336300 Steam Energy Distribution - 40 pages.pdf

Des Moines VAMC, Des Moines IA VA Project 636A6-23-101

Construct Steam Tunnel 02/05/2025

3600 30th Street Revision 1

Des Moines, IA 50310

33 63 00-1

STEAM ENERGY DISTRIBUTION

SECTION 33 63 00

PART 1 - GENERAL

1.1 DESCRIPTION

A. This section specifies materials and procedures for construction of underground steam distribution and condensate return piping system, including manholes, outside the buildings. System shall be: walk through concrete tunnels

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

Section 23 05 10, COMMON WORK RESULTS FOR BOILER PLANT AND STEAM

GENERATION.

C. Definitions:

1. System: The complete underground steam and condensate distribution system including all components such as carrier piping, pipe supports, insulation, protective enclosures, anchors, corrosion protection, stress analysis, and accessories.

2. Pre-Engineered Direct-Buried System: A factory-fabricated system.

3. Drainable-Dryable-Testable (DDT) Pre-Engineered Direct-Buried

System: A factory-fabricated system.

4. Concrete Shallow Trench: A system with removable concrete cover in sections located at grade.

5. Walk-through Concrete Tunnels: A system located below grade with sufficient space for carrier pipes, other services, and space to walk upright along the entire length of the system.

6. Carrier Pipe: Pipe carrying the steam or condensate.

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 57 19, TEMPORARY ENVIRONMENTAL CONTROLS: Erosion and

Sediment Controls.

D. Section 01 74 19, CONSTRUCTION WASTE MANAGEMENT.

E. Section 01 81 13, SUSTAINABLE CONSTRUCTION REQUIREMENTS.

F. Section 01 91 00, GENERAL COMMISSIONING REQUIREMENTS.

G. SECTION 02 82 11, TRADITIONAL ASBESTOS ABATEMENT.

33 63 00-2

H. Section 03 30 00, CAST-IN-PLACE CONCRETE: Concrete Work, Reinforcing, Placement and Finishing.

I. Section 05 50 00, METAL FABRICATIONS: Steel for trench and tunnel pipe supports.

J. Section 09 91 00, PAINTING, Painting exposed steel and other surfaces.

K. Section 23 05 10, COMMON WORK RESULTS FOR BOILER PLANT AND STEAM

GENERATION.

L. Section 25 10 10, ADVANCED UTILITY METERING SYSTEM: Metering.

M. Section 26 42 00, CATHODIC PROTECTION: Cathodic Protection of DDT Pre-

Engineered Direct-Buried Systems.

N. Section 31 20 00, EARTHWORK: Excavation, Trench Widths, Pipe Bedding, Backfill, Shoring, Sheeting, Bracing.

O. Section 33 08 00, COMMISSIONING OF SITE UTILITY SYSTEMS.

1.3 APPLICABLE PUBLICATIONS

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

B. American Association of State Highway and Transportation Officials

(AASHTO):

M300-03-UL-2007.........Standard Specification for Inorganic Zinc-Rich

Primer

M273-11-UL-2011.........Standard Specification for Precast Reinforced

Concrete Box Sections for Culverts, Storm

Drains, and Sewers with Less Than 2 Feet of

Cover Subjected to Highway Loadings

C. American Society of Heating, Refrigerating and Air-Conditioning

Engineers (ASHRAE):

90.1-2013...............Energy Efficient Design of New Buildings Except

Low-Rise Residential Buildings

D. American Society of Mechanical Engineers (ASME):

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

B16.5-2013..............Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard

33 63 00-3

B16.9-2012..............Factory-Made Wrought Buttwelding Fittings

B16.11-2011.............Forged Fittings, Socket-Welding and Threaded

B16.21-2011.............Nonmetallic Flat Gaskets for Pipe Flanges

B18.2.1-2012............Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy Hex, Hex Flange, Lobed Head, and

Lag Screws (Inch Series)

B31.1-2014..............Power Piping

B31.9-2014..............Building Services Piping

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

ASME Boiler and Pressure Vessel Code -

BPVC Section VIII-1-2015 Rules for Construction of Pressure

Vessels, Division 1

BPVC Section IX-2015....Welding, Brazing, and Fusing Qualifications

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

A36/A36M-2014...........Standard Specification for Carbon Structural

Steel

A53/A53M-2012...........Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and

Seamless

A105/A105M-2014.........Standard Specification for Carbon Steel

Forgings for Piping Applications

A106/A106M-2015.........Standard Specification for Seamless Carbon

Steel Pipe for High-Temperature Service

A126-2004 (R2014).......Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

A139/A139M-2016.........Standard Specification for Electric-Fusion

(Arc)-Welded Steel Pipe (NPS 4 and over)

