specs_hot_water_heater2 _rev_8-18-16.doc

Solicitation No. AG-32SD-S-16-0034, Amendment 01 Replace steam water heaters, Clay Center, NE

STEAM WATER HEATER REPLACEMENT, BLDG #17-24

USDA, Agricultural Research Service

Roman L. Hruska U.S. Meat Animal Research

Center Clay Center, Nebraska

Furnish labor, supervision, materials, tools, equipment, transportation, etc., necessary to replace steam hot water heaters, pre-heat pumps, re-heat pumps, steam to water heater exchanger, and to install a new motorized damper, all in the main floor and the penthouse mechanical rooms of Bldg. #17-24.

TABLE OF CONTENTS

DIVISION 1 - GENERAL REQUIREMENTS

0101 - SUMMARY OF WORK

0130 - SHOP DRAWINGS

0160 - USE OF GOVERNMENT FACILITIES (UTILITIES, ETC.)

0180 - CLEANUP

DIVISION 2 - DEMOLITION

0211- DEMOLITION AND REMOVAL

DIVISION 15 - MECHANICAL

1520 - MECHANICAL EQUIPMENT

1525 –INSULATION

1551 –STEAM HOT WATER, CONDENSATE PIPING

DIVISION 16 - ELECTRICAL

1605 - ELECTRICAL SYSTEMS

DIVISION I - GENERAL REQUIREMENTS

SECTION 0101, SUMMARY OF WORK

The work consists of providing all labor, material, and equipment and performing all work to replace hot water heaters, pumps and motors, a heat exchanger, motorized damper, valves, flanges, piping, gaskets, check valves, steam traps, strainers, thermometers, pressure gauges, etc., necessary for complete and operable systems in the mechanical rooms of Building #17-24.

Work in Bldg. #17-24 mechanical rooms on the main floor and penthouse shall include but shall not necessarily be limited to the following (See photographs for additional information.):

1. Replace 2-1,850,000 Btu/hr (input) steam to water heat exchanger hot water heaters, DWH-1 and DWH-2, and associated pipe, steam control valves, pumps, valves, check valves, strainers, steam traps, thermometers, pressure gauges, etc. Each hot water heater package shall be supplied with a circulating pump. There is also an in-line circulating pump (CP-6) which is to be replaced.

2. Replace 2-25 hp pre-heat hot water circulating pumps and motors, CP-4.

3. Replace 2-15 hp re-heat hot water circulating pumps and motors, CP-3.

4. Each pre-heat and re-heat hot water circulating pump shall have a strainer, pressure gauges, union connections, check valve, balancing valve (outlet), and butterfly valves and isolation fittings on inlet and outlet of each pump.

5. Install new steel pipe for hot water heaters and pumps (CP-3, CP-4) as necessary to accommodate connection locations on new equipment.

6. Install vibration isolation fittings on inlet and outlet of pumps CP-3 and CP-4.

7. Replace properly sized "heaters" and fuses for the new CP-3 and CP-4. The starters, heaters, and fuses are located in MCC-1.

8. Install pipe insulation on steam, hot water, and condensate pipe where missing or where existing was removed to install new equipment.

9. Replace steam to hot water heat exchanger (HX-1) and associated control valves, valves, strainers, steam traps, circulating pump (CP-7), pressure and temperature gauges, and exchanger and pipe insulation all located in the penthouse of Bldg. #17.

10. Install motor operated 4' x 9' damper in front of existing relief air louver. It shall be controlled by a thermostat in the boiler room.

SECTION 0130, SHOP DRAWINGS

1. Submit shop drawings to the Contracting Officer’s Representative (COR) for approval prior to installation. Information in the form of drawings, product literature, manufacturer’s specification, equipment lists, etc. shall be submitted on the following:

Description Drawings Specification Literature Schedule

a. Valves x x

b. Flanges, Gaskets x x

c. Pipe, Equipment Insulation x

d. Strainers x x

e. Check Valves x x

f. Pumps x x

g. Hot Water Heaters x x

h. Pipe, Fittings x x

i. Heat Exchanger x x

j. Items under Division 16 x

The Contracting Officer may request submittals in addition to those listed when deemed necessary to adequately describe the work covered in the respective sections.

2. Each submittal shall be complete and in sufficient detail for ready determination of compliance with the contract requirements.

3. Submittal shall be submitted in four (4) copies to the COR using the transmittal form. The form shall be properly completed by filling out all the heading block spaces and identifying each item submitted. Special care should be exercised to insure proper listing of the specification paragraph and/or sheet number of the contract drawings pertinent to the data submitted for each item. A separate transmittal form shall be attached to each copy of the data being submitted.

4. Brand Name: Identification of items in the contract documents is intended to be descriptive, not restrictive, and is to indicate the quality and characteristics of products that will be satisfactory.

SECTION 0160, USE OF GOVERNMENT FACILITIES (UTILITIES, ETC.)

1. Water, Gas, Electricity:

a. As mutually agreed upon between the Contractor and the COR, the Contractor may use nearby utilities required for his performance under this contract.

b. Contractor shall bear the cost of temporary connections (if necessary) and restoration upon conclusion of use.

c. The Government shall bear the cost of reasonable utility consumption. Government will not pay the cost of utilities if usage is abused.

d. The Contractor shall submit for approval written notification not less than 4 working days in advance of requirement to shut down any utilities or other services to or within existing building or facilities used by others.

