shipping.

i. Unit-mounted keypad/display operable within a temperature range of 0 to 70 degrees C (32 to 158 degrees F) and provides backlighting for viewing in low light.

j. Alarms, unit configuration, and usage timer values shall remain in nonvolatile memory indefinitely during a power outage.

k. The controls shall monitor, control, and/or adjust the following parameters:

1) Relative humidity (RH) set point, actual conditions in the space (from humidity transmitter), RH offset.

2) Dew point set point, actual conditions in the space (from dew point transmitter), dew point offset.

3) Relative humidity (RH) duct high limit set point (switch) and actual conditions.

4) Relative humidity (RH) duct high limit set point, actual conditions (from transmitter), high limit span, and high limit offset.

5) Total system demand in % of humidifier capacity.

6) Total system output in kg/hr (lb/hr).

7) Drain/flush duration, allowed days, and frequency based on usage.

8) End-of-season drain status and hours humidifier is idle before end of season draining occurs.

9) System alarms and system messages, current and previous.

l. Programmable outputs for remote signaling of alarms and/or messages, device activation (such as a fan), or for signaling tank heating and/or steam production.

m. System diagnostics that include:

1) Test outputs function to verify component operation.

2) Test humidifier function by simulating demand to validate performance.

3) Data collection of RH, air temperature, water use, energy use, alarms, and service messages for viewing from the keypad/display or Web interface.

4) Service notification scheduling.

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5) Password-protected system parameters.

6) Keypad/display or Web interface displays in English.

7) Numerical units displayed in inch-pound or SI units.

3. Other humidifier control features:

a. Interoperability using BACnet MS/TP.

b. Access panel interlock switch: The control subpanel shall have an interlock control switch with manual override to remove control voltage when access panel is opened.

4. Distribution Manifold: Stainless steel, composed of dispersion pipe and surrounding steam jacket, manifold shall span the width of duct or air handler, and shall be multiple manifold type under any of the following conditions:

5. Duct section height exceeds 900 mm (36 inches).

6. Duct air velocity exceeds 5.1 m/s (1000 feet per minute).

7. If within 900 mm (3 feet) upstream of fan, damper or pre-filter.

8. If within 3 m (10 feet) upstream of after-filter.

2.10 GAUGES, PRESSURE AND COMPOUND

A. ASME B40.100, Accuracy Grade 1A, (pressure, vacuum, or compound), initial mid-scale accuracy 1 percent of scale (Qualify grade), metal or phenolic case, 115 mm (4-1/2 inches) in diameter, 6 mm (1/4 inch) NPT bottom connection, white dial with black graduations and pointer, clear glass or acrylic plastic window, suitable for board mounting. Provide red "set hand" to indicate normal working pressure.

B. Provide steel, lever handle union cock. Provide steel or stainless-steel pressure snubber for gauges in water service. Provide steel pigtail syphon for steam gauges.

C. Pressure gauge ranges shall be selected such that the normal operating pressure for each gauge is displayed near the midpoint of each gauge’s range. Gauges with ranges selected such that the normal pressure is displayed at less than 30 percent or greater than 70 percent of the gauge’s range are prohibited. The units of pressure shall be psig.

2.11 PRESSURE/TEMPERATURE TEST PROVISIONS

A. Provide one each of the following test items to the COR:

1. 6 mm (1/4 inch) FPT by 3.2 mm (1/8 inch) diameter stainless steel pressure gauge adapter probe for extra-long test plug.

Pressure/temperature plug is an example.

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2. 90 mm (3-1/2 inch) diameter, one percent accuracy, compound gauge, 762 mm (30 inches) Hg to 690 kPa (100 psig) range.

3. 0 to 104 degrees C (32 to 220 degrees F) pocket thermometer one-half degree accuracy, 25 mm (1 inch) dial, 125 mm (5 inch) long stainless-steel stem, plastic case.

2.12 FIRESTOPPING MATERIAL

A. Refer to Section 23 05 11, COMMON WORK RESULTS FOR HVAC.

PART 3 - EXECUTION

3.1 GENERAL

A. If in the substantiated evaluation of the COR, the installation fails to meet the requirements of the construction documents with respect to function and maintainability, an installation is unsatisfactory to the

COR, the Contractor shall correct the installation at no additional cost or time to the Government.

B. The contract documents show the general arrangement of pipe and equipment but do not show all required fittings and offsets that may be necessary to connect pipes to equipment, fan-coils, coils, radiators, etc., and to coordinate with other trades. Provide all necessary fittings, offsets and pipe runs based on field measurements and at no additional cost or time to the Government. Coordinate with other trades for space available and relative location of HVAC equipment and accessories to be connected on ceiling grid. Pipe location in the contract documents shall be altered by contractor where necessary to avoid interferences and clearance difficulties.