A193/A193M-2016.........Standard Specification for Alloy-Steel and

Stainless-Steel Bolting for High Temperature or

High-Pressure Service and Other Special Purpose

Applications

A194/A194M-2015a........Standard Specification for Carbon Steel, Alloy

Steel, and Stainless-Steel Nuts for Bolts for

High Pressure or High Temperature Service, or

Both

33 63 00-4

A234/A234M-2015.........Standard Specification for Piping Fittings of

Wrought Carbon Steel and Alloy Steel for

Moderate and High Temperature Service

A240/A240M-2015b........Standard Specification for Chromium and

Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General

Applications

A733-2015...............Standard Specification for Welded and Seamless

Carbon Steel and Austenitic Stainless-Steel

Pipe Nipples

B61-2015................Standard Specification for Steam or Valve

Bronze Castings

C177-2013...............Standard Test Method for Steady-State Heat Flux

Measurements and Thermal Transmission

Properties by Means of the Guarded-Hot-Plate

Apparatus

C411-05.................Standard Test Method for Hot-Surface

Performance of High-Temperature Thermal

Insulation

C552-07.................Cellular Glass Thermal Insulation

C655-2015...............Standard Specification for Reinforced Concrete

D-Load Culvert, Storm Drain, and Sewer Pipe

C920-2014a..............Standard Specification for Elastomeric Joint

Sealants

C1728-2013..............Standard Specification for Flexible Aerogel

Insulation

E84-2015b...............Standard Test Method for Surface Burning

Characteristics of Building Materials

F. American Welding Society (AWS):

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

Performance Qualification

D10.12M/D10.12-2000.....Guide for Welding Mild Steel Pipe

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

Processes

33 63 00-5

G. Federal Specifications (Fed. Spec.):

A-A-60005-2015..........Frames, Covers, Gratings, Steps, Sump and Catch

Basin, Manhole

L-S-125-1987............Screening, Insect, Nonmetallic

H. Manufacturer’s Standardization Society (MSS):

MSS SP-58-2009..........Pipe Hangers and Supports - Materials, Design, Manufacture, Selection, Application and

Installation

I. Military Specifications (Mil. Spec.):

MIL-S-901-1989..........Shock Tests H.I. (High Impact) Shipboard

Machinery, Equipment and Systems, Requirements for

J. NACE International (NACE):

SP0169-2013.............Control of External Corrosion on Underground or

Submerged Metallic Piping Systems

K. National Fire Protection Association (NFPA):

255-2006................Standard Method of Test of Surface Burning

Characteristics of Building Materials

L. Society for Protective Coatings (SSPC):

SP-2-2004...............Hand Tool Cleaning

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 33 63 00, STEAM ENERGY DISTRIBUTION”, with applicable paragraph identification.

C. 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.

D. If equipment is submitted which differs in arrangement from that shown, provide drawings that show the rearrangement of all associated systems.

Approval will be given only if all features of the equipment and associated systems, including accessibility, are equivalent to that required by the contract.

33 63 00-6

E. Prior to submitting shop drawings for approval, contractor shall certify in writing that manufacturers of all major items of equipment have each reviewed drawings & specifications and have jointly coordinated and properly integrated their equipment and controls to provide a complete and efficient installation.

F. 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.

G. 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.

H. Submittals and shop drawings for interdependent items, containing applicable descriptive information, shall be furnished together and complete in a group. Coordinate and properly integrate materials and equipment in each group to provide a completely compatible and efficient installation. Final review and approvals will be made only by groups.

I. Coordination/Shop Drawings:

1. Submit complete consolidated and coordinated shop drawings for all new systems, and for existing systems that are in the same areas.

2. The coordination/shop drawings shall include plan views, elevations and sections of all systems and shall be on a scale of not less than

1:32 (3/8 inch equal to one foot). Clearly identify and dimension the proposed locations of the principal items of equipment. The drawings shall clearly show the proposed locations and adequate clearance for all equipment, controls, piping, pumps, valves and other items. All equipment requiring service shall be provided with an access door sized for the complete removal of device, component, or servicing of the equipment. Access for service and access for removal of components may be separate as necessary. Provide detailed

33 63 00-7 coordination/shop drawings and loading calculations for all piping systems. The drawings should include all lockout/tagout points for all energy/hazard sources for each piece of equipment. Coordinate lockout/tagout procedures and practices with local VA requirements.

3. Do not install equipment foundations, equipment or piping until coordination/shop drawings have been approved.

J. 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.

K. 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 33 08 00, COMMISSIONING OF SITE UTILITY

SYSTEMS. This shall include pressure testing and cleaning of piping systems.

L. Submit training plans and instructor qualifications in accordance with the requirements of Section 33 08 00, COMMISSIONING OF SITE UTILITY

SYSTEMS.

1.5 QUALITY ASSURANCE

A. Products Criteria:

1. Standard Products: Material and equipment shall be the standard products of a manufacturer regularly engaged in the manufacture, supply and servicing of the specified products for at least 5 years.

However, digital electronics devices, software and systems such as controls and instruments, shall be the current generation of technology and basic design that has a proven satisfactory service record of at least 5 years.

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

33 63 00-8

3. The products and execution of work specified in Division 33 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.

4. When two or more units of the same type or class of materials or equipment are required, these units shall be products of one manufacturer.

5. Assembled Units: Manufacturers of equipment assemblies, which use components made by others, assume complete responsibility for the final assembled product.

6. A nameplate bearing manufacturer's name or trademark, including model number, shall be securely affixed in a conspicuous place on equipment. In addition, the model number shall be cast integrally with equipment, stamped, or otherwise permanently marked on each item of equipment.