2. Telephone: Contractor shall arrange and pay for any telephone service they choose to provide for themselves.

3. Toilet: Contractor shall provide their own toilet facility.

4. Access to Buildings: Contractor’s access to buildings shall be limited to those areas where work is being performed.

5. Material Receiving: Contractor shall be on-site to receive materials. Contractor shall arrange for own storage of materials unless other arrangements have been agreed to by owner.

SECTION 0180, CLEANUP

1. Cleanup:

a. The Contractor shall keep the premises clean during construction and shall remove all rejected material, rubbish, etc., after completion of work and prior to final inspection.

b. Materials removed by the Contractor shall become the property of the contractor and shall be removed from the site unless otherwise agreed to by the owner.

c. Government dumpsters shall not be used by the contractor.

DIVISION 2 - DEMOLITION

SECTION 0211, DEMOLITION AND REMOVAL

1. General:

a. This section includes the removal of:

1. Two (2) steam to water heat exchanger hot water heaters, DWH-1, in Building#17-24

2. Two (2) hot water pre-heat pumps with motors, CP-4, and associated material in Building #17-24

3. Two (2) hot water re-heat pumps with motors, CP-3, and associated material in Building #17-24.

4. One (1) steam to hot water heat exchanger and associated material in the penthouse mechanical room of Building #17-24.

This shall include the items listed above plus piping, valves, fittings, insulation, and any other materials, as noted, or as obviously required to complete the project.

b. Contractor shall be responsible for temporarily securing pipe, conduit, electrical conductors, etc. during removal operations and prior to installation of the new chiller packages.

c. Do not begin demolition until authorization is received from owner. Remove rubbish and debris from the work area daily. Do not allow accumulations inside or outside the building.

2. Regulatory and Safety Requirements: Comply with federal, state, and local hauling and disposal regulations. In addition to the requirements of the “Contract Clauses,” Safety Requirements.”

3. Protection of Existing Facility: Protect existing work which is to remain in place, be reused, or remain the property of the government. Any damage shall be repaired/replaced at the Contractor’s expense.

4. Schedule: A written schedule of equipment removal and shutdowns shall be submitted to the Owner, for approval, 10 days, prior to the start of work.

5. Title to Materials: All materials and equipment removed, and not reused, shall become the property of the contractor and shall be removed from the property. Notwithstanding the above, the Governments retains first right of refusal on all equipment and material to be demolished or removed.

DIVISION 15 – MECHANICAL

SECTION 1520, MECHANICAL EQUIPMENT

1. General:

A. The work shall include furnishing, installing, and testing of hot water heaters and hot water pumping equipment. This shall include hot water pumps, steam to water heat exchanger hot water heaters, a motor operated damper, a steam to water shell and tube heat exchanger, and all associated piping and appurtenances as necessary for complete and operable systems. Work includes modifications and connections to existing steam, hot water, and condensate systems. All material shall be provided, including all hangers and supports, and the installation shall be complete for a safe, secure, fully functional re-heat and pre-heat pumping and hot water heating systems. This shall include all hangers, supports B. System design and test pressures shall not be less than 1.5 times the respective maximum operating pressure at design pressure. Piping components shall be suitable for use under design pressures specified.

2. Products:

A. General: All pumps, piping, fittings, gaskets, valves, flanges, bolts, and all other products installed in these systems shall be suitable for the service, temperature and pressure for which they are installed, and where applicable shall be Energy Star compliant.

i. Building Heat Pumps: Pumps shall be base mounted, close coupled end suction pumps with premium efficient ODP motors. Motors shall be 230/460 V, 3 phase, 60 hz rated. Pumps, seals, and packing shall be designed for 250 F continuous operating temperature. Casing shall be cast iron, impeller shall be bronze, shaft shall be carbon steel, and the mechanical sleeve shall be ceramic. They shall be as manufactured by Taco, Bell & Gossett, or Gardner Denver as follows:

a. Pre-heat pumps (CP-4): Pumps shall be rated for 600 gpm at 90 ft. head, and shall be as manufactured by Taco, model #C14011C, 5" x 4", or equal.

b. Re-heat pumps (CP-3): Pumps shall be rated for 250 gpm at 90 ft. head, and shall be as manufactured by Taco, model #C14011C, 5" x 3-1/2"", or equal.

ii. Water Heater (DWH-1): Each water heater shall produce 140 F water at 35 gpm with 1,850 MBH input. It shall be provided 50 psi steam to achieve this. Water heater shall have a stainless steel tank (nominal 55 gallon) and stainless steel threaded openings and nozzles and shall be mounted on 4 inch skids. It shall be insulated per ASHRAE guidelines and it is to conform to ASHRAE requirements for a tank that produces140 F water. It shall have 1-1/2" fiberglass insulation and a minimum 22 gauge metal jacket. Test pressure shall be 195 psi with a working pressure of 150 psi.

a. Steam package shall included the following:

1. 1/2 hp, 115 V, 1 phase, bronze pump (CP-7, CP-8) with electric on/off

2. bronze hand valves, copper pipe and fittings

3. thermal overload protection switch

4. console with 3-1/2" dial thermometer & steam pressure gauge

5. air operated control valve

6. main steam strainer with integral black steel pipe, float & thermostatic main trap, auxiliary trap, and strainer

7. pressure and temperature relief valve

Hot water heater shall be an Adamson Dura-Mite, or equal which is a replacement for Adamson hot water heater, serial number #PMS-474-N.

