232213 02-2020 Steam and Condensate Heating Piping.pdf

Department of Veterans Affairs VA Project No. 502-17-102 Alexandria VA Health Care System Replace Roof and HVAC System in Bldg. 9 Pineville, LA Bid Documents: 08/10/20 Addendum #1: 01/10/2025

02-01-20

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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 09 91 00, PAINTING.

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

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

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

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

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

I. Section 23 25 00, HVAC WATER TREATMENT.

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 standard will govern.

B. American Society of Mechanical Engineers (ASME):

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

B16.5-2017..............Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard

B16.9-2018..............Factory Made Wrought Buttwelding Fittings

B16.11-2016.............Forged Fittings, Socket-Welding and Threaded

B16.42-2016.............Ductile Iron Pipe Flanges and Flanged Fittings:

Classes 150 and 300

B31.1-2018..............Power Piping

B31.9-2017..............Building Services Piping

B40.100-2013............Pressure Gauges and Gauge Attachments

ASME Boiler and Pressure Vessel Code (BPVC) -

BPVC Section II-2019 Materials

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BPVC Section VIII-2019 Rules for Construction of Pressure Vessels, Division 1

BPVC Section IX-2019Welding, Brazing, and Fusing Qualifications

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

A53/A53M-2018...........Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and

Seamless

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

Steel Pipe for High-Temperature Service

A193/A193M-24a..........Standard Specification for Alloy-Steel and

Stainless Steel Bolting for High Temperature or

High Pressure Service and Other Special Purpose

Applications

A216/A216M-2018.........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

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

Plates, Carbon Steel, for Moderate- and Lower-

Temperature Service

A536-1984(2019e1).......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. National Board of Boiler and Pressure Vessel Inspectors (NB):

Relieving Capacities of Safety Valves and Relief Valves

G. 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.

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. Strainers.

7. All specified steam system components.

8. Gauges.

9. Thermometers and test wells.

10. Electric heat tracing systems.

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

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

2. Flash tanks.

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.

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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 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.

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.

2. Comply with provisions in ASME B31.9.

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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:

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1. 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.

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 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.

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 80.

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.

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2.3 FITTINGS FOR STEEL PIPE

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

1. Cast iron fittings or piping is not acceptable for steam and steam condensate piping. Bushing reduction or use of close nipples is not acceptable.

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 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 under.

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 not acceptable 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: Alloy-Steel or Stainless Steel, ASTM A193

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.

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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.

2.5 VALVES

A. Asbestos packing is not acceptable.

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 m (7 feet) or more above the floor or operating platform.

D. Shut-Off Valves:

1. Gate 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. 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

23 22 13 - 9 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.

F. 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.

G. Manual Radiator/Convector Valves: Brass, packless, with position indicator.

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2.6 STRAINERS

A. 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 must 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 on the contract drawings.

2.8 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 m/s (7.5 f/s).

2. Tube fouling factor: TEMA Standards, but not less than 0.00018 m2K/W (0.001 ft2hrF/Btu).

3. Materials:

a. Shell: Steel.

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

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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 db(A) at 1.5 m (5 feet) elevation above adjacent floor, and 1.5 m (5 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

23 22 13 - 12 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. Steam Trap: Each type of trap shall be the product of a single manufacturer. Provide trap sets at all low points and at 61 m (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 on the drawings, 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, constructed to permit ease of removal and servicing working parts without disturbing connecting piping. The use of raised face flange is required on pipe sizes 1½ inch and above. The use of unions is acceptable for pipe sizes below 1½ 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.

G. 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

23 22 13 - 13 be balanced pressure type that responds to steam pressure-temperature curve and vents air at any pressure.

H. NON-JACKETED RAPID ABSORPTION STEAM HUMIDIFIERS

1. The steam humidifier panel assembly shall consist of an insulated steam supply header/condensate separator, a condensate collection header and a bank of closely spaced vertical high-efficiency insulated steam dispersion tubes spanning the distance between the two headers. It shall provide for rapid absorption of steam within the airstream, drip-free of condensate, utilizing saturated steam at any pressure from 2.9 ounces to 50 psig.

2. Construct tubes and headers of Type 304 stainless steel, with heli-arc welded joints.

3. Each dispersion tube shall be fitted with two rows of steam discharge tubelets inserted into the tube wall, centered on the diametric line and spaced 1-1/2-inches apart.

a. The tubelets shall be made of a non-metallic material designed for a maximum steam temperature of 300 deg. F.

b. The two rows shall discharge steam in diametrically opposite directions.

c. Each tubelet shall contain a steam orifice sized for its required steam capacity.

d. Unless otherwise indicated on the drawings, furnish a vertical tube model.

