(SOW) PCT FCV - Chiller Valve Replacement.pdf

Drawings and Specifications for the

Replacement of Flow Control Valves Serving the Chilled Water System and the Condenser

Water System at the Federal Aviation Administration Potomac Consolidated

TRACON in Warrenton, VA

March 2024

Prepared By: Ashburn, VA TSC

Table of Contents

TAB 1 Project Summary

TAB 2 Pictures Picture 1 ChWR Ball Valves at Chillers Picture 2 TYP ChWR Ball Valves at Chiller Picture 3 TYP CTS Ball Valve at Chiller Picture 4 HE and CTF BF Valves Picture 5 TYP HE Butterfly Valve – gnd level Picture 6 TYP HE Butterfly Valve- high elev Picture 7 Cooling Towers Picture 8 TYP CTR Butterfly Valve at CT Picture 9 TYP CTS Butterfly Valve at CT Picture 10 TYP CT Equalizing Line Butterfly Valve Picture 11 CTR Butterfly and BYPASS Ball Valves

TAB 3 Drawings

TSC-23-190-001 Flow Control Valve Schedule

AEA-E-36173-M204 REDLINED ORIG CONTRACT DWG

AEA-E-36173-M205 REDLINED ORIG CONTRACT DWG

TAB 4 Specifications Section 01100 General Conditions Section 15100 Valves Section 15250 Mechanical Insulation Section 16856 Electric Heat Trace Section 17200 Control Systems

TAB 1

Project Summary

PCT Flow Control Valve Replacement March 2024

Project Summary Page 1

Project Summary

A. Project Identification:

Flow Control Valve Replacement

FAA -Potomac Consolidated TRACON 3599 MacIntosh Drive Warrenton, VA 20187

B. Project Requirements:

1.) Replacement of (24) flow control valves and associated actuators and positioners serving both the Chilled Water system and the Condenser Water system. Valve sizes range from 4” thru 8”. Valve type are butterfly and ball.

2.) Removal and replacement/reconnection of control wiring at each device.

3.) Removal and replacement/reconnection of pneumatic piping/tubing each the device.

4.) Removal and replacement of exterior pipe insulation, where required.

5.) Removal and replacement of electric heat trace for piping, where required.

6.) Removal and replacement of interior pipe insulation, where required.

7.) Isolation of flow using pipe freeze method, where required.

8.) All staging, scaffolding and rigging, as required.

9.) The actual replacement of valves – where a disruption to chilled water or condenser water flow will be effected – shall be completed during off peak hours.

Off peak hours are typically 10pm to 6am. Set up, prep work and breakdown can be accomplished during normal day shift hours.

10.) A pre-bid site visit is strongly encouraged.

TAB 2

Pictures

John McCormick Typewritten Text PICTURE 1: Chilled Water Return Ball Valves at Chillers

PICTURE 2: TYPICAL CHILLED WATER RETURN BALL VALVE

PICTURE 3: TYPICAL CTS BALL VALVE AT CHILLER

PICTURE 4: HEAT EXCHANGER AND CT FILTER VALVES

PICTURE 5: TYP HEAT EXCHANGER VALVE - GND ELEV

PICTURE 6: TYP HE VALVE - HIGH ELEV

PICTURE 7: COOLING TOWERS

PICTURE 8: TYP CTR BUTTERFLY VALVE

PICTURE 9: TYPICAL CTS BUTTERFLY VALVE

PICTURE 10: TYP CT EQUALIZING LINE BUTTERFLY VALVE

PICTURE 11: TYP CT BYPASS BALL VALVE AND CTR BUTTERFLY VALVE

TAB 3

Drawings

Oval

John McCormick Oval

John McCormick Oval

John McCormick Rectangle

John McCormick Rectangle

Rectangle

Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Line

John McCormick Line

John McCormick Line

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Oval

John McCormick Rectangle

John McCormick Rectangle

John McCormick Rectangle

John McCormick Rectangle

John McCormick Rectangle

John McCormick Rectangle

John McCormick Rectangle

John McCormick Rectangle

John McCormick Rectangle

John McCormick Rectangle

John McCormick Rectangle

John McCormick Rectangle

Rectangle

TAB 4

Specifications

General Conditions 01100-1

SECTION 01100 – GENERAL CONDITIONS

PART 1 – SCOPE AND SCHEDULE

1.1 PROJECT SUMMARY

A. Location:

FAA -Potomac Consolidated TRACON

3599 MacIntosh Drive Warrenton, VA 20187

B. Scope of Work:

1.) Replacement of (24) flow control valves and associated actuators and positioners serving both the Chilled Water system and the Condenser Water system.

2.) Return all ancillary insulation, electric hear tape, interior pipe insulation, ect. to original status.

3.) Pipe freeze method is the preferred method for isolation of flow.

4.) All staging, scaffolding and rigging.

5.) Pre-bid site visit is strongly encouraged.

1.2 WORK SCHEDULE

A. Work shall be completed within 120 days of Notice to Proceed.

B. The actual replacement of valves – where a disruption to chilled water or condenser water flow will be effected – shall be completed during off peak hours. Off peak hours are typically 10pm to 6am. Set up and breakdown can be accomplished during normal day shift hours.

PART 2 – PROJECT COORDINATION

2.1 PROJECT COORDINATION

A. The Contractor is made aware that this facility is responsible for the control and navigation of air traffic. The unscheduled loss or shut down of air traffic control equipment or associated support equipment for any amount of time will jeopardize safety of the flying public. Contractor shall closely coordinate all work activities with the FAA site POC as to not impact the operation of the facility.

B. The contractor is advised that ongoing maintenance activities will continue at this facility and that full cooperation is required with maintenance personnel in order to assure continued operation of equipment.

General Conditions 01100-2

C. The contractor shall not operate existing electronic, electrical or mechanical equipment at this facility.

D. The contractor shall accurately plan and lay out the sequence of replacement. A Valve Replacement Plan shall be submitted to the FAA for review and approval which shall detail the method of flow isolation (using existing valves, where possible or by freezing).