b. Hot Water Circulating Pump (CP-6): The circulating pump for the water heaters shall be a 115V, 1/4 hp in-line pump rated for 16 gpm @ 10' head. It shall be for a minimum of 200 F hot water and shall be as manufactured by Taco, model #1600, or equal.

iii. Heat Exchanger (HX-1): Steam to hot water heat exchanger shall boost 80 gpm of hot water to the abattoir (slaughter floor) from 120 F to 200 F. It shall have a carbon steel shell and seamless copper tubes. Working pressure shall be 150 psi for shell and tube sides. It shall conform to all code requirements including ASME code, section VIII. Heat exchanger shall be a model #CV-2B-96B, as manufactured by Yula, or equal. Heat exchanger shall be fully insulated (minimum 1-1/2" fiberglass) per ASHRAE as well as all associated piping, fittings, etc.

a. Controls: Heat Exchanger (HX-1) shall be provided with two way automatic steam valve system. Automatic steam valve shall not cause more than 2 psi pressure drop with control by HX-1 water discharge controller which shall maintain a water discharge temperature of 200 F to 210 F. Contractor shall install an additional controller, thermometer and time clock as required to have night time and weekend set back to 120 F. Controls shall be installed in existing Honeywell control panel as shown on the drawings.

SEQUENCE OF OPERATION:

i. Day Operation: Temperature controller T1 shall modulate steam valve to maintain hot water temperature.

ii. Night Operation: Temperature controller T2 shall take over control according to time clock setting (time schedule) to maintain lower temperature set point.

b. Air piping for controls shall be hard drawn copper or polyethylene tubing installed in EMT conduit.

c. Flanged elbows shall be installed for hot water connections to HX-1 to allow easy removal of tube bundle. No obstruction shall be placed in space requiring tube removal. HX-1 shall be installed complete with ASME approved relief valves, thermometers and accessories as shown or specified.

d. Circulating Pump (CP-7): Circulating pump for HX-1 circulating system shall be a horizontal in line circulator with a capacity of 4 GPM at 10 foot head. Pump shall be for use with hot water at a temperature of 230 F and a pressure of 125 psig. Pump shall be provided with mechanical seals, ball bearings, and shall have non-overloading characteristics. Pump shall be as manufactured by Amtrol, Armstrong, Bell and Gossett, Taco, or approved equal. Impellers shall be no larger than 85% of maximum.

iv. Motor operated boiler room damper: Damper shall be a nominal 4' x 9' long opposed blade damper to be installed on the east side of Bldg. #17 boiler room at the relief louvers. It shall be controlled by the existing thermostat and it shall open when fresh air fan turns on. It is expected that the damper will require 3 motors to properly operate without binding. Motorized damper shall be a model #CD-120 as manufactured by United Enertch, or equal. It shall be the responsibility of the contractor to accurately measure and fit the damper before actual installation.

3. Installation:

A. Building Heat Pumps (CP-3, CP-4): Support pipe adjacent to pump such that weight of pipe is not carried on pump casing. Properly support elbows. Install and anchor pumps according to manufacturer's instructions. Install grout as necessary to achieve proper stability and levelness for each pump. Install according to manufacturer's installations.

i. Each pump shall be installed with a strainer on the inlet, pressure gauges and lug style butterfly valves on the inlets and outlets, union connections on the inlets and outlets, a check valve on the outlets, a balancing valve on the outlets, and vibration isolation fittings on the inlets and outlets of each pump.

B. Hot Water Heaters (DWH-1): Install in area where previous water heaters were located. Install according to manufacturers' instructions and with no less than existing configuration with regard to parts, fittings, equipment, if more than shown on drawings.

C. Shell and Tube Heat Exchanger (HX-1): Heat exchanger shall be installed to permit removal of tube bundle without disturbing other piping and equipment.

D. Motor Operated Damper: Damper shall be installed so as to minimize leakage in the closed position and to prevent the binding of blades. It shall be proven that damper operates in conjunction with fresh air fan and thermostat.

E. Cleaning pipe and equipment: Clean pipe and other components of systems prior to final connections so as not to trap dirt or other contaminants.

4. Operation and Maintenance Manuals: The contractor shall, during the time of the contract and before final approval of the installation, obtain and submit, suitably bound three (3) copies of descriptive literature, maintenance and operation manuals and data, and parts lists of each item of mechanical equipment furnished and installed under this contract. Final payment will not be made until this submittal is made. Electrical interlock and control diagrams, etc., shall also be included.

5. Tests and Adjustments:

A. After completion of the work, but before final payment is made, the contractor shall run a test over a sufficient amount to proper capacity and performance of all apparatus, etc., and of the system as a whole.

B. All controls and safety devices shall be thoroughly checked to assure proper operation and protection.

C. All valves and specialties shall be adjusted to operate smoothly and without binding or leaking. All vents shall be tested and proved to open freely for the passage of air.

D. Pump pressure readings shall be taken and recorded, and flow adjusted as required based on design requirements and pump curves.

E. All motor ampere readings shall be taken and recorded along with nameplate data.

F. The contractor shall, upon completion of the installation and before acceptance of the installation, make all necessary tests and adjustments to place the systems in fully functional working conditions.

DIVISION 15, MECHANICAL

SECTION 1525, INSULATION

1. General:

a. This section covers insulation of piping, valves, fittings, equipment, etc.

b. Although such work is not specifically shown or specified, all supplementary or miscellaneous items, appurtenances and devices incidental to or necessary for a sound, secure, and complete installation shall be furnished and installed as part of this work.

