232213-Steam and Condensate Heating Piping.pdf

Steam Supply and Condensate Steam and Condensate Heating Piping Return Piping Replacement 232213-1 PGRU, Geneva, NY

SECTION 232213

STEAM AND CONDENSATE HEATING PIPING

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes the following for HP steam and condensate piping:

1. Pipe and fittings.

2. Strainers.

3. Steam traps.

4. High Temperature Direct Buried Pipe.

1.2 DEFINITIONS

A. HP Systems: High-pressure piping operating at more than 15 psig as required by ASME B31.1.

1.3 PERFORMANCE REQUIREMENTS

A. Components and installation shall be capable of withstanding the following minimum working pressures and temperatures:

1. HP Steam Piping: 125 psig at 400 deg F.

2. Condensate Piping: 10 psig at 300 deg F.

1.4 SUBMITTALS

A. Product Data: Include catalog sheets, specifications and compliances for each type of the following:

1. Steam trap.

2. Strainers.

3. Steel Pipe and Fittings

4. High Temperature-Direct Buried Insulated Pipe.

B. Shop Drawings: Detail, scale, fabrication of pipe anchors, hangers, pipe, multiple pipes, alignment guides, and expansion loops and their attachment to the building structure. Detail locations of anchors, alignment guides, and expansion joints and loops.

C. Qualification Data: For Installer.

D. Welding certificates.

E. Field quality-control test reports.

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F. Operation and Maintenance Data: For valves and steam traps to include in emergency, operation, and maintenance manuals.

1.5 QUALITY ASSURANCE

A. Installer Qualifications:

B. Steel Support Welding: Qualify processes and operators according to AWS D1.1, "Structural Welding Code - Steel."

C. Pipe Welding: Qualify processes and operators according to the following:

1. Comply with provisions in ASME B31 Series, "Code for Pressure Piping."

2. Certify that each welder has passed AWS qualification tests for welding processes involved and that certification is current.

D. ASME Compliance: Comply with ASME B31.9, "Building Services Piping" for materials, products, and installation.

PART 2 - PRODUCTS

2.1 STEEL PIPE AND FITTINGS

A. Steel Pipe: ASTM A 53/A 53M, black steel, plain ends, Type, Grade, and Schedule as indicated in Part 3 piping applications articles.

B. Cast-Iron Threaded Fittings: ASME B16.4; Classes 150, and 300 as indicated in Part 3 piping applications articles.

C. Malleable-Iron Threaded Fittings: ASME B16.3; Classes 150 and 300 as indicated in Part 3 piping applications articles.

D. Malleable-Iron Unions: ASME B16.39; Classes 150, 250, and 300 as indicated in Part 3 piping applications articles.

E. Wrought-Steel Fittings: ASTM A 234/A 234M, wall thickness to match adjoining pipe.

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

1. Material Group: 1.1.

2. End Connections: Butt welding.

3. Facings: Raised face.

G. Steel Pipe Nipples: ASTM A 733, made of ASTM A 53/A 53M, black steel of same Type, Grade, and Schedule as pipe in which installed.

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2.2 HIGH TEMPERATURE- DIRECT BURIED INSULATED PIPING

A. Manufacturers:

1. Thermacor Process, Duo-Therm 505LP.

2. Preinsulated Class "A " Steel Piping Systems with HDPE Overjacket.

3. Rovanco

B. Conduit

1. The conduit shall be 10 gauge, welded, smooth-wall black steel conforming to ASTM A-

211, A-139, A-134, and A-135.

2. Conduit shall be tested at the factory to insure air and watertight welds prior to any fabrication or application of coating.

3. The outside conduit surface shall be blasted to clean, bright metal.

C. Conduit Closure

1. Conduit closures shall be 10-gauge steel, furnished with the conduit at a ratio of one closure for each fabricated item or length.

2. Closures shall be field welded over adjacent units after pipe insulation.

3. After testing, all exposed closures shall be covered in the field with a heat shrinkable sleeve, furnished with the conduit.

D. Piping in conduit

1. Piping in the conduit shall be Schedule 40, steel, ASTM A-53, Grade B, ERW.

2. Pipe joints shall be welded in accordance with the Power Piping Code for ASME/ANSI B

31.1.

E. Piping Insulation

1. The pipe insulation shall be mineral wool, of the thickness Minimum of 2”.

F. Pipe Fittings

1. Prefabricated ells and tees shall be furnished and installed where shown on plans and shall consist of pipe, insulation, and conduit conforming to the same specification as hereinbefore stated for straight runs.