2.2 ACCESS

A. Contractor personnel will be assigned an FAA point of contact/escort and be continually escorted throughout the project.

2.3 TECHNICAL GUIDANCE/REQUESTS FOR INFORMATION

A. Contractor shall submit, in writing, any requests for technical guidance or requests for changes due to differing field conditions, improved means or methods, material substitutions, or any other reason. Requests shall be submitted to the Contracting Officer.

PART 3 - EXECUTION

3.1 FIELD MEASUREMENTS

A. Contractor is responsible for making complete field measurements. Check all dimensions at the job site for components requiring fit to existing conditions.

3.2 SUBMITTALS

A. The contractor shall submit of list of proposed submittals and shop drawings for approval. This list will be known as the Submittal Register. At a minimum, submittals are required for:

a. Valves

b. Actuators

c. Positioners

d. Replacement Plan

B. Contractor shall make a submittal and/or shop drawing for each type of material and system list on the Submittal Register. Submittal shall include four (4) copies of cut sheet(s) and/or shop drawings where required. One (1) copy will be returned to contractor with disposition and comments within 21 days of receipt. Action on the shop drawing or submittal shall be one of the following:

a. Approved

b. Approved as Noted

c. Approved as Noted, Resubmission Required

d. Disapproved

If the submittal or shop drawing is returned as Approved as Noted, Resubmission Required the contractor may or may not be able to proceed with procurement of the component as it will depend on the disposition of the required resubmission. Disapproved submittals or shop drawings will require complete rectification of the issue prior to procurement.

General Conditions 01100-3

3.3 PROJECT SAFETY AND HEALTH PROGRAM REQUIREMENTS

A. All on-site work under this Contract shall be performed in compliance with the requirements of all Federal and State Occupational Safety and Health laws and regulations as they apply to construction site activity.

1. Comply with applicable Occupational Safety and Health Standard (29 CFR 1910 and 1926) promulgated pursuant to authority of the Occupational Safety and Health Act of 1970.

2. Comply with any other applicable Federal, State, or local regulations governing workplace safety to the extent that they do not conflict with other clauses of this contract. If a conflict exists between sections of this Contract, the more stringent requirement takes precedence.

3. Take all other proper precautions to protect the safety and health of the contractor’s employees, Federal Aviation Administration employees, and the public. Provide and maintain barricades, guard rails, covered walkways, lighting devices and other protective devices necessary to warn and protect the workmen and general public from hazards at the construction site.

4. Contractor shall maintain a Project Safety and Health Plan which shall address site-specific safety and health requirements and procedures to include, but not limited to excavations, fall protection, electrical safety, scaffold safety, cranes, steel erection, welding, burning and cutting safety, concrete and masonry work.

5. In addition to compliance with applicable statutory and regulatory requirements, the Project Safety and Health Plan shall contain provisions for mandatory safety orientation for every contractor, subcontractor, and vendor employee assigned or sent to the site. Safety orientation shall cover as a minimum the rules and regulations governing on-site construction activities, special known hazards, accident prevention, emergency procedures, and personal protection equipment requirements.

6. As work progresses, the Plan shall be updated to adapt to new situations and new conditions.

Changes to the Project Safety and Health Plan shall be made only with full concurrence of the Contracting Officer.

7. If any unforeseen hazard should become evident during the performance of the work, bring such information to the attention of the Contracting Officer, verbally and in writing. Take the necessary action to re-establish and maintain safe working conditions.

8. The Project Safety and Health Plan shall include MSD sheets for materials and products to be used on the project. MSD sheets shall be maintained at the project site where all employees will have access.

B. The Project Superintendent shall act as Safety Director and be responsible for the implementation, execution and oversight of the Project Safety and Health Plan. The Superintendent shall have authority from the contractor to stop work to abate hazardous conditions or unsafe practices, and to eject any contractor, subcontractor, or vendor employee from the project site for failure to comply with safety requirements. The Project Superintendent’s authority, responsibilities, and duties in the capacity of Safety Director shall be incorporated as part of the written Project Safety and Health Plan. These responsibilities shall include, but not be limited to conducting subcontractor pre-construction safety program reviews, conducting the employee safety orientation training, conducting weekly safety meetings, conducting daily site

General Conditions 01100-4 safety inspections, auditing subcontractor safety compliance, conducting accident investigations, and preparing required periodic and special safety reports.

C. When the Contractor is notified by the Contracting Officer of non-compliance with the safety or health provisions of this contract, the contractor shall immediately, unless otherwise instructed, correct the unsafe or unhealthy condition. If the Contractor fails to comply promptly, all or part of the Work will be stopped by notice from the Contracting Officer. There will not be any allowance for time or compensation due to work stoppage for an unsafe condition.

D. The contractor will maintain an accurate record of exposure data and all accidents incidental to work performed under this Contract. The contractor must report the exposure data and accidents to the Contracting Officer.

E. All subcontracts and vendor purchase orders related to this project shall contain provisions requiring compliance with the contractor’s approved Project Safety and Health Plan.

F. Prior to commencing construction, representatives of the Contractor, including the Project

Superintendent, shall hold a Safety Meeting with designated representatives of the Contracting Officer for the purpose of reviewing the approved Project Safety and Health Plan and discussing the implementation of the plan.

G. The Contractor shall take all necessary precautions to prevent injury to the public, occupants, or damage to property of others. The public and occupants include all persons not employed by the Contractor or a subcontractor.

H. Wherever practical, the work area shall be fenced, barricaded or otherwise blocked off from public or occupants to prevent unauthorized entry into the work area.

1. Provide traffic barricades and traffic control signage where construction activities occur in vehicular areas.

2. Corridors, aisles, stairways, doors and exits shall not be obstructed or used in a manner to encroach upon routes of ingress or egress utilized by the public or occupants, or to present an unsafe or unhealthy condition to the public or occupants.