7. Asbestos products or equipment or materials containing asbestos shall not be used.

B. Contractor shall restore damaged items to as-new operating condition or replace damaged items as directed by the COR, at no additional cost or time to the Government.

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 B31.1.

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.

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D. ASME Compliance: Comply with ASME B31.1 for materials, products, and installation. Safety valves and pressure vessels shall bear appropriate

ASME labels.

1.6 DELIVERY, STORAGE AND HANDLING

A. Equipment and material placed on the job site shall remain in the custody of the Contractor until phased acceptance, whether or not the

Government has reimbursed the Contractor for the equipment and material. The Contractor is solely responsible for the protection of equipment and material against damage or theft.

B. Protect piping systems against the entry of water, mud or other foreign substances by installing watertight covers on open ends at all times.

Both inside and outside shall be cleaned before painting or placing equipment in operation. Protect direct-buried system coatings from ultraviolet light (sunlight). Existing equipment worked on by the

Contractor or in the Contractor's working area shall be considered to be in the custody and responsibility of the Contractor and shall be protected as required for new work.

C. Damaged equipment shall be replaced with an identical unit as determined and directed by the COR. All insulated piping systems exposed to water must be replaced prior to installation at no additional cost or time to the Government.

1.7 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)

33 63 00-10 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. As-built drawings are to be provided, with a copy of them on AutoCAD version 2023 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.

1.8 COORDINATION

A. Coordinate exterior steam lines and associated systems and connections to building services up to the actual extent of building wall.

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1.9 UTILITY LOCATION SERVICES

A. Prior to any demolition or excavation, provide for utility location services to mark on the ground with fluorescent paint the location of existing underground utilities, and their identification. The term

“utility(ies)” includes both public utilities and VA-owned utilities, for all underground services.

PART 2 - PRODUCTS

2.1 STEEL PIPES AND FITTINGS

A. Steel Pipe: ASTM A53/A53M, Type E, Grade A, black with plain ends.

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

1. Material Group: 1.1.

2. End Connections: Butt welding.

3. Facings: Raised face.

C. Steel Welding Fittings: ASME B16.9seamless 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.

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

E. Pipe-Flange Gasket Materials: ASME B16.21, suitable for chemical and thermal conditions of piping system contents, nonmetallic, flat, asbestos free, 3.2 mm (1/8 inch) maximum thickness unless thickness or specific material is indicated.

1. For flat-face, Class 125 flanges.

2. For raised-face, Class 250 steel flanges.

F. Flange Bolts and Nuts: ASTM A193/A193M Class 2, Grade B7 and nuts shall be ASTM A194/A194M.

G. Carrier Pipe Insulation:

1. Conform to minimum thickness and type of insulation listed in Tables

1 and 2 below as required for service temperature in carrier pipe as listed below.

2. High Pressure Steam temperature is 170 degrees C (338 degrees F), steam pressure is 100psig. Pumped condensate temperature is 93

33 63 00-12 degrees C (200 degrees F). Drip return temperature is 100 degrees C

(212 degrees F).

3. Medium Pressure Steam temperature is 128 degrees C (262 degrees F), steam pressure is 22psig). Pumped condensate temperature is 93 degrees C (200 degrees F). Drip return temperature is 100 degrees C

(212 degrees F).

4. Allowable Carrier Pipe Insulation Type and Minimum Insulation

Thickness:

TABLE 1

Minimum Pipe Insulation Thickness mm (inches) For Steam 110 to 2800 kPa (16 to 406 psig) gauge

Nominal Pipe Diameter mm (inches)

Pre-Formed Mineral Wool

Calcium Silicate

25 (1) 65 (2-1/2) 100 (4)

40 (1-1/2) 65 (2-1/2) 100 (4)

50 (2) 90 (3-1/2) 115 (4-1/2)

65 (2-1/2) 90 (3-1/2) 115 (4-1/2)

75 (3) 100 (4) 125 (5)

100 (4) 100 (4) 125 (5)

125 (5) 100 (4) 125 (5)

150 (6) 115 (4-1/2) 140 (5-1/2)

200 (8) 115 (4-1/2) 140 (5-1/2)

250 (10) 125 (5) 150 (6)

300 (12) 125 (5) 150 (6)

355 (14) 125 (5) 150 (6)

406 (16) 125 (5) 150 (6)

457 (18) 125 (5) 150 (6)

Notes:

1. Submittals shall include manufacturer’s certification that all insulation have passed the 96-hour boiling water test.

2. Pipes smaller than 25 mm (1 inch) shall have same insulation thickness as required for 25 mm (1 inch) pipe.

33 63 00-13

TABLE 2

Minimum Pipe Insulation Thickness mm (inches) For Steam Less than 110 kPa (16 psig) gauge, Condensate Return

Nominal Pipe Diameter mm (inches)

Pre-Formed Mineral Wool

Calcium Silicate

25 (1) 50 (2) 75 (3)

40 (1-1/2) 50 (2) 75 (3)

50 (2) 50 (2) 75 (3)

65 (2-1/2) 50 (2) 75 (3)

75 (3) 65 (2-1/2) 90 (3-1/2)

100 (4) 65 (2-1/2) 90 (3-1/2)

125 (5) 65 (2-1/2) 90 (3-1/2)

150 (6) 75 (3) 115 (4-1/2)

200 (8) 75 (3) 115 (4-1/2)

250 (10) 100 (4) 125 (5)

300 (12) 100 (4) 125 (5)

355 (14) 100 (4) 125 (5)

406 (16) 100 (4) 125 (5)

457 (18) 100 (4) 125 (5)

Notes:

1. Submittals shall include manufacturer’s certification that all insulation have passed the 96-hour boiling water test which indicates that satisfactory performance in underground service can be expected.