2. Expansion loops shall be designed in accordance with the stress limits dictated by power piping code ASME/ANSI B31.1.

3. Loop piping shall be installed in conduit suitably sized to handle indicated pipe movement.

G. Terminal Ends

1. Terminal ends of conduits inside manholes, pits or building walls shall be equipped with end seals consisting of a 1/2" steel bulk head plate welded to the pipe and conduit.

2. If there is no anchor within five feet of a terminal end, conduits shall be equipped with gland seals consisting of a packed stuffing box and gland follower mounted on a steel plate welded to the end of the conduit.

3. End seals or gland seals shall be equipped with drain and vent openings.

4. Terminate all conduits 2" beyond the inside face of manhole or building walls.

H. Thrust Block

1. A concrete thrust block shall be cast over the anchor plate and conduit, large enough for firm anchorage into undisturbed trench sidewalls and/or bottom.

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2. The concrete block shall be at least 36" in length and extend a minimum of 12" beyond the top and bottom of the anchor plate.

I. Sleeves

1. Wall sleeves with leak plates shall be provided at all building and manhole entries to provide an effective moisture barrier.

2. The wall sleeve and leak plate shall be electrically isolated from building rebar.

3. The space between the conduit and wall sleeve shall be made watertight by use of Link-

Seal assemblies, which will also provide electrical isolation.

J. Steel Conduit

1. Shall be insulated with polyurethane foam insulation minimum thickness of 1".

Insulation shall be rigid, 90-95% closed cell polyurethane with 2.0 to 2.5 pounds per cubic foot density and coefficient of thermal conductivity (K factor) of .14 per ASTM C518.

2. The urethane shall conform to ASTM C591. Maximum conduit interface temperature shall not exceed 250°F.

K. Jacketing

1. Material shall be extruded, black, high density polyethylene (HDPE), having a minimum wall thickness of 125 mils for jacket sizes less than or equal to 12.

L. Moisture barrier

1. End seals shall be factory applied, sealed to the jacket and carrier pipe.

2. End seals shall be certified as having passed a 20-foot head pressure test.

3. End seals shall be mastic completely sealing the exposed end of the insulation.

4. Field applied end seals shall be installed at each field cut to the piping before continuing with the installation.

M. Straight Run Joints

1. Insulated using a wrap around HDPE jacket placed over the field joint and insulated with polyurethane foam.

2. HDPE Closure Sleeves are to be pressured tested to a minmimum of 5.0 PSIG for a minimum of 5 minutes. Either electric fusion, Canusa or Raychem pressure testable sleeves are acceptable. Heat Shrink Sleeve alone are NOT acceptable.

N. Conduit fittings

1. Factory prefabricated and preinsulated with urethane to the thickness specified and jacketed with a molded, extrusion welded, or butt fusion welded PE jacket.

2. NO TAPING OR HOT AIR WELDING SHALL BE ALLOWED.

O. Alignment Guides

1. Furnish alignment guides specifically designed for and integral to the direct buried insulated piping system.

2.3 JOINING MATERIALS

A. Pipe-Flange Gasket Materials: Suitable for chemical and thermal conditions of piping system contents.

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1. ASME B16.21, nonmetallic, flat, asbestos free, 1/8-inch maximum thickness unless thickness or specific material is indicated.

a. Full-Face Type: For flat-face, Class 125, cast-iron and cast-bronze flanges.

b. Narrow-Face Type: For raised-face, Class 250, cast-iron and steel flanges.

B. Flange Bolts and Nuts: ASME B18.2.1, carbon steel, unless otherwise indicated.

C. Welding Filler Metals: Comply with AWS D10.12 for welding materials appropriate for wall thickness and chemical analysis of steel pipe being welded.

D. Welding Materials: Comply with Section II, Part C, of ASME Boiler and Pressure Vessel Code for welding materials appropriate for wall thickness and for chemical analysis of pipe being welded.

2.4 STRAINERS

A. Y-Pattern Strainers:

1. Body: ASTM A 126, Class B cast iron, with bolted cover and bottom drain connection.

2. End Connections: Threaded ends for strainers NPS 2 and smaller; flanged ends for strainers NPS 2-1/2 and larger.

3. Strainer Screen: Stainless-steel, 20 mesh strainer, and perforated stainless-steel basket with 50 percent free area.

4. Tapped blowoff plug.

5. CWP Rating: 400°F at 250-psig working steam pressure.

2.5 STEAM TRAPS

A. Thermo-Dynamic Traps:

1. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

a. Spirax Sarco, Inc.

b. Armstrong, Inc.

c. Hoffman Specialty; Division of ITT Industries.