3. Store, position and use equipment, tools, materials, scraps and trash in a manner that does not present a hazard to the public or occupants by accidental shifting, ignition or other hazardous activity.

4. Store and transport refuse and debris in a manner to prevent unsafe and unhealthy conditions for the public and occupants. Cover refuse containers, and remove refuse on a frequent regular basis acceptable. Use tarpaulins or other means to prevent loose transported materials from dropping from trucks.

3.4 TEMPORARY FACILITIES

A. The Contractor shall provide and maintain all required temporary facilities and equipment required to complete the project to include, but not limited to, scaffolding, lighting, staging, storage, physical protection barriers and temporary ventilation.

B. The contractor make provisions to protect the work and all areas/equipment surrounding the work area. Barriers for soldering and shall be of fire resistant construction and shall protect all adjacent areas. A dedicated Fire Watch is required during all welding, torching or open flame operations.

A fire watch is defined as a competent person whose sole responsibility is to monitor the welding, General Conditions 01100-5 torching or open flame operation and assure that the sparks and fumes generated do not pose a risk to life or property. See section 3.5 for fire extinguisher requirements.

C. The contractor shall be permitted to use facility utility power only after close coordination with the FAA POC on type of power and location of connection points.

D. The contractor is advised that running water and sanitary facilities are available at this facility.

3.5 FIRE PROTECTION

A. At the pre-construction meeting, the contractor will be shown the locations of fire extinguishers and informed about fire and emergency procedures applicable to the facility during the pre-construction meeting.

B. Contractor shall provide at least one fire extinguisher for welders and plumbers or other trades using open flames in the execution of their work. Maintain “Fire Watch” personnel, with fire extinguisher in hand, during all welding/cutting/soldering or other open flame operations.

3.6 ENVIRONMENTAL PROTECTION AND POLLUTION CONTROL

A. The contractor shall perform all work necessary to prevent environmental pollution during or as a result of construction performed under this contract.

3.7 MATERIALS AND EQUIPMENT

A. Ordering of Materials: Orders for materials and equipment shall be made promptly after approval of submittal in order to avoid any delay to project schedule.

B. Transportation and Delivery: Arrange for delivery to avoid impact to project schedule and to avoid impact to the operation of the existing facility. Deliver materials and equipment in their original, unopened containers bearing the manufacturers label.

C. Storage: Store materials and equipment to provide protection from damage from damage, dust and moisture. Store all flammable or volatile materials properly off site.

D. Arrange storage in a manner to provide easy access for inspection.

E. Manufacture and Fabrication: Design, fabricate and assemble materials and equipment using the best engineering and shop practices. Manufacture all like parts of duplicate units to standard sizes and gages, to be interchangeable. Two or more items of the same kind shall be identical.

F. Equipment and member capacities, sizes and dimensions shown or specified shall be adhered to unless variations are approved in writing.

G. Manufacturer’s Instructions: When contract documents require that the installation of the work shall comply with the manufacturer’s printed instructions, obtain and distribute copies of such instructions to those involved in the installation, including (2) copies to the Contracting Officer.

Maintain one set of instructions at the job site. Strict adherence to the manufacturer’s instructions

General Conditions 01100-6 is required. When project conditions or unique circumstances require deviation from the printed instructions, consult with the Contracting Officer for further guidance. Do not proceed until clear direction has been obtained.

3.8 INITIAL MAINTENANCE

A. Maintain new systems until the project is turned over to the FAA.

3.9 CLEANUP AND RESTORATION

A. Contractor is responsible for maintaining the worksite in a clean and safe condition during the work shift as well as after work hours. The contractor shall restore the site to the original condition upon completion of the project.

END OF SECTION 01100

VALVES 15100 - 1

SECTION 15100 - VALVES

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes general duty valves common to several mechanical piping systems.

B. Grooved Mechanical joint pipes and valves shall not be used in Environmental, Administration, Commons Wings, or in the Penthouse. Their use is permitted only in the trenches under the raised floor in the Electronic/Operations Wings.

C. All exterior valve operator shall be electric type.

1.2 REFERENCE STANDARDS

A. American Iron and Steel Institute (AISI))

B. American National Standards Institute (ANSI))

1. B16.1: Cast Iron Pipe Flanges and Flanged Fittings.

2. B16.10: Face-to-Face and End-to-End Dimensions of Valves.

3. B16.18: Cast Copper Alloy Solder Joint Pressure Fittings.

4. B16.34: Valves, Flanged, Threaded, and Welding End.

5. B31.9: Building Services Piping.

6. 221.21: 93 Automatic Valves for Gas Appliances.

C. American Society of Mechanical Engineers (ASME)

1. B1.20.1: Pipe Threads, General Purpose (Inch).

2. B16.1: Cast Iron Pipe Flanges and Flanged Fittings.

3. B16.5: Pipe Flanges and Flanged Fittings.

4. B31.1: Power Piping.

5. B31.9: Building Services Piping.

6. Section VIII - Rules for Construction of Pressure Vessels.

D. American Society for Testing and Materials (ASTM)

1. A126: Specification for Gray Iron Castings for Valves, Flanges and PipeFittings.

2. A148: Steel Castings, High Strength, for Structural Purposes

3. A395: Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated

Temperatures.

4. A536: Ductile Iron Castings

5. B16: Free Cutting Brass Rod, Bar and Shapes for Use in Screw Machines.

6. B62: Standard Specification for Composition Bronze or Ounce Metal Castings.

7. B371: Copper-Zinc Silicon Alloy Rod.

E. Manufacturers Standardization Society (MSS)

1. SP25: Marking System for Valves, Fittings, Flanges and Unions.

2. SP68: High Pressure Offset Seat Butterfly Valves.

VALVES 15100 - 2

3. SP70: Cast Iron Gate Valves, Flanged and Threaded Ends.

4. SP71: Cast Iron Swing Check Valves, Flanges and Thread Ends.

5. SP78: Cast Iron Plug Valves, Flanged and Threaded Ends.

6. SP80: Bronze Gate, Globe, Angle and Check Valves.

7. SP85: Cast Iron Globe and Angle Valves, Flanged and Threaded Ends.

F. National Fire Protection Agency (NFPA)

1. 54: National Fuel Gas Code.