2. Pipes smaller than 25 mm (1 inch) shall have the same insulation thickness as required for 25 mm (1 inch) pipe.

H. Insulation Banding and Jacket: 304 stainless steel bands and clips, at least 13 mm (1/2 inches) wide, maximum spacing 457 mm (18 inches). A minimum of two bands is required for each 1200 mm (4 foot) section of insulation.

I. Vinyl-coated Fiberglass Scrim Jacket: Fed. Spec. L-S-125, Type II, Class 2, with 18 x 16 mesh (number of filaments per inch) and made of

0.335 mm (0.013 inch) diameter vinyl-coated fibrous glass yarn. Install bands over the jacket to secure the insulation to the carrier pipe.

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J. Casing: ASTM A139/A139M, smooth-wall steel, electric resistance welded.

Plastic casings are prohibited. Use eccentric connectors as necessary between casing sections to provide continuous gravity drainage in bottom of casing between manholes and between manholes and buildings.

Casing Diameter mm (inches) Minimum Thickness mm (inches)

150 - 1170 (6 – 46) 6.35 (0.250)

K. Casing End Seal Plates with Vents and Drains: ASTM A36/A36M, steel, minimum thickness 10 mm (3/8 inch) for casings up through 300 mm (12 inches) diameter and 13 mm (1/2 inch) for casings over 300 mm (12 inches) diameter. Provide 25 mm (1 inch) drain at the bottom and vent at the top. Construct with threaded steel half couplings. Install threaded brass plugs in drains.

2.2 TUNNELS (WALK THROUGH)

A. Reinforced Concrete Tunnel: Place waterproof membrane between mud slab and bottom concrete slab and continue up sides and over top of tunnel roof slab.

B. Precast Concrete Tunnel: ASTM C655. Construct precast concrete pipe tunnel with straight runs of tunnel. Provide cast-in-place concrete tunnel sections at each bend and at each change in grade of the tunnel.

Mortar shall be as recommended by the precast concrete tunnel manufacturer.

C. Ventilation Ducts: Galvanized sheet steel constructed in accordance with ASHRAE Handbook recommendations. Gravity ventilators shall be factory-fabricated of aluminum or galvanized steel.

D. Provide drainage system at all low points of tunnel systems as shown on the drawings.

E. Waterproof manholes and below grade ventilation ducts.

2.3 STEAM PIPING

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

B. Joints:

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

33 63 00-15

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.

C. 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.

D. Flanges and Bolts: 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.

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

2.4 STEAM CONDENSATE PIPING

A. Pipe: ASTM A53/A53M, seamless, Grade B Schedule 80. Grade F, furnace butt-welded pipe is prohibited. Use Schedule 80 pipe and fittings for threaded joints.

B. 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. For system pressures of 103 kPa (15 psi) or less, thread or socket weld pipe sizes 50 mm (2 inches) and less.

For system pressures of 103 kPa (15 psi) and no greater than 700 kPa

(100 psig), socket weld pipe sizes 25 mm (1 inch) and greater, and thread pipe sizes less than 25 mm (1 inch). For higher system pressure, socket weld pipe sizes of 50 mm (2 inches) or less.

C. Fittings:

1. Welded joints: ASTM A234/A234M, steel, Grade B, or ASME B16.9, same schedule as adjoining pipe.

33 63 00-16

2. Threaded joints: ASME B16.11, forged steel fittings, Class 2000. Use

Schedule 80 pipe and fittings only.

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

D. Unions (Except in Trenches): Pipe 50 mm (2 inches) and less, 2050 kPa

(297 psig) steel.

E. Flanges: Weld neck ASME B16.5 or ASTM A105/A105M, forged steel, 1035 kPa (150 psig).

2.5 EXPANSION LOOPS AND BENDS

A. Stresses: Less than the maximum allowable stress in accordance with

ASME B31.1. Submit shop drawings and stress and anchor force calculations for all loops and bends. Show locations of all anchors, guides and supports. Base calculations on 1035 kPa (150 psig) and 185 degrees C (366 degrees F) for steam line loops and bends and 345 kPa

(50 psig) and 154 degrees C (310 degrees F) for condensate return line loops and bends. Base calculations on actual pressures and temperatures if they are higher than those listed above. Stress analysis shall cover all conditions under which the system can conceivably experience during its lifetime.