2. Body: Stainless Steel, ASTM A743 GR.CA40F.

3. Disc: Stainless Steel, AISI 420.

4. Cap: Stainless Steel, ASTM A743 GR.CA40F.

5. Insulator: Ceramic.

6. End Connections: Threaded.

7. Maximum Operating Pressure: 600 psig.

8. Max operating Temp: 800°F.

9. Provide strainer ahead of steam trap

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PART 3 - EXECUTION

3.1 HP STEAM PIPING APPLICATIONS

A. HP Steam Piping, NPS 1-1/2 and Smaller Schedule 40, Type S, Grade B, steel pipe; Class 150 cast-iron fittings; and threaded joints.

B. HP Steam Piping, NPS 2 through NPS 8 Schedule 40, Type E, Grade B, steel pipe; Class 150 wrought-steel fittings, flanges, and flange fittings; and welded and flanged joints.

C. Condensate piping above grade shall be the following:

1. Schedule 80, Type S, Grade B, steel pipe; Class 125 cast-iron fittings; and threaded joints.

3.2 PIPING INSTALLATION

A. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems. Use indicated piping locations and arrangements if such were used to size pipe and calculate friction loss, expansion, and other design considerations. Install piping as indicated unless deviations to layout are approved on Coordination Drawings.

B. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise.

C. Install piping to permit valve servicing.

D. Install piping free of sags and bends.

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

F. Install piping to allow application of insulation.

G. Select system components with pressure rating equal to or greater than system operating pressure.

H. Install groups of pipes parallel to each other, spaced to permit applying insulation and servicing of valves.

I. Install steam supply piping at a minimum uniform grade of 0.2 percent downward in direction of steam flow. In areas where conditions may not allow for 0.2 percent grade consult engineer.

J. Install condensate return piping at a minimum uniform grade of 0.4 percent downward in direction of condensate flow. In areas where conditions may not allow for 0.4 percent grade consult engineer.

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K. Reduce pipe sizes using eccentric reducer fitting installed with level side down for steam and condensate pipe.

L. Install valves according to Division 23 Section "General-Duty Valves for HVAC Piping."

M. Install unions in piping, NPS 1-1/2 and smaller, adjacent to valves, at final connections of equipment, and elsewhere as indicated.

N. Install flanges in piping, NPS 2 and larger, at final connections of equipment and elsewhere as indicated.

O. Install strainers on supply side of traps, and elsewhere as indicated.

P. Identify piping as specified in Division 23 Section "Identification for HVAC Piping and Equipment."

Q. Install drip legs at low points and natural drainage points such as ends of mains and bottoms of risers.

1. On straight runs with no natural drainage points, install drip legs at intervals not exceeding 200 feet.

2. Size drip legs same size as main.

3.3 INSTALLATION - BURIED PIPING SYSTEMS

A. The installing contractor shall be responsible to excavate, string conduit, weld test, place in trench, backfill or otherwise treat and install the system as per the specifications and the directions furnished by the manufacturer and approved by the design engineer in accordance with plans and specifications.

B. The conduit shall be air tested at 15 psi for two hours. Repair any carrier pipe leaks and retest prior to making field closure.

C. A factory trained or qualified representative shall be present at the jobsite during critical periods of the installation such as unloading, commencement of the installation, and testing. Back filling shall not begin until approval of pressure tests by the Thermacor field representative.

D. A hydrostatic pressure test of the carrier pipe shall be performed per the engineer’s specification with a factory recommendation of one and one-half times the normal system operating pressure for not less than two hours. Care shall be taken to insure all trapped air is removed from the system prior to the test. Appropriate safety precautions shall be taken to guard against possible injury to personnel in the event of a failure.

E. Verify connection to existing piping system - size, location, and invert.

F. Install pipe to elevation as required.

G. Place bedding material at trench bottom to provide a uniform bedding for piping, level bedding materials in one continuous layer

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H. Install pipe on prepared bedding.

I. Route pipe in straight line.

J. Install pipe to allow for expansion and contraction without stressing pipe or joints.

K. Install shutoff and drain valves at locations shown on Drawings.

L. Install plastic ribbon tape continuous over top of pipe and buried 6 inches below finish grade, above pipeline.

3.4 STEAM-TRAP INSTALLATION

A. Install steam traps in accessible locations as close as possible to connected equipment.

B. Install high performance isolation valve, strainer, and union upstream from trap; install union, check valve, and high performance isolation valve downstream from trap unless otherwise indicated.