2. 70: National Electrical Code.

1.3 SUBMITTALS

A. Product Data for each valve type. Include body material, valve design, pressure and temperature classification, end connection details, seating materials, trim material and arrangement, dimensions and required clearances, and installation instructions. Include list indicating valve and its application.

B. Maintenance data for valves to include in the operation and maintenance manual specified in

Division 1. Include detailed manufacturer's instructions on adjusting, servicing, disassembling, and repairing.

C. Flow Control Valve Schedule: Provide flow control valve schedule indicating valve model number, body type, Cv factor, actual pressure drop, actuator model number, and valve pressure shutoff rating.

1.4 QUALITY ASSURANCE

A. ASME Compliance: Comply with ASME B31.9 for building services piping and ASME B31.1 for power piping.

B. MSS Compliance: Comply with the various MSS Standard Practice documents referenced.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Prepare valves for shipping as follows:

1. Protect internal parts against rust and corrosion.

2. Protect threads, flange faces, grooves, and weld ends.

3. Set globe and gate valves closed to prevent rattling.

4. Set ball and plug valves open to minimize exposure of functional surfaces.

5. Set butterfly valves closed or slightly open.

6. Block check valves in either closed or open position.

B. Use the following precautions during storage:

1. Maintain valve end protection.

2. Store indoors and maintain valve temperature higher than ambient dew-point temperature. If outdoor storage is necessary, store valves in weather protected shed and cover valves with polyurethane sheets.

VALVES 15100 - 3

C. Use a sling to handle large valves. Rig to avoid damage to exposed parts. Do not use handwheels and stems as lifting or rigging points.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Valves: Provide valves from the valve table indicated in the Index of Systems and Services, located in Part 3 of this Section, for each piping system.

B. General:

1. Furnish valves of each type, made by one manufacturer. Where rising stem gate and globe valves cannot be opened fully due to insufficient clearance, nonrising stem valves may be used

2. Grooved mechanical joint pipes and valves shall not be used.

C. Gate Valves: Provide gate valves designed and fabricated as indicated, and in accordance with the following:

1. Manufactured in accordance with MSS-SP80 or MSS-SP70 as applicable;

2. Face to face dimensions in accordance with ANSI B16.10;

3. End flanges in accordance with ANSI B16.10;

4. Solder joint ends in accordance with ANSI B16.18;

5. Body markings in accordance with MSS-SP25;

6. Rising type stem;

7. Backseat to allow repacking under pressure;

8. Packing suitable for intended service, and to prevent sticking or freezing of valve stem; and

9. Seats renewable without removing valve from line.

D. Globe Valves: Provide globe valves designed and fabricated as indicated, and in accordance with the following:

1. Manufactured in accordance with MSS-SP80 or MSS-SP85 as applicable;

3. End flanges in accordance with ANSI B16.1;

4. Solder joint ends in accordance with ANSI B16.18;

5. Body markings in accordance with MSS-SP25;

6. Rising type stem;

7. Backseat to allow repacking under pressure;

8. Packing suitable for intended service, and to prevent sticking or freezing of valve stem;

9. Seats renewable without removing valve from line.

E. Ball Valves: Provide ball valves designed and manufactured as indicated, and in accordance with

1. Manufactured in accordance with ANSI B16.34;

3. End flanges in accordance with ANSI B16.1;

4. Solder joint ends in accordance with ANSI B16.18;

5. Body markings in accordance with MSS-SP25;

6. Self-aligning;

7. Quarter turn operation;

8. Operating handle stops;

VALVES 15100 - 4

9. Tetrofluroethylene (TFE) or TFE coated seats, stem seals, and thrust washer;

10. Internals removable without removing valve from line;

11. Top or end loaded;

12. Leak tight without using springs;

13. Grooved end valves in accordance with description in Valve Table II.

F. Check valves: Provide check valves as indicated, and in accordance with the following:

1. Manufactured in accordance with MSS-SP80 or MSS-SP71 as applicable;

2. Face to face dimensions in accordance with ANSI B16.10;

3. End flanges in accordance with ANSI B16.1;

4. Solder joint ends in accordance with ANSI B16.18;

5 Body markings in accordance with MSS-SP25;

6. Suitable for installation in horizontal or vertical lines;

7. Seats renewable without removing valve from line;

8. Grooved end valves in accordance with description in Valve Table II.

G. Butterfly valves: Provide butterfly valves as indicated, and in accordance with the following:

1. Manufactured in accordance with MSS-SP68;

2. Body markings in accordance with MSS-SP25;

3. Seats replaceable without removing disc and stem;

4. Grooved end valves in accordance with description in Valve Table II.

H. Strainers: Unless otherwise indicated, provide strainers upstream of traps, solenoid, and control valves. Furnish ductile iron, cast iron or cast carbon steel, Y pattern strainers. Furnish sizes two inches and smaller as grooved or screwed type, 250 pound construction, and 2-1/2 inches and larger as grooved or flanged type, 250 pound construction. Arrange cap for easy removal of screen and provide opening for blow out. Furnish strainer with blow out nipple and ball valve of same size as blow out connection. Known acceptable source: Armstrong or Mueller.