C. Store materials to avoid excessive exposure to weather or foreign materials. Keep inside of piping relatively clean during installation and protect open ends when work is not in progress.

D. Support piping securely. Refer to PART 3, Section 23 05 11, COMMON WORK

RESULTS FOR HVAC. Install heat exchangers at height sufficient to provide gravity flow of condensate to the flash tank and condensate pump.

E. Install piping generally parallel to walls and column center lines, unless shown otherwise in the contract documents. Space piping, including insulation, to provide 25 mm (1 inch) minimum clearance between adjacent piping and another surface. Unless shown otherwise, slope steam, condensate and drain piping down in the direction of flow

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23 22 13 - 20 not less than 25 mm (1 inch) in 12 meter (40 feet). Provide eccentric reducers to keep bottom of sloped piping flat.

F. Locate and orient valves to permit proper operation and access for maintenance of packing, seat and disc. Generally, locate valve stems in overhead piping in horizontal position. Provide a union adjacent to one end of all threaded end valves. Control valves usually require reducers to connect to pipe sizes shown in the contract documents.

G. Offset equipment connections to allow valving off for maintenance and repair with minimal removal of piping. Provide flexibility in equipment connections and branch line take-offs with 3-elbow swing joints where noted in the contract documents.

H. Tee water piping runouts or branches into the side of mains or other branches. Avoid bull-head tees, which are two return lines entering opposite ends of a tee and exiting out the common side.

I. Connect piping to equipment as shown in the contract documents. Install components furnished by others such as flow elements (orifice unions), control valve bodies, flow switches, pressure taps with valve, and wells for sensors.

J. Firestopping: Fill openings around uninsulated piping penetrating floors or fire walls, with firestop material. For firestopping insulated piping refer to Section 23 07 11, HVAC AND BOILER PLANT

INSULATION.

K. Pipe vents to the exterior. Where a combined vent is provided, the cross-sectional area of the combined vent shall be equal to sum of individual vent areas. Slope vent piping 25 mm (1 inch) in 12 meter (40 feet) 0.25 percent in direction of flow. Provide a drip pan elbow on relief valve outlets if the vent rises to prevent backpressure.

Terminate vent minimum 300 mm (12 inches) above the roof or through the wall minimum 2.4 meter (8 feet) above grade with down turned elbow.

L. Contract documents do not identify all locations where steam trap sets are required. Contractor shall provide at no additional cost as many trap-sets as are necessary for the proper, reliable operation of the system. Provide trap-sets at all low points and at 61 meter (200 feet) intervals on all horizontal main lines.

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3.2 WELDING

A. The contractor is entirely responsible for the quality of the welding and shall:

1. Conduct tests of the welding procedures used on the project, verify the suitability of the procedures used, verify that the welds made will meet the required tests, and also verify that the welding operators have the ability to make sound welds under standard conditions.

2. Perform all welding operations required for construction and installation of the piping systems.

B. Qualification of Welders: Rules of procedure for qualification of all welders and general requirements for fusion welding shall conform with the applicable portions of ASME B31.1, AWS B2.1/B2.1M, AWS Z49.1, and also as outlined below.

C. Examining Welder: Examine each welder at job site, in the presence of the COR, to determine the ability of the welder to meet the qualifications required. Test welders for piping for all positions, including welds with the axis horizontal (not rolled) and with the axis vertical. Each welder shall be allowed to weld only in the position in which he has qualified and shall be required to identify his welds with his specific code marking signifying his name and number assigned.

D. Examination Results: Provide the COR with a list of names and corresponding code markings. Retest welders who fail to meet the prescribed welding qualifications. Disqualify welders, who fail the second test, for work on the project.

E. Beveling: Field bevels and shop bevels shall be done by mechanical means or by flame cutting. Where beveling is done by flame cutting, surfaces shall be thoroughly cleaned of scale and oxidation just prior to welding. Conform to specified standards.

F. Alignment: Provide approved welding method for joints on all pipes greater than 50 mm (2 inches) to assure proper alignment, complete weld penetration, and prevention of weld spatter reaching the interior of the pipe.

G. Erection: Piping shall not be split, bent, flattened, or otherwise damaged before, during, or after installation. If the pipe temperature falls to 0 degrees C (32 degrees F) or lower, the pipe shall be heated to approximately 38 degrees C (100 degrees F) for a distance of 300 mm

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(1 foot) on each side of the weld before welding, and the weld shall be finished before the pipe cools to 0 degrees C (32 degrees F).