B. Steam systems 103 kPa (15 psig) and less: ASME B31.9, base calculations for steam and condensate on 103 kPa (15 psig) and 121 degrees C (250 degrees F).

2.6 VALVES

A. Gate Valves (ASTM A126):

1. Type 101:

a. Type applies to steam valves with sizes 65 mm (2-1/2 inches) and greater.

b. Steel body rated 1035 kPa (150 psig) at 260 degrees C (500 degrees F), 11-1/2 to 13 percent chromium stainless steel flexible wedge and hard faced (stellite) or nickel copper alloy seats, 1035 kPa (150 psig) flanged ends, OS&Y, rising stem, bolted bonnet.

c. Factory installed globe valved bypass on all steam valves greater than 75 mm (3 inches).

d. Drill and tap bosses for connection of drains where shown.

33 63 00-17

2. Type 102 is not used.

3. Type 103:

a. Type applies to condensate valves with sizes 65 mm (2-1/2 inches) and greater.

b. 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, renewable seat rings.

4. Type 104:

a. Type applies to condensate valves with sizes 50 mm (2 inches) and less.

b. 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, union bonnet.

5. Type 105 is not used.

6. Type 106:

a. Type applies to steam valves with sizes 50 mm (2 inches) and less.

b. Forged steel body, rated for 2070 kPa (300 psig) at 216 degrees C

(420 degrees F) minimum Class 4138 kPa (600 psig) or Class 5515 kPa (800 psig), hardened stainless steel or satellite wedge and seats, threaded ends, OS&Y, rising stem, bolted bonnet.

B. Globe Valves (ASTM A126):

1. Type 201:

a. Type applies to steam valves with sizes 65 mm (2-1/2 inches) and greater.

b. Carbon steel body rated 1035 kPa (150 psig) at 260 degrees C (500 degrees F), 11-1/2 to 13 percent chromium stainless steel or stellite disc and seat, 1035 kPa (150 psig) ASME flanged ends, OS&Y, rising stem, bolted bonnet, renewable seat rings. Drill and tap bosses for connection of drains.

2. Type 202 is not used.

3. Type 203:

a. Type applies to condensate valves with sizes 65 mm (2-1/2 inches) and greater.

33 63 00-18

b. 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, renewable seat rings.

4. Type 204:

a. Type applies to steam valves and condensate valves with sizes 50 mm (2 inches) and less.

b. ASTM B61, 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, renewable seat rings.

C. Check Valves (ASTM A126):

1. Type 401:

a. Type applies to steam valves with sizes 65 mm (2-1/2 inches) and greater.

b. Steel body, swing-type, rated for 1035 kPa (150 psig) at 260 degrees C (500 degrees F), stainless steel or stainless steel -faced disc and seat, 1035 kPa (150 psig) ASME flanged ends, bolted cover, renewable disc.

2. Type 402 is not used.

3. Type 403:

a. Type applies to condensate valves with sizes 65 mm (2-1/2 inches) and greater.

b. Forged Steel body, Class B, swing-type, rated for 850 kPa (123 psig) saturated steam, 1380 kPa (200 psig) WOG, bronze or bronze-faced disc and seat, 850 kPa (123 psig) ASME flanged ends, bolted cover, renewable disc and seat.

4. Type 404:

a. Type applies to steam valves and condensate valves with sizes 50 mm (2 inches) and less.

b. Forged Steel body, swing-type, rated for 1380 kPa (200 psig) saturated steam, 2758 kPa (400 psig) WOG, bronze disc, threaded ends, regrinding disc.

D. Ball Valves (ASTM A126):

33 63 00-19

1. Type 501 is not used.

2. Type 502:

a. Type applies to steam valves and condensate valves with sizes 50 mm (2 inches) and less.

b. Forged steel body, rated for 1035 kPa (150 psig) at 185 degrees C

(365 degrees F), 1725 kPa (250 psig) at 121 degrees C (250 degrees F); reinforced TFE seat, stem seal and thrust washer; end entry, threaded ends, one-fourth turn to open.

3. Type 503 is not used.

4. Type 504:

a. Type applies to steam valves and condensate valves with sizes 65 mm (2-1/2 inches) and greater.

b. Carbon steel or ductile iron body, saturated steam service, rated for 1035 kPa (150 psig), stainless steel ball and stem, Polyfil seat, live-loaded stem seal, 1035 kPa (150 psig) ASME flanged ends.

2.7 STEAM PRESSURE REDUCING VALVES

A. Valves: Single seated, diaphragm operated, spring loaded, steam pilot controlled, normally closed, packless, adjustable set pressure. Pilot shall sense controlled pressure downstream of main valve.

B. Controlled reduced pressure to steam piping systems: Design for saturated steam at pressures shown on drawings.

C. Pressure Control: Smooth, continuous. Maximum 10percent deviation from set pressure over a 10 to 1 turndown. Refer to schedules on drawings for flow and pressure requirements. Downstream safety valve to be sized to equal or exceed the maximum total flow capacity of the pressure reducing station.