I. Screens: Provide Y-pattern strainers with free screen area minimum of three times the area of the strainer inlet pipe. Include with 1/2 inch valved drain and a 1/4 inch air vent cock. Known acceptable source: Armstrong or Mueller. Furnish bronze, monel or 18-8 stainless steel screens with perforations as follows:

Strainer Size Perforation Size 3/4 inch to 2 inches 1/32 inch 2-1/2 inches to 5 inches 1/16 inch

8 inches to 12 inches 1/8 inch

J. Pressure Reducing Valves: Provide direct operating type, pressure reducing valves in which a composition diaphragm and spring act directly on the valve stem. Furnish a valve that will provide a constant outlet pressure with a variable inlet pressure, with low inlet pressure check valve and inlet strainer, removable without system shutdown.

K. Unless otherwise indicated, valves installed in connection with mechanical piping shall comply with the following and as specified in “Basic Mechanical Materials and Methods,” Section 15050:

1. Furnish one make throughout the project. Known acceptable manufacturers are Jamesbury, Watts, and Crane. All valves of a given type shall be provided by the same manufacturer.

2. Properly pack stems.

3. Mark each valve at the factory with the following minimum information, engraved, stamped, or

VALVES 15100 - 5

cast on each valve or metal tag permanently attached to the valve indicating manufacturer’s name, catalog or figure no., size and pressure class and arrows to indicate direction of flow on check, globe, angle and eccentric plug valves.

4. Valves shall be furnished with TFE, tetraflouroethylene coating (or TEFLON trademark coating) on seats and gaskets. Packing materials shall be impregnated with material to prevent sticking or freezing of valve operation.

5. Valves and actuators located outdoors shall be designed to operate in corrosive coastal environment.

L. Water system automatic air vents shall be provided at high points of chilled and heating hot water piping and at all other air pockets of closed circulating piping systems, and as indicated on the drawings to eliminate air from the system. Materials shall be cast-iron body and cap, copper ball float, stainless steel ball-type disc, and Type 303 stainless steel seat. Pipe all air vent discharge drains to the nearest floor sink or trench. Known acceptable source for automatic vents: Crane Co., No. 976, Sarco 13W, with shut-off valves, Bell and Gossett No. 97.

M. Water pressure relief valves shall be bronze body and trim. The valve body shall be cast in one piece, so internal parts can be removed for cleaning or repairing without breaking pipe connections.

Known acceptable source: Bell and Gossett, Model No. 7.

N. Water pressure reducing valves shall be bronze body, renewable nickel alloy seat, electroplated steel spring, and high temperature resistant diaphragm. Regulation shall be tight shut-off at no-flow condition. Pressure setting shall be changeable by adjustment screw over a range of 10-35 psi. Unit shall be supplied with a separate strainer with perforated stainless steel screen. Known acceptable source: Watts Regulator Company, Series 223S.

O. Vacuum breakers shall be automatic check-valve type vacuum breakers. Vacuum breakers shall be provided for drain down during maintenance. Vacuum breakers shall be provided for positive bubble-tight closing, even at very low differential pressure. Vacuum breaker valve body shall be brass or bronze with screwed ends. Bushing guide and springs shall be stainless steel. Valve check shall be brass with Viton disc rated for maximum 180 degrees F. The valve adapter end shall be bronze. Known acceptable source: Watts Regulator Company, Maxi-Flo, Series 601.

P. Chilled water and cooling tower water flow control valves (6" & 8" Segmented Ball Valves):

1. Segmented Ball Valves: Valves shall be in accordance with description in Valve Table II

2. Actuators: Actuators shall be double acting or spring return as required by the sequence of operation in Section 17200, “Control Systems, Electronic and Direct Digital,” and as listed on the ECMS point function schedule. Actuators shall utilize 60 psig minimum compressed air as provided under Section 17200, “Control Systems, Electronic and Direct Digital.” Actuators shall be sized to provide at least 125 percent of the torque/force required to close the valve off against the pump shutoff head in the system. Modulating valves actuators shall be provided with a pilot positioner which takes an analog 4-20 mA signal from the DDCP and smoothly operates the valve from fully open to fully closed. Provide valve actuator with analog position indicator which transmits the valve position through a 4-20 mA signal to the DDCP. Spring return actuators shall include handwheel for manual operation of valve, while double acting actuators shall have dual handwheels for manual operation of valve. The handwheels shall not rotate during normal actuator operation. The yoke attachment between the valve and the actuator shall be sized properly to eliminate flexing of the mounting brackets.

Q. Chilled water and cooling tower water flow control valves (4" & 8" Butterfly Valves): Provide butterfly valves as indicated, and in accordance with the following:

1. Manufactured in accordance with MSS-SP68;

2. Body markings in accordance with MSS-SP25;

VALVES 15100 - 6

3. Seats replaceable without removing disc and stem;

4. Grooved end valves in accordance with description in Valve Table II.

5. Actuators: Actuators shall be double acting or spring return as required by the sequence of operation in Section 17200, “Control Systems, Electronic and Direct Digital,” and as listed on the ECMS point function schedule. Actuators shall utilize 60 psig minimum compressed air as provided under Section 17200, “Control Systems, Electronic and Direct Digital.” Actuators shall be sized to provide at least 125 percent of the torque/force required to close the valve off against the pump shutoff head in the system. Modulating valves actuators shall be provided with a pilot positioner which takes an analog 4-20 mA signal from the DDCP and smoothly operates the valve from fully open to fully closed. Provide valve actuator with analog position indicator which transmits the valve position through a 4-20 mA signal to the DDCP. Spring return actuators shall include handwheel for manual operation of valve, while double acting actuators shall have dual handwheels for manual operation of valve. The handwheels shall not rotate during normal actuator operation. The yoke attachment between the valve and the actuator shall be sized properly to eliminate flexing of the mounting brackets.

R. Cooling tower water make-up water valves and blowdown valves (1-1/2” & 2” Slow Closing

Solenoid valves): Use slow closing solenoid valves to reduce hammering. Provide slow closing solenoid valves in accordance with the description in Valve Table II.

VALVES 15100 - 7

3.1 EXAMINATION

A. Examine piping system for compliance with requirements for installation tolerances and other conditions affecting performance of valves. Do not proceed with installation until unsatisfactory conditions have been corrected.