3.5 PIPE JOINT CONSTRUCTION

A. Join pipe and fittings according to the following requirements and Division 23 Sections specifying piping systems.

B. Ream ends of pipes and tubes and remove burrs. Bevel plain ends of steel pipe.

C. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly.

D. Threaded Joints: Thread pipe with tapered pipe threads according to ASME B1.20.1. Cut threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and restore full ID. Join pipe fittings and valves as follows:

1. Apply appropriate tape or thread compound to external pipe threads unless dry seal threading is specified.

2. Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or damaged. Do not use pipe sections that have cracked or open welds.

E. Welded Joints: Construct joints according to AWS D10.12, using qualified processes and welding operators according to Part 1 "Quality Assurance" Article.

F. Flanged Joints: Select appropriate gasket material, size, type, and thickness for service application. Install gasket concentrically positioned. Use suitable lubricants on bolt threads.

3.6 FIELD QUALITY CONTROL

A. Prepare steam and condensate piping according to ASME B31.9, "Building Services Piping," and as follows:

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

2. Provide temporary restraints for expansion joints that cannot sustain reactions due to test pressure. If temporary restraints are impractical, isolate expansion joints from testing.

3. Flush system with clean water. Clean strainers.

4. Isolate equipment from piping. If a valve is used to isolate equipment, its closure shall be capable of sealing against test pressure without damage to valve. Install blinds in flanged joints to isolate equipment.

B. Perform the following tests on steam and condensate piping:

1. Use ambient temperature water as a testing medium unless there is risk of damage due to freezing. Another liquid that is safe for workers and compatible with piping may be used.

2. Subject piping system to hydrostatic test pressure that is not less than 1.5 times the working pressure. Test pressure shall not exceed maximum pressure for any vessel, pump, valve, or other component in system under test. Verify that stress due to pressure at bottom of vertical runs does not exceed 90 percent of specified minimum yield strength.

3. After hydrostatic test pressure has been applied for at least 10 minutes, examine piping, joints, and connections for leakage. Eliminate leaks by tightening, repairing, or replacing components, and repeat hydrostatic test until there are no leaks.

C. Prepare written report of testing.

3.7 WELDING FIELD QUALITY CONTROL

A. Welding Requirements

1. Butt and Fillet welds:

a. End Preparation:

1) End preparation for butt weld contained in ASME B16.25 are acceptable.

2) Oxygen or arc cutting is acceptable only if cut is reasonably smooth, and all slag is removed from flame cut surfaces.

b. Cleaning:

1) Surfaces for welding shall be clean and shall be free from paint, oil, rust, scale and other material which is detrimental to welding.

c. Internal alignment:

1) The inside diameters of piping components to be butt welded shall be aligned as accurately as is practical within existing commercial tolerances on diameters, wall thicknesses, and out of roundness. Alignment shall be preserved during welding as accurately as possible.

B. Welding Records

1. The employer shall maintain a record signed by him, and available to the agent and inspector of the welding procedure specifications used and the welders, and/or welding operators employed by him, showing the date and results of procedure and performance qualification.

C. 100% of the welds for the high pressure steam and condensate piping shall be tested by Contractor per 014000 – 1.6..

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D. Coordinate Work with owner.

E. Contractor shall repair all failed welds, at their cost, to the satisfaction of the owner and/or inspection agency.

3.8 TEST REQUIREMENTS FOR WELDS

A. 100% of the welds for the high pressure steam and condensate piping above ground in the building shall be tested by Contractor’s independent testing company.

B. Limitations on Imperfections for Butt and Fillet welds

1. Cracks:

a. None permitted.

2. Incomplete Penetration:

a. The total joint penetration shall not be less than the thickness of the thinner of the components being joined, except that incomplete root penetration is acceptable if it does not exceed the lesser of 1/32” of 20% of the required thickness, and its extent is not more than 1-1/2” in any 6” of weld.

3. Undercut and Reinforcement:

a. Undercut shall not exceed the lesser of 1/32” of 12.5% of wall thickness.

Thickness of weld reinforcement shall not exceed 3/16”.

4. Concave Root:

a. Concavity of the root surface shall not reduce the total thickness of the joint, including reinforcement, to less than the thickness of the thinner of the components being joined.

5. Excess Root Penetration:

a. The excess shall not exceed the lesser of 1/8” or 5% of the inside diameter of the pipe.

6. Weld Surfaces:

a. There shall be no overlaps or abrupt ridges or valleys.

END OF SECTION 23 2213