D. Construction:

1. Main Valve:

a. Pipe sizes 50 mm (2 inches) and less: Steel body rated for 1725 kPa (250 psig), threaded ends. Globe body valve and seat shall be replaceable, Type 316 stainless steel and include stainless steel stem.

b. Pipe sizes greater than 50 mm (2 inches): Steel body rated for

1035 kPa (150 psig) ASME flanged ends, or steel body 1725 kPa

(250 psig) ASME flanged ends, globe body valve and seat shall be

33 63 00-20 replaceable, Type 316 stainless steel and include stainless steel stem.

2. Pilot Valve: Valve plug and seat shall be replaceable, stainless steel.

3. Select pressure reducing valves to develop less than 85 dB(A) at

1500 mm (5 feet) elevation above adjacent floor, and 1500 mm (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.

E. Direct Digital Control PRV Valves: May be furnished in lieu of steam operated valves. All specification requirements for steam operated valves shall apply. In the event of signal failure, valves shall be normally closed. Install per manufacturer’s recommendation.

2.8 STEAM TRAPS

A. Apply at steam line drip points.

B. Fixed orifice or Venturi type traps are prohibited.

C. Construct inverted bucket type with thermostatic vent in bucket, except closed-float-thermostatic on discharge side of pressure reducing stations. Each type furnished by a single manufacturer. Select the traps for pressures and capacities as shown or required.

D. Traps: Steelbodies. Construction shall permit ease of removal and servicing working parts without disturbing connecting piping. Include stainless steel floats, hardened chrome steel valves, stainless steel mechanisms and bi-metallic air vent on inverted bucket traps.

E. Provide electronic trap performance monitoring devices that are compatible with the existing monitoring system. Trap malfunctions shall be automatically transmitted to and properly interpreted by the existing monitoring system. Provide all necessary power sources, transmitting and retransmitting devices and batteries to achieve a properly operating system.

F. All traps shall include ports for future installation of monitoring devices. To facilitate future removal of plugs, remove plugs, install

Teflon tape on the threads, and reinstall the plugs.

33 63 00-21

G. Label each trap at the factory with an identification number keyed to the contract drawings. Label shall be a metal tag permanently attached to the trap.

2.9 STRAINERS, Y TYPE

A. Provide as shown on steam and condensate piping systems.

B. Include open end removable cylindrical screen and threaded blow off connection.

C. For steam service up to 1035 kPa (150 psig) and at drip traps, strainer shall be rated for minimum 1035 kPa (150 psig) saturated steam; rated for 1035 kPa (150 psig), flanged ends, steel, for pipe sizes greater than 50 mm (2 inches). Use forged steel, rated for 1725 kPa (250 psig) saturated steam, threaded ends, for pipe sizes 50 mm (2 inches) and less.

D. For condensate service, strainer shall be rated for 850 kPa (123 psig) saturated steam, 1200 kPa (175 psig) WOG. Provide steel, flanged ends, for pipe sizes greater than 50 mm (2 inches). Provide forged steel, threaded ends, for pipe sizes 50 mm (2 inches) and less.

E. Strainer screen shall be stainless steel, with a free area not less than 2-1/2 times flow area of pipe. Diameter of openings shall be 1.3 mm (0.05 inch) or less on steam service and 1.5 mm (0.06 inch) or less on water service.

F. Include gate type valve and quick couple hose connection on all blowoff connections.

2.10 SAFETY VALVES AND VENT CONNECTORS

A. Safety Valves: Conform to the requirements of ASME BPVC Section VIII, Unfired Pressure Vessels) and be approved by the National Board of

Boiler and Pressure Vessel Inspectors.

B. Relieving Capacity: Not less than that shown on the drawings with a pressure rise above set pressure not to exceed 10 percent of set pressure.

2.11 PRESSURE GAUGES

A. Provide gauges immediately downstream of each steam line isolation valve, before and after each steam pressure reducing station and where shown on the drawings.

33 63 00-22

B. Gauges: ASME B40.100.

1. Solid armored front between measuring element and dial, blowout back, bottom connection, phenol turret type.

2. Non-corrosive, 115 mm (4-1/2 inches) diameter face with black markings on white background.

3. Bourdon tube measuring element designed for service. Provide bellows for pressure ranges less than 103 kPa (15 psig).

4. Stainless steel, rotary movement.

5. Micrometer adjustable, black color pointer.

6. Plastic window.

7. Provide liquid filled gauges at outlet of all pumps.

8. Factory calibrated and certified.

C. Accuracy: Grade 2A, 1/2 percent, on all gauges; except Grade A, one percent permitted on diaphragm actuated gauges, liquid filled gauges, and compound gauges.

D. Include:

1. Red set hands on gauges located at automatic pressure regulator valve outlets.

2. Needle valve or gauge cock rated for the service.

3. Syphon on all steam gauges.

4. Overload stop on all pressure gauges.

E. 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.

2.12 THERMOMETERS, PIPE OR TANK MOUNTED

A. Thermometer locations are shown on the drawings.

B. Thermometers:

1. Industrial type, separable well and socket.

2. Red reading mercury combination Celsius/Fahrenheit scale, 225 mm (9 inches) long.

3. Stainless steel corrosion resistant case with safety glass front.

4. Adjustable angle for ease of viewing.

33 63 00-23

5. Wells sized to suit pipe diameter without restricting flow, or provide oversized pipe at well location. Snug sliding fit between socket and well. Well shall be 316 stainless-steel.