B. Examine valve interior for cleanliness, freedom from foreign matter, and corrosion. Remove special packing materials, such as blocks, used to prevent disc movement during shipping and handling.

C. Operate valves from fully open to fully closed positions. Examine guides and seats made accessible by such operation.

D. Examine threads on valve and mating pipe for form and cleanliness.

E. Examine mating flange faces for conditions that might cause leakage. Check bolting for proper size, length, and material. Check gasket material for proper size, material composition suitable for service, and freedom from defects and damage.

F. Do not attempt to repair defective valves; replace with new valves.

3.2 INSTALLATION

A. Valves: Install valves in accordance with the manufacturers instructions, ANSI B31.9, and the

1. Install valves where indicated or required for proper operation of piping and equipment, including branch lines, and where necessary to isolate sections of piping or equipment;

2. Locate valves so that they are accessible for operation, maintenance, and support;

3. Install valves with stems in vertical position wherever possible;

4. Install solder joint valves in accordance with the manufacturers installation instructions and

ANSI B16.18;

5. Install check valves with cap in vertical position with hinge pin perpendicular to center line of pipe;

6. Install check valves with flow arrow pointed in direction of system flow; and

7. Install balance valves on each hydronic terminal and as indicated. After hydronic system balancing has been completed, mark each balance valve with stripe of yellow paint across body and stop plate to permanently mark final balanced position.

B. Strainers: Install Y type strainers in accordance with the manufacturers instructions, and the

1. Install strainers same size as pipe;

2. Install nipple and shut off valve in strainer blow down; same size as blow down;

3. Provide drain line from shut off valve to approved receptor; and

4. Install strainers as indicated and upstream of the temperature control valves, if integral strainer is not provided.

C. Automatic Vent Valves: Install automatic vent valves in accordance with the manufacturers instructions, and the following:

1. Top of each hydronic riser and as indicated;

VALVES 15100 - 8

2. Install shut off valve between riser and vent; and

3. Pipe vent outlet to plumbing drain or as indicated.

D. Manual Vent Valve: Install manual vent valve in accordance with the manufacturers instructions, and the following:

1. Install manual vent valves at top of each hydronic terminal at highest point; and

2. Install manual vent valves on each hydronic piping drop in direction of flow for mains, branches, and runouts.

3.3 ADJUSTING

A. Adjust or replace packing after piping systems have been tested and put into service, but before final adjusting and balancing. Replace valves if leak persists.

B. Cleaning: Clean factory finished surfaces, and repair marred or scratched surfaces.

3.4 SCHEDULES AND TABLES

A. General: Schedules and tables referenced in this Section are located in this article. Each schedule begins on a new page. Blank space at the end of a page, does not necessarily indicate the end of this Section.

B. The following schedules and tables are part of this Section:

1. Index of Systems and Services.

2. Valve Table I.

3. Valve Table II.

VALVES 15100 - 9

INDEX OF SYSTEMS AND SERVICES

System or Service

Line Symbol

Maximum Operating Temperature (Degrees F)

Valve Table

Hydrostatic Test Pressure psig

Cold Water CW Ambient I 130 Hot Water HW 120 I 130 Chilled Water Supply CWS Ambient II 150 Chilled Water Return CWR Ambient II 150 Heating Hot Water Supply HWS 180 II 150 Heating Hot Water Return HWR 180 II 150 Cooling Tower Water Supply CTS Ambient II 150 Cooling Tower Water Return CTR Ambient II 150 Compressed Air CA Ambient I --- Fire Protection F Ambient II 175 Natural Gas G Ambient I --- Diesel Engine Coolant Supply JWS 200 II 150 Diesel Engine Coolant Return JWR 200 II 150

END OF TABLE

VALVES 15100 - 10

VALVE TABLE I

Item

Size (inches)

Description

Gate 2 and smaller Body and bonnet, bronze, ASTM B62, alloy 836; Disc, wedge type, bronze, ASTM B62, alloy 836; Stem, bronze, ASTM B371, alloy 694;

Solder joint end prep; rated for nonshock pressure of 300 psig at 150 F, recommended service: Water, Oil, or Gas (WOG); known acceptable source: Crane, Number 1334.

Globe 2 and smaller Body, bronze, ASTM B62; Bonnet, 3/8 inch - 3/4 inch; Brass, ASTM B16, alloy 360, and 1 inch - 2 inches, ASTM B62; Disc, composition; Stem, bronze, ASTM B371, alloy 694; solder joint end prep; rated for nonshock pressure of 200 psig at 200 F; recommended service, water; known acceptable source: Crane, Number 1310

Drain 1/2 Body, bronze; bonnet, screwed type; disc, composition; end prep, differential, female IPS 3/4 inch hose; rated for nonshock pressure of 150 psig at 200 F; recommended service, water; known acceptable source:

Hammond, Figure 712

Ball 2 and smaller Body, 3 piece, bronze; ball, hard chrome plated brass; seats, TFE; end prep, solder joint; recommended service, WOG; rated for nonshock pressure of 200 psig at 200 F; known acceptable source: Watts Regulator, Series B-6801.

Check 2 and smaller Y pattern, swing type; body, bronze, ASTM B62; cap, screwed type, bronze, ASTM B62; disc, hinge type, brass, ASTM B16, alloy 360 for 1/4 inch - 3/4 inch or ASTM B62 for 1 inch - 2 inches; end prep, solder joint;

rated for nonshock pressure of 200 psig, recommended service WOG.

Known acceptable source: Crane, Number 1342

Backflow Preventor

2 and smaller Body bronze; bonnet integral ; body unions 175 psi rated. ASSE Standard 1013 quarter turn, full port resilient seated, bronze ball valve, internal polymer coating. Know acceptable source: Watts Regulator Company, series 909.