2. References:

American Society for Testing and Materials (ASTM)

ASTM C547-74 Mineral Fiber Preformed Pipe Insulation

ASTM C355 Water Vapor Permanence

ASTM E84 Surface Burning Characteristics of Building Materials

ASTM C534, Type II

ASTM C1056, 2B1

3. Quality Assurance:

a. Packaging and Labeling: Every package or standard container of insulation, jackets, cements, adhesives, and coatings delivered to project site shall have manufacturer's stamp or label attached giving name of manufacturer, brand and description of material. Insulation, packages, and containers shall be asbestos-free.

b. Materials shall have a fluorescent rating of not more than 25 and a smoke-developed rating of not more than 50, when tested in accordance with NFPA 255, ASTM E 84 or UL 723.

c. Piping Systems: Insulating of piping systems shall not proceed until it is proven that the piping systems are free of leaks.

d. It is the intent of this specification that all hot pipes and equipment be insulated unless specifically stated otherwise.

4. Products: Piping Insulation (Includes pipe, valves, fittings, etc.): Insulation material and thickness shall conform to Table 1. Insulation exterior shall be cleanable, grease resistant, non-flaking, and non-peeling. Whenever available, provide pre-molded insulation over pipe, flanges, valves, and fittings. Fiberglass insulation shall be fibrous glass wool and shall be one piece snap-on type. Insulation shall be suitable for use on on hot water pipes with temperature range up to 500 F with a minimum .25 “K” factor. Density shall be nominal 4 pounds per cubic foot.

a. High Temperature Glass shall be good for temperatures up to 850 F, three (3) lbs per cubic foot density, conductivity of .27.

b. For flat surfaces provide mechanical fasteners and ASJ jacket.

c. High temperature glass for curved surfaces shall be in “rigid wrap” form. The material shall be applied per manufacturer’s recommendation. All joints shall be sealed with ASJ tape.

d. Insulation and materials shall be Owens-Corning, Johns-Manville, Armstrong, Certainteed or equal. Special material shall be of manufacturer indicated or equal.

5. Adhesives, Sealants, and Coating Compounds:

a. Insulation and Vapor Barrier Adhesive: Provide ASTM C916, Type 1 adhesive for securing insulation to metal surfaces and for va por barrier lap only in building interior.

b. Lagging Adhesive: MIL-A-3316, Class 1, for bonding fibrous glass cloth to unfaced fibrous glass insulation; for bonding cotton brattice cloth to faced and unfaced fibrous glass insulation board; for sealing edges of and bonding fibrous glass tape to joints of fibrous glass board, or for bonding lagging cloth to thermal insulation, or Class 2, for attaching fibrous glass insulation to metal surfaces. Provide for pipe and duct insulation.

c. Mineral Fiber Insulation Cement: ASTM C 195.

d. Vapor Barrier Coating: Provide in accordance with insulation manufacturer’s recommendations.

6. Accessory Materials:

a. Staples ASTM A 167, Type 304 or 316 stainless steel outside-clinch type.

b. Fibrous Glass Cloth and tape; 20 by 20 maximum size mesh. Tape shall be 4-inch (100mm) wide rolls. Class 3 tape shall be 4.5 ounces per square yard (10.6 Kg.m2). In lieu of glass cloth and tape, open weave glass membrane may be provided.

c. Soft annealed stainless steel, 18 gage.

d. Vapor Barrier Tape: Wherever tape is used for sealing purposes, it shall be of a type and applied as recommended by the non-conductive covering manufacturer.

e. Vapor Barrier Materials ASTM C 1136. Resistant to flame, moisture penetration, and mold growth, color white.

f. All Purpose Jacket (APJ) on piping shall be a vapor barrier laminate. Jacket shall have a water vapor permeance of .02 perms and a Beach puncture of minimum 50 units. Insulation shall be applied over clean dry surfaces butting adjoining sections firmly together.

7. Execution:

a. Preparation: Clean and test mechanical systems prior to application of insulation.

b. Pipe Insulation: Place sections of insulation around pipe and joints tightly butted into place. Draw jacket tight and smooth. Secure jacket with fire resistant adhesive, factory-applied, self-sealing lap, or stainless steel outward clinching staples spaced not over 4 inches (100mm) on center (l.c.) and ½-inch (12.5mm) minimum from edge of lap. Cover circumferential joints with butt strips, not less than 3 inches (k75mm) wide, of material identical to jacket material. Overlap longitudinal laps of jacket material not less than 1-1/2inches (37.5mm). Adhesive used to secure butt strip shall be same as that used to secure jacket laps. Apply staples to both edges of butt strips.

c. Vapor Barrier Jacket: On ends of sections of insulation that butt against flanges, unions, valves, fittings, and joints, provide a vapor barrier coating (insulating cement). Apply vapor barrier coating at longitudinal and circumferential laps. Patch damaged jacket material by wrapping a strip of jacket material around the pipe and cementing, stapling, and coating as specified for butt strips. Extend patch not less than 1-1/2 inches (37.5m m) past the break in both directions. At penetrations by pressure gages and thermometers, fill voids with vapor barrier coating for outside service. Seal with a brush coat of the same temperatures below 35 degrees F (1.6C).

