VA SAFETY REQUIREMENTS FOR REPLACING STEAM VALVES AND PIPING.docx

VA SAFETY REQUIREMENTS FOR REPLACING STEAM VALVES AND PIPING

1. MATERIAL RESTRICTIONS

· No cast iron, malleable, or ductile iron fittings/components

· Use only cast steel or forged steel fittings.

2. MATERIAL REQUIREMENTS

· VA Master specification for steam energy distribution: SECTION 33 63 0 STEAM ENERGY DISTRIBUTION (ASTM)

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

A. Contractor shall make all necessary field measurements and investigations to assure that the equipment and assemblies will meet contract requirements and will fit the space available.

B. Installing Contractor shall provide lists of previous installations for selected items of equipment. Contact persons who will serve as references, with telephone numbers and e-mail addresses shall be submitted with the references. COMMON WORK RESULTS FOR PLUMBING", with applicable paragraph identification.

C. Manufacturers’ Literature and Data including: Full item description and optional features and accessories of the complete system including, but not limited to, dimensions, weights, materials, applications, standard compliance, model numbers, size and capacity. Submit as one package for pipes, fittings and appurtenances, including jointing materials, insulation, hangars, expansion and power set fasteners, and other miscellaneous items.

1. All items furnished shall be free from defects that would adversely affect the performance, maintainability and appearance of individual components and overall assembly.

D. 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// //ASME B31.1//.

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.

5.

3.STEEL PIPES AND FITTINGS

Forged Steel Flanges and Flanged Fittings: ASME B16.5, including bolts, nuts, and gaskets of the following material group, end connections, and facings:

6. Material Group: 1.1.

7. End Connections: Butt welding.

8. Facings: Raised face.

E. Steel Welding Fittings: //ASME B16.9// //ASTM A234/A234M//, seamless or welded.

1. Welding Filler Metals shall comply with AWS D10.12M/D10.12 for welding materials appropriate for wall thickness and chemical analysis of steel pipe being welded.

F. Nipples: ASTM A733, Standard Weight, seamless, carbon-steel pipe.

STEAM PIPING

G. Pipe: //ASTM A53/A53M, steel, seamless, Grade B// //ASTM A106/A106M, Grade B, electric resistance welded//, //Schedule 40// //Schedule 80//. Grade F, furnace butt-welded pipe is prohibited. Use Schedule 80 pipe and fittings for threaded joints.

H. Joints:

1. In trenches: Butt-weld joints. Socket weld is required for pipe sizes 50 mm (2 inches) and less.

2. In tunnels, manholes, and open areas: Butt weld pipe sizes 65 mm (2-1/2 inches) and greater; thread or socket weld pipe sized 50 mm (2 inches) and less. Use Schedule 80 pipe and fittings for threaded joints.

I. Fittings:

1. Butt welded joints: ASTM A234/A234M or ASME B16.9, steel, Grade B, same schedule as adjoining pipe. All elbows shall be long radius unless otherwise indicated. Tees shall be full size or reducing as required, having interior surfaces smoothly contoured.

2. Threaded joints: ASME B16.11, forged steel fittings, Class 2000. Use Schedule 80 pipe only.

3. Socket welded joints: ASME B16.11, forged steel, 13,800 kPa (2000 psig) class.

J. Flanges and Bolts: //ASME B16.5, weld neck, forged steel// //ASTM A105/A105M, pressure class 1035 kPa (150 psig)//. Bolts shall be high strength ASTM A193/A193M, Class 2, Grade B7. Nuts shall be ASTM A194/A194M.

K. Unions: Pipe 50 mm (2 inches) and less shall be threaded, steel, 2050 kPa (297 psig) class.

2. Operational safety

· Ensure all work is coordinated with the VA COR at least 5 days in advance of planned shutdown/startup.

· VA engineering will provide lockout/tagout; isolation of building at the end of the day, on the day before the actual work is scheduled.

· The VA will not cover or reimburse if asbestos coverage is required or pay any additional premiums if required.This is the responsibility of the contractor.

· VA engineering will clear lockout/tagout of steam system to building after repairs are completed.

· VA engineering will align steam to building and warm-up replaced components and place system back in operation.

3. Testing and inspection.

A. Tests and Inspections:

1. Steam and condensate piping for testing: ASME B31.1 and ASME B31.9 and as follows:

a. Leave joints, including welds, uninsulated and exposed for examination during test.

b. Isolate equipment. Do not subject equipment to test pressure.

c. Fill system with normal temperature water between 4 degrees C (40 degrees F) and 32 degrees C (90 degrees F). Ensure the water filled pipe system is protected against freezing during the test such as providing heat tracing along the pipe.

d. Use vents installed at high points to release trapped air while filling system. Use drip legs installed at low points for complete removal of liquid.

2. Test steam and condensate piping as follows:

a. Subject steam and condensate piping to hydrostatic test pressure that is not less than 1-1/2 times the design pressure.

b. After hydrostatic test pressure has been applied for 10 minutes, examine joints for leakage. Remake leaking joints using new materials and repeat hydrostatic test until no leaks exist.

· Prepare and submit test and inspection reports to the COR within 5 working days of test completion and prior to covering the pipe. The cost of testing, documenting, and reporting results is the responsibility of the contractor.

· 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.

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.

4. Wage Determination:

This contract is not a construction project and therefore not subject to Davis-Bacon Act. SCA WD 2015-5613 Revision 32 / FAR 52.222-41.