Solenoid Valves

2 and smaller Bronze, aluminum, or cast-iron body; 120 VAC, 60 Hz, Class B continuous-duty molded coil; UL labeled and FM approved. Include NEMA ISC 6, Type 4, coil enclosure and electrically opened and closed dual coils. Valve position is normally closed. Include threaded ends conforming to ASME B1.20.1. Known acceptable source: Magnatrol Valve Corp.

Solenoid Valves

2-1/2 larger Same as above with flanged ends. Known acceptable source: Magnatrol Valve Corp.

1. Service: See Index of Systems and Services.

END OF TABLE

VALVE TABLE II

VALVES 15100 - 11

Gate 2 and smaller Body and bonnet, bronze, B62, alloy 836; disc, wedge type, bronze, ASTM B62, alloy 836; Stem, bronze, ASTM B371, alloy 694; end prep, threaded; rated for nonshock pressure of 300 psig at 150 F; recommended service WOG; known acceptable source:

Crane, Number 431.

Gate 2-1/2 and larger Body and bonnet, carbon steel, ASTM A126 Grade WCB; OS&Y bolted type bonnet; solid wedge disc with elongated disc guide;

200 psig flanged end prep; standard trim; known acceptable source: Crane, Number 47.

Globe 2 and smaller Body, bronze, ASTM B62; Bonnet, screwed type, bronze, ASTM B62; disc, brass, ASTM B62, stem, bronze, ASTM B62 sizes 1 inch - 2 inches, bronze ASTM B371, alloy 694, size 3/4 inch; end prep, threaded; rated for nonshock pressures of 200 psig at 150 F;

recommended service WOG; known acceptable source: Crane, Number 1

Globe 2-1/2 and larger Body and bonnet, carbon steel, ASTM A126 Grade WCB; OS&Y bolted type bonnet; 200 psig flanged end prep; standard trim;

known acceptable source: Crane, Number 143.

Ball 1/2 through 1- 1/2

Body, carbon steel; ball, 316 stainless steel; stem, 17-4 PH stainless steel; end prep, threaded; rated for nonshock pressure of 200 psig, recommended service WOG, TFE seats, thrust washer and stem seals; known acceptable source: Jamesbury, Series 4000, full port.

Ball 2 Body, carbon steel; ball, 316 stainless steel; stem, 17-4 PH stainless steel; end prep, threaded; rated for nonshock pressure of 200 psig, recommended service WOG, TFE seats, thrust washer, and stem seals; known acceptable source: Jamesbury, Series 4000, full port.

Ball 2-1/2 Body ASTM A126 carbon steel Grade WCB; Ball AISI 316 stainless steel; seats, TFE; Stem AISI 316 stainless steel; 200 psig flanged end prep; known acceptable source: Watts Regulator Model, Series CF-1500.

Ball 3 and larger End prep, 150 psig flanged, rated for 250 psig nonshock pressure, recommended service, WOG; floating ball, full port; known acceptable source: Jamesbury, Type 6150.

Check 2 and smaller Check 2-1/2 and larger Body and bonnet, carbon steel, ASTM A126 Grade WCB; bolted type bonnet; swing type disc; 250 psig flanged end prep; standard trim; known acceptable source: Crane, Number 147.

Butterfly 6 and larger Body, ductile iron, ASTM A395, disc, ductile iron; seat, TFE;

stem, one piece, 316 stainless steel; end prep, 150 psi flanges;

accessories, worm gear operator with memory stop and position indicator; rated for 250 psi at 100 F, recommended service, WOG;

Bearings, TFE composite; capable of isolating and holding 150 psig across disc with downstream flange removed; chevron type

VALVES 15100 - 12

shaft seals; known acceptable source: Jamesbury, Model 815L.

Calibrated Balancing

1/2 through 2 Furnish and install circuit balancing valves with provision for connecting a portable differential (Ft of Head) pressure meter.

Each meter connection shall have pressure/temperature readout ports. The circuit balancing valve shall be Y-pattern style design and all metal parts of nonferrous, pressure die cast, nonporous “Ametal” copper alloy. Each valve can be installable in any direction without affecting flow measurement and shall provide four (4) functions as follows: Precise flow measurement, precision flow balancing, positive shut-off with no drip seat, and drain port suitable for hose bib fitting. Valves shall have four (4) 360 degree adjustment turns of digital handwheel for maximum setting with hidden memory feature to set the valve with precision tamper-proof setting. Valves shall be manufactured by Tour & Anderson Hydronics A.B. Model STAD.

Slow Closing Solenoid Valves

2 and smaller UL listed, slow closing, normally closed solenoid valve with brass body rated for 150 psi, Buna N Disc, Rulon Seals, 305 stainless steel core tube, 430F stainless steel core and plugnut, and stainless steel springs and piston. Solenoid shall be NEMA 4X watertight with 24 or 120 VAC coil. Valve shall close slowly to prevent water hammer. Known acceptable source: ASCO 8221-Series Slow Closing Solenoid Valves.

Segmented Ball 6 and 8 150 psi class carbon steel body, flanged ends, quarter-turn stainless steel segmented rotary v-ball, upper and lower shaft. Seat to be UNS S21800 with spring-energized filled TFE lip seal to protect against calcium build up. Valve body rating - 285 psi at 80°F.

Known acceptable source: Neles Controls R-Series

Calibrated Balancing

2-1/2 through 12 Furnish and install circuit balancing valves with provision for connecting a portable differential (FT of Head) pressure meter.

Each meter connection shall have pressure/temperature readout ports. The circuit balancing valve shall be Y-pattern style design and with ductile iron body. All other metal parts shall be of nonferrous, pressure die cast, nonporous “Ametal” copper alloy.

Each valve shall provide three (3) functions as follows: Precise flow measurement, precision flow balancing, and positive shut-off with no drip seat. Valves shall have eight (8), twelve (12) or sixteen (16) 360 degree adjustment turns of digital handwheel for maximum setting with hidden memory feature to set the valve with precision tamper-proof setting. All valves shall be manufactured by Tour & Anderson Hydronics A.B. Model STAF-SG.