d. Hangers and Anchors: Pipe insulation shall be continuous through pipe hangers. Where pipe is supported by insulation, provide galvanized steel shields and protection saddles. Where shields are used on pipes 2 inches (50mm) and larger, provide insulation inserts at points of hangers and supports. Insulation inserts shall be of calcium silicate, cellular, glass, minimum 8 pcf (0.1 Kg/m3), molded glass fiber, minimum 8 pcf (0.1 Kg/m3), or other approved material of the circumference and be not less in length than the protection shield. Vapor-barrier facing of insert shall be of same material as facing on adjacent insulation. Seal inserts into insulation with vapor barrier coating or weatherproof coating as applicable. Where protection saddles are used, fill voids with same insulation material as used on adjacent pipe. Where anchors are secured to chilled piping that is to be insulated, insulate anchors same as piping for a distance not less than four times the insulation thickness to prevent condensation. Vapor seal insulation around anchors.

e. Sleeves and Wall Chases: Where interior wall is penetrated, extend an aluminum jacket 2 inches (50mm) out on either side of wall and secure on each end with a band. Where roof is penetrated, extend a metal jacket from a point below back up material to a point 10 inches (250mm) above roof with one band at the roof and one not more than one inch (25mm) from end of metal jacket.

f. Flanges, Unions, Valves and Fittings for Piping: Provide insulation for cold piping and hot piping of 110 degrees F (43C) or higher. Factory fabricated removable and reusable insulation covers may be used. When nesting size insulation is used, overlap 2 inches (50mm) or one pipe diameter, whichever is larger. Use insulating cement to fill voids. On pipe sizes larger than 2-1/2 inches (62.5m ), elbows insulated using segments shall not have less than three segments per elbow. Place and joint segments with manufacturer’s recommended water-vapor resistant, fire retardant, and adhesive appropriate for the temperature limit of the service. Overlap tape seams one inch. Extend adhesive onto adjoining insulation not less than two inches. Total dry film thickness shall not be less than 1/16 inch (1.5mm). Where unions are indicated not to be insulated, taper insulation to union at a 45 degree angle.

g. Insulation Finishes and Joint Sealing: Fill breaks, punctures, and voids with vapor barrier coating compound. Vapor seal joint by embedding a single later of 3-inch (75mm) wide open weave glass membrane, maximum 20 by 20 mesh per linear inch (25.4mm) between two 1/16-inch (1.5mm) wet film thickness coats of vapor barrier coating compound. Draw glass fabric smooth and tight with a 1-1/2 inch (37.5mm) overlap. At jacket penetrations such as hangers, thermometers, and damper operating rods, fill voids in insulation with vapor barrier coating. Provide vapor barrier jacket continuous across seams, reinforcements, and projections.

TABLE 1 - Insulation Material

System

Location

Insulation/Thickness Jacket

Hot water

All piping, Fiberglass pipe insulation APJ

Heating fittings, valves, ½”-2” Size - 1” etc.

2-1/2” & Up Size – 1-1/2”

Steam

All piping, ½” - 2” Size - 2-1/2”

2-1/2”-4” Size – 3”

5” & Up Size – 3-1/2”

Condensate

All piping, ½”-1” Size 1”

1-1/4”-2” Size – 1-1/2”

2-1/2” & Up Size – 2”

Heat Exchanger

Heat Exchanger

Fiberglass insulation APJ

2"

Domestic Hot

Hot Water Heaters Factory Insulated Factory

Water

Hot Water Pumps Pumps Uninsulated

It is the intent that any piping, fitting, equipment, or any other surface 120 F, or warmer shall be insulated with a minimum of 1" fiberglass insulation unless otherwise scheduled above.

* Note: If existing adjoining surfaces of those to be insulated are of a different thickness than above, use the same thickness as existing insulation.

** This line to be coated (painted) to match existing insulation exterior color. All insulation shall be labeled as to contents and flow direction with manufactured labels.

DIVISION 15 – MECHANICAL

SECTION 1551, STEAM, HOT WATER, CONDENSATE PIPING

1. General:

a. The work shall include furnishing, installing, and testing of steam, hot water, water, and condensate piping. This shall include piping, flexible connectors, flanges, bolting, gaskets, valves, fittings, flow control equipment, and associated appurtenances necessary for complete and operable systems. Work includes modifications and connections to existing boiler, hot water, water, and condensate systems.

b. Steam, hot water, water, and condensate water piping, fittings, and valves shall be for the conditions, temperatures, and pressures for which they shall operate.

c. System design and test pressures shall not be less than 1.5 times the respective maximum operating pressure at design pressure. Piping components shall be suitable for use under design pressures specified.

d. Butterfly valves, lug type, shall be used hot water pre-heat and re-heat hot water. Ball valves shall be used in water, steam, and condensate pipe at water heaters.

e. Valves shall be rated for as a minimum, the maximum pressure and temperature to which they shall be exposed.

f. The contractor shall carefully investigate the structural and finish conditions affecting all work and shall arrange such accordingly, furnishing such fittings and accessories as may be required to meet such conditions.

