36C25622R0094 232123 HYDRONIC PUMPS.docx

REPLACE AHU #104 AND DUCTWORK BLDG. 7

DEPARTMENT OF VETERANS AFFAIRS HEALTH CARE SYSTEM-ALEXANDRIA, LA

PROJECT NO.: 502-19-107

SECTION 23 21 23

HYDRONIC PUMPS

GENERAL

DESCRIPTION

Capacity: (Gallons per minute (gpm)) of the fluid pumped. Hydronic pumps for Heating, Ventilating and Air Conditioning.

Definitions:

Capacity: (Gallons per minute (gpm)) of the fluid pumped.

Head: Total dynamic head in feet of the fluid pumped.

Flat head-capacity curve: Where the shutoff head is less than 1.16 times the head at the best efficiency point.

A complete listing of common acronyms and abbreviations are included in Section 23 05 11, COMMON WORK RESULTS FOR HVAC.

RELATED WORK

Section 01 00 00, GENERAL REQUIREMENTS.

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

Section 01 81 13, SUSTAINABLE CONSTRUCTION REQUIREMENTS.

Section 01 91 00, GENERAL COMMISSIONING REQUIREMENTS.

Section 23 05 11, COMMON WORK RESULTS FOR HVAC.

Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC AND STEAM GENERATION EQUIPMENT.

Section 23 05 41, NOISE AND VIBRATION CONTROL FOR HVAC PIPING AND EQUIPMENT.

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

Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

Section 23 21 13, HYDRONIC PIPING.

Section 26 29 11, MOTOR CONTROLLERS.

APPLICABLE PUBLICATIONS

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 standard will govern.

American Society of Mechanical Engineers (ASME):

B16.1-2015 Cast Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and 250 American Society for Testing and Materials (ASTM):

SUBMITTALS

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

Information and material submitted under this section shall be marked “SUBMITTED UNDER SECTION 23 21 23, HYDRONIC PUMPS”, with applicable paragraph identification.

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.

Pumps and accessories.

Motors and drives.

Variable speed motor controllers.

Characteristic Curves: Head-capacity, efficiency-capacity, brake horsepower-capacity, and NPSHR-capacity for each pump and for combined pumps in parallel or series service. Identify pump and show fluid pumped, specific gravity, pump speed and curves plotted from zero flow to maximum for the impeller being furnished and at least the maximum diameter impeller that can be used with the casing.

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

Include complete list indicating all components of the systems.

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

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

Completed System Readiness Checklist provided by the Commissioning Agent 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.

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

QUALITY ASSURANCE

Design Criteria:

Pumps design and manufacturer shall conform to Hydraulic Institute Standards.

Pump sizes, capacities, pressures, operating characteristics and efficiency shall be as scheduled.

Head-capacity curves shall slope up to maximum head at shut-off. Curves shall be relatively flat for closed systems. Select pumps near the midrange of the curve, so the design capacity falls to the left of the best efficiency point, to allow a cushion for the usual drift to the right in operation, without approaching the pump curve end point and possible cavitation and unstable operation. Select pumps for open systems so that required net positive suction head (NPSHR) does not exceed the net positive head available (NPSHA).

Pump Driver: Furnish with pump. Size shall be non-overloading at any point on the head-capacity curve, including in a parallel or series pumping installation with one pump in operation.

Provide all pumps with motors, impellers, drive assemblies, bearings, coupling guard and other accessories specified. Statically and dynamically balance all rotating parts.

Furnish each pump and motor with a nameplate giving the manufacturers name, serial number of pump, capacity in gpm and head in feet at design condition, horsepower, voltage, frequency, speed and full load current and motor efficiency.

Test all pumps before shipment. The manufacturer shall certify all pump ratings.

After completion of balancing, provide replacement of impellers or trim impellers to provide specified flow at actual pumping head, as installed.

Allowable Vibration Tolerance for Pump Units: Section 23 05 41, NOISE AND VIBRATION CONTROL FOR HVAC PIPING AND EQUIPMENT.

AS-BUILT DOCUMENTATION

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

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.

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:

As-built drawings are to be provided, with a copy of them on AutoCAD provided on CD or DVD. The CAD drawings shall use multiple line layers with a separate individual layer for each system.

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.

Certification documentation shall be provided to COR 21 working 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.

SPARE MATERIALS

Furnish one spare seal and casing gasket for each pump to the COR.