H. Non-Destructive Examination of Piping Welds:

1. Perform radiographic examination of 50 percent of the first 10 welds made and 10 percent of all additional welds made. The COR reserves the right to identify individual welds for which the radiographic examination shall be performed. All welds shall be visually inspected by the COR. The VA reserves the right to require testing on additional welds up to 100 percent if greater than 25 percent of the examined welds fail the inspection.

2. An approved independent testing firm regularly engaged in radiographic testing shall perform the radiographic examination of pipe joint welds. All radiographs shall be reviewed and interpreted by an ASNT Certified Level III radiographer, employed by the testing firm, who shall sign the reading report.

3. Comply with ASME B31.1. Furnish a set of films showing each weld inspected, a reading report evaluating the quality of each weld, and a location plan showing the physical location where each weld is to be found in the completed project. The COR and the CxA shall be given a copy of all reports to be maintained as part of the project records and shall review all inspection records.

I. Defective Welds: Replace and reinspect defective welds. Repairing defective welds by adding weld material over the defect or by peening are prohibited. Welders responsible for defective welds shall be requalified prior to resuming work on the project.

J. Electrodes: Electrodes shall be stored in a dry heated area and be kept free of moisture and dampness during the fabrication operations.

Discard electrodes that have lost part of their coating.

3.3 PIPE JOINTS

A. Welded: Beveling, spacing and other details shall conform to ASME B31.1 and AWS B2.1/B2.1M. See Welder’s qualification requirements under

"Quality Assurance" in Section 23 05 11, COMMON WORK RESULTS FOR HVAC.

B. Screwed: Threads shall conform to ASME B1.20.1; joint compound shall be applied to male threads only and joints made up so no more than three threads show. Coat exposed threads on steel pipe with joint compound, or red lead paint for corrosion protection.

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C. 125 Pound Cast Steel Flange (Plain Face): Mating flange shall have raised face, if any, removed to avoid overstressing the cast steel flange.

3.4 STEAM TRAP PIPING

A. Install to permit gravity flow to the trap. Provide gravity flow (avoid lifting condensate) from the trap where modulating control valves are used. Support traps weighing over 11 kg (24 pounds) independently of connecting piping.

1. On pipe size 1-1/2 inch and greater a raised face flange is required to allow for removal of the steam trap without disturbing surrounding piping.

2. On pipe size less than 1-1/2inch raised face flanges or unions may be used to allow for removal of the traps.

3.5 SEISMIC BRACING

A. Provide in accordance with Section 13 05 41, SEISMIC RESTRAINT

REQUIREMENTS FOR NON-STRUCTURAL COMPONENTS.

3.6 LEAK TESTING

A. Inspect all joints and connections for leaks and workmanship and make corrections as necessary to the satisfaction of the COR in accordance with the specified requirements. Testing shall be performed in accordance with the specification requirements.

B. An operating test at design pressure, and for hot systems, design maximum temperature.

C. A hydrostatic test at 1.5 times design pressure. For water systems, the design maximum pressure would usually be the static head, or expansion tank maximum pressure, plus pump head. Factory tested equipment

(convertors, exchangers, coils, etc.) need not be field tested. Avoid excessive pressure on mechanical seals and safety devices.

D. Prepare and submit test and inspection reports to the COR within 5 calendar days of test completion and prior to covering the pipe.

E. All tests shall be witnessed by the COR, their representative, or the

CxA and be documented by each section tested, date tested, and list or personnel present.

3.7 FLUSHING AND CLEANING PIPING SYSTEMS

A. Steam, Condensate and Vent Piping: The piping system shall be flushed clean prior to equipment connection. Cleaning includes pulling all strainer screens and cleaning all scale/dirt legs during startup

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23 22 13 - 24 operation. Contractor shall be responsible for damage caused by inadequately cleaned/flushed systems.

3.8 STARTUP AND TESTING

A. Perform tests as recommended by product manufacturer and listed standards and under actual or simulated operating conditions and prove full compliance with design and specified requirements. Tests of the various items of equipment shall be performed simultaneously with the system of which each item is an integral part.

B. When any defects are detected, correct defects and repeat test at no additional cost or time to the Government.

C. The CxA shall observe startup and contractor testing of selected equipment. Coordinate the startup and contractor testing schedules with

COR and CxA. Provide a minimum notice of 10 calendar days prior to startup and testing.

D. Adjust red set hand on pressure gauges to normal working pressure.

3.9 COMMISSIONING

A. Provide commissioning documentation in accordance with the requirements of Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

B. Components provided under this section of the specification shall be tested as part of a larger system.

3.10 DEMONSTRATION AND TRAINING

A. Provide services of manufacturer’s technical representative for 4 hours to instruct each VA personnel responsible in operation and maintenance of the system.

B. Submit training plans and instructor qualifications in accordance with the requirements of Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

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