2. Products:

a. General: All piping, fittings, gaskets, valves, flanges, bolts, and all other products installed in the piping system shall be suitable for the service, temperature and pressure for which they are installed.

b. Steam and Condensate Piping: Piping shall be welded or threaded, Schedule 40 black steel pipe conforming to ASTM A120. Condensate piping shall be Schedule 80 black steel pipe. Threaded fittings shall be gray cast iron, free of sand holes and imperfections with clean American Standard taper pipe threads.

c. Water and Hot Water Piping at DWH-1: Piping shall be hard drawn copper tubing, Type L. Fittings for copper piping shall be 99.5% wrought copper. Solder shall be 95-5 tin-antimony solder.

d. Hot Water Piping for CP-3 and CP-4: Piping shall be Schedule 40 black steel conforming to ASTM A120.

e. Fittings and Flanges for steel pipe:

i. Steel fittings, ASME/ANSI b16.9, butt-welding type, or ASME/ANSI B16.5, flanged type, or convoluted steel flanges conforming to ASME BPVC SEC VIII D1; cast iron fittings, ASME/ANSI B16.1, flanged type; bronze fittings up to 8-inch size, ANSI B16.24, flanged type.

ii. Stainless steel flexible connectors: Connectors shall be stainless steel with carbon steel flanges and shall be for pressure and temperature for which it is installed. Flexible connector shall be as manufactured by "Vibration Eliminator", or equal.

iii. Fittings for Copper Pipe: Material shall be as manufactured for the service, pressure, and temperature intended.

f. Strainers: Furnish and install strainers ahead of all pumps, regulators and control valves and traps. Strainers shall be as manufactured by Keckley, Muessco, Sarco, or equal. Keckley model numbers are examples. Strainers shall be self-cleaning, iron body, stainless steel, perforated screens with suitable openings for steam or water lines as required for service involved.

g. Check Valves: 2" and smaller shall be bronze swing check, 200 W.O.G. 2-1/2" and larger shall be iron body, Buna seat, and nickel coated ductile iron discs for pump discharge. Install a ball valve and hose end on blow off on all strainers.

h. Butterfly Valves: MSS SP-67, Type I tight shutoff valve, and valve ends shall be lug type. Valve body material shall be cast iron or steel and shall be bubble tight for shutoff at design pressure. Flanged valves shall have 300 series corrosion-resistant steel stems and discs or bronze discs with molded elastomer disc seals. Flow conditions shall be for regulation from maximum flow to complete shutoff by the throttling effect. Valves shall have throttling handles. Valves shall have a minimum of seven locking positions. Any valve above 8’-0” AFF shall be equipped with a wheel & chain to floor control.

i. Cast Iron Gate Valves: MSS SP-70, outside screw-and-yoke type with bronze trim.

j. Globe and Angle Valves: MSS SP-85, with bronze trim, tapped drains, and brass plugs.

k. Ball Valves: Ball valves shall be Apollo, or equal. Valves shall have bronze body for 600 psi W.O.G. stainless steel stem and chrome plated brass ball removable Teflon seats.

l. Drain Valves: Gate valves conforming to MSS SP-80, manually operated ¾-inch pipe size and above, with threaded ends.

m. Air Vent Valves: Manually-operated general service type shall be of ball-float type. Provide ¾-inch pipe size for water piping.

n. Pressure relief, Pressure Limiting, Venting: All pressure relief, pressure limiting, and vent devices shall be provided and installed per ASHRAE 15.

o. Pressure Gauges: Dial type, liquid-filled, elastic element, ANSI/ASME B40.1 with integrally mounted restrictor, as manufactured by Marshalltown, or equal. Dial size shall be 4-1/2 inches. Valves shall be installed in front of all pressure gauges.

p. Thermometers: ASTM E1, liquid-in-glass thermometer. Die-cast case, aluminum finished and baked epoxy enamel, glass front, spring secured, 9 inches long, 180 degree adjustment in vertical plane, 360 degree adjustment in horizontal plane with locking devices. Tube shall be red reading, organic liquid-filled with magnifying lens. Scale shall have permanently markings.

q. Thermometer Wells: Thermometer wells shall be brass or stainless steel and shall have a pressure rating not less than the system design pressure.

r. Pipe Hangers and Supports: Design and fabrication of pipe hangers, supports, and welding attachments shall conform to MSS SP-58, ASME/ANSI B31.9, and MSS SP-69. Provide metal protection shields and inserts for insulated piping.

i. Hangers shall be of the adjustable band type with hanger rod, or of the trapeze type with horizontal angle iron, "U" bolts and hanger rods. Where hanger is in contact with pipe, proper isolation shall be provided to prevent electrolytic action.

ii. Hangers shall be installed around the outside of insulation with vapor barriers, and insulation shall be protected against crushing by sheet metal jacket of proper area and weight.

iii. Approved foam glass or rigid closed cell elastomeric insulating blocking shall be placed around the pie where normal insulation alone cannot prevent crushing. Insulation jacket or vapor barriers shall be sealed at ends after installing blocking.

s. Vibration Isolators (Flexible Connectors): Vibration isolators / flexible connectors shall be used where pumps connect to piping as shown on the drawings. They shall be stainless steel connectors as manufactured by Vibration Eliminator, or equal. Guides shall be used as recommended by the flexible connector manufacturer.

t. Flow Meter: Flow meter shall be installed in hot water pipe as shown on the drawings. It shall be a turbine style with a display module. It shall be shall capable of detecting flow from 5- 200 gpm at a temperature of up to 250 F. Flow meter shall be a model #F-1110 as manufactured by Onicon, or equal. Display meter shall be compatible with flow meter and shall be a System 10 Btu meter as manufactured by Onicon, or equal. All sensors and components shall be supplied for a complete and fully functional meter and display. See drawings for meter and display locations.

u. Steam Traps: Steam traps shall be located as shown on the drawings. They shall be F & T type as manufactured by Armstrong, Sarco, Hoffman, TLV, or equal. Traps shall be installed with a ball valve, strainer, and union on the inlet, plus a union and ball valve on the outlet, unless shown otherwise. Trap capacities shall be a minimum of four times the capacity of the device, unless recommended otherwise by the trap manufacturer.

v. Sleeves: All pipes passing through floors, walls, and ceilings shall be installed in sleeves. Sleeves shall be black steel pipe, flush with wall, ceilings, and finished floor, and of size to accommodate the pipe and pipe insulation.