PRODUCTS

CENTRIFUGAL PUMPS, BRONZE FITTED

General:

Provide pumps that will operate continuously without overheating bearings or motors at every condition of operation on the pump curve, or produce noise audible outside the room or space in which installed.

Provide pumps of size, type and capacity as indicated, complete with electric motor and drive assembly, unless otherwise indicated. Design pump casings for the indicated working pressure and factory test at 1-1/2 times the designed pressure.

Provide pumps of the same type, the product of a single manufacturer, with pump parts of the same size and type interchangeable.

General Construction Requirements Balance: Rotating parts, statically and dynamically.

Construction: To permit servicing without breaking piping or motor connections.

Pump Motors: Provide high efficiency motors, inverter duty for variable speed service. Refer to Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC AND STEAM GENERATION EQUIPMENT. Motors shall be TEFC and operate at 1750 RPM unless noted otherwise.

Heating pumps shall be suitable for handling water to 107 degrees C (225 degrees F).

Provide coupling guards that meet OSHA requirements.

Pump Connections: Flanged.

Pump shall be factory tested.

Performance: As scheduled on the Contract Drawings.

Chiller Mounted Pumps:

The pumps shall be the type shown on the drawings and specified herein direct coupled to a TEFC motor.

Pump operation and speed control shall be as shown on the drawings.

Direct drive pumps with integrated variable frequency drive (VFD) utilizing the design pump curve programmed on board the built-in controller (also known as sensor-less, or self-sensing). Pump to comply with paragraphs in this section. VFD and motor to comply with Section 26 29 11, MOTOR CONTROLLERS and Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC AND STEAM GENERATION EQUIPMENT.

In-Line Type, Base Mounted End Suction or Double Suction Type:

Casing and Bearing Housing: Close-grained cast iron, ASTM A48/A48M.

Casing Wear Rings: Bronze.

Suction and Discharge: Plain face flange, 861 kPa (125 psig), ASME B16.1.

Casing Vent: Manual brass cock at high point.

Casing Drain and Gauge Taps: 15 mm (1/2 inch) plugged connections minimum size.

Impeller: Bronze, ASTM B62, enclosed type, keyed to shaft.

Shaft: Steel, Type 1045 or stainless steel.

Shaft Seal: Manufacturer's standard mechanical type to suit pressure and temperature and fluid pumped.

Shaft Sleeve: Bronze or stainless steel.

Motor: Furnish with pump. Refer to Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC AND STEAM GENERATION EQUIPMENT.

Provide line sized shut-off valve and suction strainer, maintain manufacturer recommended straight pipe length on pump suction (with blow down valve). Contractor option: Provide suction diffuser as follows:

Body: Cast iron with steel inlet vanes and combination diffuser-strainer-orifice cylinder with 5 mm (3/16 inch) diameter openings for pump protection. Provide taps for strainer blowdown and gauge connections.

Provide adjustable foot support for suction piping.

Strainer free area: Not less than five times the suction piping.

Provide disposable startup strainer.

EXECUTION

INSTALLATION

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

Follow manufacturer's written instructions for pump mounting and startup. Access/Service space around pumps shall not be less than minimum space recommended by pumps manufacturer.

Provide drains for bases and seals for base mounted pumps, piped to and discharging into floor drains.

Coordinate location of thermometer and pressure gauges as per Section 23 21 13, HYDRONIC PIPING.

STARTUP AND TESTING

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.

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

The Commissioning Agent will observe startup and contractor testing of selected equipment. Coordinate the startup and contractor testing schedules with COR and Commissioning Agent. Provide a minimum notice of 10 working days prior to startup and testing.

Verify that the piping system has been flushed, cleaned and filled.

Lubricate pumps before startup.

Prime the pump, vent all air from the casing and verify that the rotation is correct. To avoid damage to mechanical seals, never start or run the pump in dry condition.

Verify that correct size heaters-motor over-load devices are installed for each pump controller unit.

Field modifications to the bearings and or impeller (including trimming) are prohibited. If the pump does not meet the specified vibration tolerance send the pump back to the manufacturer for a replacement pump. All modifications to the pump shall be performed at the factory.

Ensure the disposable strainer is free of debris prior to testing and balancing of the hydronic system.

After several days of operation, replace the disposable startup strainer with a regular strainer in the suction diffuser.

COMMISSIONING

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

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

DEMONSTRATION AND TRAINING

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

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

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