6. Accuracy shall be one percent of scale range.

7. 0 to 149 degrees C (32 to 300 degrees F).

8. Factory calibrated and certified.

2.13 PIPE HANGERS AND SUPPORTS

A. Requirements: MSS SP-58 and ASME B31.1.

B. Applies to all piping not in factory-fabricated direct-buried system.

All systems shall be completely supported. Arrange supports so that all loads due to weight, thermal expansion, seismic shock (if applicable), and pressure are transferred from the support system to the structure.

The design and location of supports shall at all times prevent excessive forces, moments, and stresses from being imposed on the equipment, structure, supported system, and supports. Heated systems generally require resilient or roller/slide supports.

C. Manufacturer Certification: Factory built products of a manufacturer whose principal business is pipe supports for 5 years. All components must have published load ratings. For concrete trenches, non-factory-built products that comply with details may be utilized.

D. Components:

1. Roller supports: MSS SP-58, Type 41. Provide vertical adjustment for

Type 41 with threaded studs and nuts adjacent to the roller.

E. Clevis Supports: MSS SP-58, Type 1.

F. Wall Brackets: MSS SP-58, Type 33.

G. Pipe Stands: MSS SP-58, Type 38.

H. Riser Clamp: MSS SP-58, Type 42.

I. Alignment Guides: Welded steel as shown to restrain movement perpendicular to the long axis of the piping. If not welded, provide steel spider clamped to pipe, enclosed within steel sleeve that is boltedto structural support. Must provide lateral force equal to minimum of 15 percent of anchor loading.

J. Trapeze Supports: MSS SP-58, may be used where pipes are close together and parallel, structural steel channels or angles. Bolt roller supports

33 63 00-24 to steel to support piping subject to horizontal thermal expansion.

Attach other piping with “U” bolts.

K. Pipe Covering Protection Saddles: MSS SP-58, Type 39. Provide at all support points on insulated pipe except where Type 3 pipe clamps are provided.

L. Sliding Supports: MSS SP-58, Type 35. Welded steel attachments to pipe and structure with Teflon or graphite sliding surfaces bonded to the attachments. Provide steel guides, except at expansion bends, to prevent lateral movement of the pipe.

M. Pipe Racks and Miscellaneous Supports: ASTM A36/A36M, structural steel shapes. Manufactured strut systems are acceptable if they have the required load carrying ability.

N. Supports, including all structural steel, in trenches and manholes:

Hot-dip galvanized.

2.14 BURIED UTILITY WARNING TAPE

A. Tape: 0.1 mm (0.004 inch) thick, 150 mm (6 inches) wide, yellow polyethylene with a ferrous metallic core, acid and alkali-resistant and shall have a minimum strength of 12,000 kPa (1740 psig) lengthwise and 10,300 kPa (1500 psig) crosswise with an elongation factor of 350 percent. Provide bold black letters on the tape identifying the type of system. Tape color and lettering shall be unaffected by moisture and other substances contained in the backfill material.

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. Connect new work to existing work in a neat and workmanlike manner.

Where an existing structure must be cut or existing utilities interfere, such obstruction shall be bypassed, removed, replaced or relocated, patched and repaired. Piping connections shall be made only in manholes, tunnels or buildings.

C. Coordinate the location of all items of equipment and work of all trades. Maintain operability and maintainability of the equipment and systems. The contractor at his cost shall perform any relocation of

33 63 00-25 equipment or systems to comply with the requirement of operability and maintainability.

D. Unless otherwise shown in the contract documents, steam lines shall be graded downward not less than 50 mm in 12 meters (2 inches in 40 feet) in direction of the flow. Provide eccentric reducing fittings on steam mains and branches, (except on vertical piping). Install said fittings to maintain continuity of grade in bottom of pipeline. Provide risers with drip pockets and steam traps on steam lines where space restrictions prevent continuous grading. All steam traps must be located in manholes or tunnels.

3.2 DEMOLITION

A. Perform work in accordance with requirements for phasing and the

Drawings. Phasing shown on drawings is an outline from which the contractor will use to provide more details in executing the work in each phase.

B. If asbestos containing materials are suspected to be present in the demolished items not identified in the drawings to be part of the asbestos abatement, the contractor shall secure the area, remove their personnel and refer the matter to COR immediately for resolution. Refer to Section 02 82 11, TRADITIONAL ASBESTOS ABATEMENT.

C. Completely remove all pipe, valves, fittings, insulation, and all hangers including the connection to the structure and any fastenings.

D. Seal all openings in manhole or building walls after removal of piping.

E. All material and equipment removed shall become the property of the

Contractor and shall be removed from Government property and shall not be stored in operating areas unless designated as being turned over to the owner.

F. All flame cutting shall be performed with facility burn permit in place and adequate fire protection facilities available as required by safety codes and COR.

3.3 PIPING INSTALLATION

A. Drawings indicate general location and arrangement of piping systems.

For field installed insulation, install piping insulation as specified herein and/or as recommended by the manufacturer.