3. Installation: Install Piping and piping components to ensure proper and efficient operation of equipment and controls. Provide proper supports for mounting of vibration isolators, stands, guides, anchors, clamps, and brackets. Arrange piping connections to equipment so that removal of equipment or components of equipment including tube withdrawal from condensing unit, pump casing, shaft seals and similar work can be accomplished with the least amount of disassembly or removal of piping systems. Provide piping connected to equipment with vibration isolators with flexible connections which shall conform to vibration and sound isolation requirements for system. Electric isolation shall be provided between dissimilar metals to reduce rate of galvanic reaction. All pipe and equipment shall be properly supported so as not to put undue stress on equipment, fittings, and connections. Particular attention shall should be given to the support of piping above vibration isolators and the support of steam traps.

a. Steam, Condensate, Water, and Hot Water:

i. Welding, heating, and soldering shall conform to ANSI/ASME B31.9 and as specified. Provide pipe, fittings, valves, etc., as necessary, to connect to existing piping. Horizontal runs of piping shall pitch to assure adequate drainage and venting. Provide drain valves at low points and automatic air vent valves at high points of system where air pockets would occur. Blow out piping with high pressure steam, high pressure water, or compressed air, as necessary, to remove rust, scale, oil, and debris. Before final connections are made, wash interior of piping with water. Plug or cap foreign objects from entering. Insure clearance is provided on all piping, fittings, etc. to install insulation. Provide unions and flanges, as necessary, to permit removal of tube bundles, control valves, etc. Provide shutoff valves to vessels to permit servicing without draining system. Locate valves so as not to interfere with head removal.

ii. Allowance for expansion shall be made in the installation of all piping so that the usual variation in temperature will not cause undue stress at any point. Pipes shall be securely anchored where necessary to properly distribute expansion stresses.

b. Water and hot water: Proper allowance shall be made for expansion and all lines and risers shall be blocked as may be necessary to prevent noise or vibration when water is turned on or off.

c. Valves: Install at equipment to allow maintenance or isolation, and to establish proper and sequential operation of complete system. Shell and tube liquid coolers shall have fluid valves installed so that tubes are accessible for cleaning or replacing.

Provide globe valves or plug cocks where required to regulate flow to obtain equal distribution of fluid handled.

d. Pressure Gages and Thermometers:

i. Pressure Gage: Provide a shutoff valve or pet cock between pressure gages and pipe line. Gauges shall be easily read from the floor.

ii. Thermometers: Provide thermometers and thermal sensing elements of control valves with a separate socket. Install sockets (thermowells) in pipe lines in such a manner to sense temperature of flowing fluid and minimize obstruction to flow. Thermometers shall be installed such that they can be easily read from the floor.

e. Flow Meter: Install flow meter and flow meter display according to manufacturer's instructions. Display module shall be installed at a location and height so as to be easily readable and serviceable. Flow meter and display shall be wired to electricity and all electrical and material required for meter to operate as per manufacturer's instructions shall be provided and installed.

f. Identification of Piping: Identify piping in accordance with 29CFR 1910.144, ANSI A13.1, ANSI 253.1. All pipe shall be clearly marked with contents and flow direction with labels specifically for intended purpose. Tag gages, thermometers, and valves with tags of brass.

g. Field Inspections: Prior to initial operation, examine and inspect piping systems for conformance to plans and specifications.

h. Tests and Adjustments:

i. After completion of piping installation and prior to initial operation, conduct hydrostatic tests on piping. Test piping systems at 1-1/2 design pressure or 150 psi, whichever is higher with water. Before tests, remove or isolate gages and other apparatus in new and old systems which may be damaged. Repair leaks. Do not caulk joints. Install a calibrated pressure gage in system to observe any loss in pressure. Maintain test pressure for a sufficient period of time. Correct defects.

ii. Startup: Start up and initially operate hot water, water, steam, and condensate water systems. During this time, periodically clean strainers until no further accumulation of foreign material occurs. Correct deficiencies.

i. Operation and Maintenance Manuals: The contractor shall, during the time of the contract and before final approval of the installation, obtain and submit, suitably bound three (3) copies of descriptive literature, maintenance and operation manuals and data, and parts lists of each item of mechanical equipment furnished and installed under this contract. Final payment will not be made until this submittal is made. Electrical interlock and control diagrams, etc., shall also be included.

DIVISION 16, ELECTRICAL

SECTION 1605, ELECTRICAL SYSTEMS

1. Scope: The work covered by this section of the specifications consists of furnishing all electrical labor, equipment, supplies, materials and in performing all operations necessary for installing a 4' x 9' motorized, thermostat controlled damper with new fusible disconnect. Also included is the replacement of 2 pre-heat pumps, 2 re-heat pumps, and 2 steam heated, hot water heaters, and hot water heater circulating pumps. CP-3 and CP-4 are to have new heaters and fuses installed in MCC-1. Included are to be all other electrical components as required for these systems to be complete in Bldg. 17-24 boiler room.