Provide two (2) portable rechargeable computerized meters in English (American) language with an optional PCB extended computer program to store balancing values, temperature measurements, logging flow or pressure. The meters shall have the following features: flow measure in GPM, differential pressure, temperature measurement, automatic calibration, automatic air purging, quick connection and computer adjustment of preset or CV values either for a given flow or proportionally

VALVES 15100 - 13

calculated flow. The meter shall be manufactured by Tour and Anderson Hydronics A.B. Model CB1-PCB. Tour and Anderson Hydronics is distributed by Victaulic Company of America.

1. Service: See Index of System and Services.

END OF SECTION 15100

MECHANICAL INSULATION 15250-1

SECTION 15250 - MECHANICAL INSULATION

A. This Section includes pipe, duct, and equipment insulation.

A. American Society for Testing and Materials (ASTM)

1. C196: Specification for Expanded or Exfoliated Vermiculite Thermal Insulating Cement.

2. C411: Hot Surface Performance of High Temperature Thermal Insulation.

3. C447: Estimating the Maximum Use Temperature of Thermal Insulation’s.

4. C449: Standard Specification for Mineral Fiber Hydraulic Setting Thermal Insulating and

Finishing Cement.

5. C533: Specification for Calcium Silicate Block and Pipe Thermal Insulation.

6. C534: Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in

Sheet and Tubular Form.

7. C547: Specification for Mineral Fiber Pipe Insulation.

8. C552: Specification for Cellular Glass Thermal Insulation.

9. C553: Specification for Mineral Fiber Blanket Thermal Insulation for Commercial.

10. C612: Mineral Fiber Block and Board Thermal Insulation.

11. C921: Specification for Determining the Properties of Jacketing Materials for Thermal

Insulation.

12. C1071: Thermal and Acoustical Insulation (Glass Fiber, Duct Lining Materials).

13. C1136: Flexible, Low Permeance Vapor Retarders for Thermal Insulation.

14. E84: Standard Test Method for Surface Burning Characteristics of Building Materials.

B. National Fire Protection Association (NFPA)

1. 255: Surface Burning Characteristics of Building Materials.

C. Underwriters Laboratories Inc. (UL)

1. 723:S Surface Burning Characteristics of Building Materials.

D. Federal Standard (FS)

1. HH-I-558B: Insulation, Blocks, Boards, Blankets, Felts, Sleeving (Pipe and Tube Covering), and Pipefitting Covering, Thermal (Mineral Fiber, Industrial Type).

E. Adhesive and Sealing Council (ASC)

1. A7001: Standards for Adhesives for Duct Liner.

F. Sheet Metal and Air Conditioning Contractors National Association (SMACNA)

1. Duct Liner Standards.

MECHANICAL INSULATION 15250-2

1.3 DEFINITIONS

A. Hot Surfaces: Normal operating temperatures of 100 deg F or higher.

B. Dual-Temperature Surfaces: Normal operating temperatures that vary from hot to cold.

C. Cold Surfaces: Normal operating temperatures less than 75 deg F.

D. Thermal resistivity is designated by an r-value that represents the reciprocal of thermal conductivity (k-value). Thermal conductivity is the rate of heat flow through a homogenous material exactly 1 inch thick. Thermal resistivity (r-value) is expressed by the temperature difference in degrees Fahrenheit between the two exposed faces required to cause 1 BTU per hour to flow through 1 square foot at mean temperatures indicated.

E. Thermal Conductivity (k-value): Measure of heat flow through a material at a given temperature difference; conductivity is expressed in units of Btu x inch/h x sq. ft. x deg F.

F. Density: Expressed in pcf.

1.4 SUBMITTALS

A. Product data for each type of mechanical insulation identifying k-value, thickness, and accessories.

B. Samples of each type of insulation and jacket. Identify each sample describing product and intended use. Submit the following sizes of sample materials:

1. Board and Block Insulation: 12 inches square section.

2. Pre-Formed Pipe Insulation: 12 inches long, 2-inch NPS.

C. Material certificates, signed by the manufacturer, certifying that materials comply with specified requirements where laboratory test reports cannot be obtained.

D. Material test reports prepared by a qualified independent testing laboratory. Certify insulation meets specified requirements.

1.5 QUALITY ASSURANCE

A. Fire Performance Characteristics: Conform to the following characteristics for insulation including facings, cements, and adhesives, when tested according to ASTM E 84, by UL or other testing or inspecting organization acceptable to the authority having jurisdiction. Label insulation with appropriate markings of testing laboratory.

1. Interior Insulation: Flame spread rating of 25 or less and a smoke developed rating of 50 or less.

2. Exterior Insulation: Flame spread rating of 75 or less and a smoke developed rating of 150 or less.

1.6 SEQUENCING AND SCHEDULING

A. Schedule insulation application after testing of piping and duct systems.

MECHANICAL INSULATION 15250-3

B. Schedule insulation application after installation and testing of heat trace tape.

2.1 GENERAL

A. Install duct and pipe insulation in accordance with manufacturer’s instructions.

B. Duct and pipe insulation shall have a flame spread rating not exceeding 25 and a smoke development rating not exceeding 50 as determined by test procedures specified in ASTM E84, NFPA 255 and UL 723. Ratings shall be determined from tests performed on the composite of insulation, jacket or facing, and adhesive. Adhesives, mastics and cements shall meet the same individual ratings as the minimum requirements.

C. Adhesives, cements, sealers, mastics, and protective finishes as recommended by the insulation manufacturer for the intended use and as indicated.

D. Staples, bands, wire, wire netting tape corner angles, anchors, and stud pins as recommended by insulation manufacturer for intended use and as indicated.

E. Known Acceptable Source:

1. Glass Fiber:

a. John Manville.

2. Cellular Glass:

a. Pittsburgh Corning Corporation.

3. Flexible Elastomeric Cellular:

a. Armstrong World…