4. Each packaged humidifier panel assembly of tubes and headers shall be contained within a flanged galvanized steel casing, enclosing the headers, to permit duct mounting or to facilitate the stacking of the end-to-end mounting of multiple humidifier panels in ducts or air handling unit casings.

5. Furnish each humidifier assembly with a modulating, normally closed (N.C.) electric steam control valve, steam strainer and float and thermostatic type steam trap, all shipped loose for field installation.

2.9 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

23 22 13 - 14 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 more than 70 percent of the gauge’s range are prohibited. The units of pressure shall be psig.

2.10 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.

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.

2.11 FIRESTOPPING MATERIAL

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

2.12 ELECTRICAL HEAT TRACING SYSTEMS

A. Systems shall meet requirements of NFPA 70.

B. Provide tracing for outdoor piping subject to freezing temperatures below 3.3 degrees C (38 degrees F) as follows:

1. Steam condensate exposed to weather.

C. Heat tracing shall be provided to the extent shown on the drawings

(Floor Plans and Elevations). Heat tracing shall extend below grade to below the defined frost line.

D. Heating Cable: Flexible, parallel circuit construction consisting of a continuous self-limiting resistance, conductive inner core material between two parallel copper bus wires, designed for cut-to-length at

23 22 13 - 15 the job site and for wrapping around valves and complex fittings. Self-regulation shall prevent overheating and burnouts even where the cable overlaps itself.

1. Provide end seals at ends of circuits. Wires at the ends of the circuits are not to be tied together.

2. Provide sufficient cable, as recommended by the manufacturer, to keep the pipe surface at 2.2 degrees C (36 degrees F) minimum during winter outdoor design temperature, but not less than the following:

a. 75 mm (3 inch) pipe and smaller with 25 mm (1 inch) thick insulation: 4 watts per foot of pipe.

b. 100 mm (4 inch) pipe and larger 40 mm (1-1/2 inch) thick insulation: 8 watts per feet of pipe.

E. Electrical Heating Tracing Accessories:

1. Power supply connection fitting and stainless-steel mounting brackets. Provide stainless steel worm gear clamp to fasten bracket to pipe.

2. 15 mm (1/2 inch) wide fiberglass reinforced pressure sensitive cloth tape to fasten cable to pipe at 300 mm (12 inch) intervals.

3. Pipe surface temperature control thermostat: Cast aluminum, NEMA 4

(watertight) enclosure, 15 mm (1/2 inch) NPT conduit hub, SPST switch rated 20 amps at 480 volts ac, with capillary and copper bulb sensor. Set thermostat to maintain pipe surface temperature at not less than 1 degrees C (34 degrees F).

4. Signs: Manufacturer's standard (NEC Code), stamped "ELECTRIC TRACED" located on the insulation jacket at 3 m (10 feet) intervals along the pipe on alternating sides.

PART 3 - EXECUTION

3.1 GENERAL

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

Government.

B. The drawings 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

23 22 13 - 16 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 on the drawings 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 convertors and other 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 on the drawings. 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 not less than 25 mm (1 inch) in 12 m (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 on the drawing.

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 on the drawings.

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 on the drawings. Install components furnished by others such as flow elements (orifice unions), 23 22 13 - 17 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 m (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 m (8 feet) above grade with down turned elbow.

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.

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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

(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 must be performed. All welds will be visually inspected by the COR. The VA reserves the right to require testing on additional welds up to 100 percent if more 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 commissioning

23 22 13 - 19 agent 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 must 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.

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 ½ inch and above a raised face flange is required to allow for removal of the steam trap without disturbing surrounding piping.

2. On pipe size below 1 ½ inch raised face flanges or unions may be used to allow for removal of the traps.

3.5 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.

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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 working days of test completion and prior to covering the pipe.

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

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

3.6 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 operation. Contractor shall be responsible for damage caused by inadequately cleaned/flushed systems.

3.7 ELECTRIC HEAT TRACING

A. Install tracing as recommended by the manufacturer.

B. Coordinate electrical connections.

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 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.

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

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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 will be tested as part of a larger system.

3.10 DEMONSTRATION AND TRAINING

A. Provide services of manufacturer’s technical representative 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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