2. General:

a. Rules: The installation shall be in strict accordance with the requirements of the latest rules of the National Electrical Code and the National Fire Protection Association and as indicated on the drawings.

b. Coordination:

The drawings indicate the extent and general location and arrangement of equipment, conduit and wiring. The contractor shall study building plans and details so that the outlets and equipment shall be properly located and readily accessible. Equipment and outlets shall be located to avoid interference with mechanical or structural features.

c. Materials and Schedules: As soon as practical and before starting installation of any material and equipment, the contractor shall submit to the Contracting Officer’s Representative (COR) for approval, a complete list in triplicate of materials and equipment proposed for installation. This list shall include manufacturer’s names and materials equipment identification such as styles, types, catalog numbers, etc., to permit ready and complete identification. The label or listing of the Underwriters’ Laboratories, Inc. will be acceptable as evidence that the materials or equipment conform to the applicable standards of that Agency.

3. Materials and Equipment:

a. Raceway

i. All wiring exposed within the building shall be installed in raceways. Raceway shall be installed exposed in general. Conduit shall be concealed in finished areas.

ii. Raceways exposed to weather, and any other area subject to damage shall be zinc-coated, rigid steel conduit. Conduit installed in the boiler room of Bldg. #17-24 shall be rigid steel.

iii. Rigid steel conduit and steel electrical metallic tubing shall be hot dipped galvanized as manufactured by Allied Tube and Conduit Corporation, or approved equal. IMC conduit shall be as manufactured by Allied Tube and Conduit Corporation, or approved equal.

iv. No raceway smaller than 3/4” shall be used unless otherwise noted. Flexible conduit may be used if permitted by the NEC.

v. All conduits shall be securely supported by means of approved conduit hangers. Suspension of conduits by approved wire hangers and clips shall be permitted only for single conduits ¾” and smaller.

vi. All conduit shall be run parallel with the lines of the building

vii. Existing conduit may be reused as approved by owner.

b. Boxes:

i. Boxes and outlets shall be hot dipped galvanized Raco or equal and shall be water tight.

ii. Conduit fittings shall be as manufactured by T & B or Raco. Bushings on all conduits 1” and larger shall be the O.Z. Type “B” insulated type, with body, threads and conduit stop of malleable iron or steel, and with phenolic insulation molded on an irregular surface at the top so that it becomes an integral part of the bushing. Grounding bushings shall be the O.Z. Type “BL”.

iii. Provide minimum NEC required size pull boxes unless larger box is noted.

iv. Disconnect (fusible) for motorized damper at L-14 shall be for 120v, 60 hz service. Power for damper motors shall be from electrical panel on south wall of boiler room.

c. Conductors:

i. All conductors shall be copper.

ii. Conductor insulation shall be of the following type: THHN, unless otherwise noted.

iii. No wire shall be smaller than #12 unless otherwise noted, except that wiring for signal and pilot control circuits may be #14.

iv. Insulated ground wires shall be run with circuit conductors for all circuits.

v. All conductors shall be color coded in their entirety for wire sizes where color coding is commercially available. Phase wires of different multi-wire circuits in same raceway shall be of different color to provide identification.

vi. Conductors in sizes which are not commercially available in color coding shall be taped with corresponding colors at all termination points and in all pull boxes, wireways, gutters, etc. All conductors found not to conform to these requirements will be directed to be removed and replaced as specified at no additional cost for the Owner.

vii. Conductors shall be continuous from outlet to outlet and no splices shall be made except within outlet or junction boxes. Junction boxes may be utilized where required. All outlet, junction and pull boxes used with rigid conduit shall be water tight.

viii. Splices and taps for smaller than #6 wire shall be made with 3M Ideal, or Buchanan twist-on insulated connectors. Connectors of the porcelain cup type, with or without metal inserts, shall not be used. Splices in wire #6 and larger, shall be made with approved solderless lugs. If any other type of connector is proposed for use in any size conductor, it shall be specifically submitted for approval prior to use.

d. New heaters and fuses for pumps CP-3 and CP-4 shall be supplied and shall be for 480 V, 3 phase, 60 Hz.

f. Any other electrical devices in addition to the receptacles and switches previously mentioned shall have Carlon, or equal cover plates.

4. Installation and Workmanship:

a. The installation of all electrical work shall be in accordance with the drawings, these specifications, and shall be accomplished by electricians with a minimum of a “journeyman’s” license.

b. Conductors shall be continuous from outlet to outlet and no splices shall be made except within outlet or junction boxes. Conductor identification shall be color coded.

c. All conduit shall be interconnected for continuous electrical connection to ground. All raceways, etc., shall be grounded in accordance with Article 250 of the National Electrical Code. All exposed non-current carrying metallic parts of electrical equipment and raceway systems shall be grounded.

d. All motors and receptacles shall be grounded with a green ground wire extending from the motor or wiring device to the ground lug within the breaker panels.

e. Upon completion of the installation, make tests for operation with and to the satisfaction of the Owner.

f. Motor Wiring: Flexible conduit “runouts” shall be installed in conduit to each motor. Conduit shall be of a liquid tight type.

g. Motorized Damper: Install disconnect at 6' above boiler room floor as shown on the drawings. Provide power to damper motor from existing panel board in boiler room. Connect damper motor to existing thermostat which controls VF-8.