B. Remove all standing water in the bottom of trench.

33 63 00-26

C. Pipe Bedding: Minimum 150 mm (6 inch) layer of sand. Provide compaction and leveling of virgin soil prior to installing bedding.

D. Clearance: Minimum 150 mm (6 inches) clearance between the external insulation/casing of pipes 300 mm (12 inches) or smaller, and if no valves and fittings are present along the pipes. Otherwise provide the required service clearances between valves/fittings on adjacent pipes to allow future replacement. Obtain minimum service clearances from valve/fitting manufacturer.

E. Testing: Do not insulate piping or backfill piping trench until field quality-control and cleaning, followed by testing has been completed and results approved by COR.

F. Grade:

1. Install condensate piping at uniform grade of 0.4 percent downward in direction of flow.

2. Install steam piping at uniform grade of 0.2 percent downward in direction of flow or as indicated on the Drawings.

G. Drain Valves and Air Vents: For carrier piping, install at low points and air vents at high points.

H. Install components with pressure rating equal to or greater than system design pressure.

I. Install piping free of sags and bends.

J. Install fittings for changes in direction and branch connections.

K. On direct-buried pipes, secure anchors with concrete thrust blocks.

3.4 DRAIN VALVES AND VENT VALVES

A. Provide 40 mm (1-1/2 inch) minimum pipe size drain valves on condensate return carrier pipes at all low points in manholes. Provide 25 mm (1 inch) minimum manual air vent valves in manholes at all high points in condensate return carrier piping.

B. Do not install any valves at the outer casing piping vents.

3.5 PIPE SUPPORT INSTALLATION (IN TRENCHES, TUNNELS, MANHOLES)

A. Coordinate support locations prior to erection of piping. Hanger parts must be marked at the factory with a numbering system keyed to hanger layout drawings. Layout drawings must be available at the site during construction.

33 63 00-27

B. Upper Attachments to Structure:

1. New reinforced concrete construction shall have concrete inserts.

2. For existing reinforced concrete construction, upper attachment shall be welded or clamped to steel clip angles or other construction methods/detail shown on the drawings that are expansion bolted to the concrete. Expansion bolting shall be located so that bolts are shear loaded.

3. For steel deck and structural framing, upper attachments shall be welded or clamped to structural steel members.

C. In existing concrete construction, expansion fasteners may be used for hanger loads up to one third the manufacturer's rated strength of the expansion fastener. Power set fasteners may be used for loads up to one fourth of rated load. When greater hanger loads are encountered, additional fasteners may be used and interconnected with steel members combining to support the hanger.

D. Special Supports:

1. Secure horizontal pipes where necessary to prevent vibration or excess sway.

2. Where hangers cannot be adequately secured as specified, make special provisions for hanging and supporting pipe to be submitted to COR for A/E review.

3. Do not attach pipe supports, hangers, clamps or anchors to equipment unless specified for that equipment or unless the COR gives written permission.

E. Minimum Clearances in Tunnels and Trenches:

1. Floor to bottom of pipe support beam: 150 mm (6 inches).

2. Floor to bottom of pipe insulation jacket: 150 mm (6 inches).

3. Wall to side of pipe insulation jacket: 150 mm (6 inches.)

4. Ceiling to top of pipe insulation jacket: 150 mm (6 inches).

5. Greater clearances shall be provided to meet maintenance, repair/replacement, and service requirements of valves, fittings and equipment as recommended by their manufacturers.

33 63 00-28

3.6 PAINTING EXPOSED STEEL SURFACES IN MANHOLES, TUNNELS AND CONCRETE SHALLOW

TRENCHES

A. For manholes and walk-through tunnels, provide surface cleaning and preparation in accordance with SSPC SP-2 and apply prime coat of rust resistant metal primer.

B. For concrete shallow trenches, provide surface cleaning and preparation in accordance with SSPC SP-2 and apply primer and finish coat of zinc-rich paint.

3.7 DIRECT-BURIED SYSTEM INSTALLATION

A. The Contractor shall deliver, store, install and test the system as per manufacturer’s recommendations. All work shall be in strict accordance with the requirements specified by the manufacturer. Printed instructions must be available on site prior to delivery of system components. Any changes required to the design and layout of the system due to site conditions must be approved in writing by the manufacturer and submitted for review by the COR. All branch piping connections, valves and drip traps must be located within manholes.

B. Excavation, Trenching, and Backfilling: Perform all excavation, trenching, and backfilling as required by the system manufacturer’s design. Beach sand or any sand with large amounts of chlorides is prohibited. Install per manufacturers recommendations and as shown on contract drawings based on soil conditions. Foundation for system must be firm and stable. Foundation and backfill must be free from rocks.

Concrete anchor and thrust blocks must be installed in undisturbed earth. Backfilling must not commence until elevations have been surveyed and accepted and system has been satisfactorily pressure tested and cleaned, including hydrostatic testing of carrier pipes and air testing of casings.

C. Maintain constant slope of carrier pipes as shown or specified. Prior to backfilling over the top of the casing, but after removal of temporary supports, Contractor shall measure and record elevations of top of casing in the trench.