Specification.pdf

U S

D ep ar tm en t o f A gr ic ul tu re

U S

D ep ar tm en t o f A gr ic ul tu re

APPALACHIAN FRUIT APPALACHIAN FRUIT

RESEARCHRESEARCH

STATIONSTATION

KearneysvilleKearneysville, West Virginia, West Virginia

RMF Project No.:

108285.A0

23 June 2009

Repair 100,000 gallon Potable Water Storage Tank

SpecificationsSpecifications

RMF ENGINEERING, INC.

CONSULTING ENGINEERS

5520 RESEARCH PARK DRIVE

BALTIMORE, MARYLAND 21228

(410) 576-0505 Fax: (410) 385-0327

Slide Number 1

USDA-ARS: Repair 100,000 Gallon Potable Water Tank 53-3615-0-0100 Appalachian Fruit Research Station, Kearneysville, WV 23 June 2009

SECTION 01 78 23

OPERATION AND MAINTENANCE DATA

01/04

PART 1 GENERAL

1.1 SUBMISSION OF OPERATION AND MAINTENANCE DATA

Submit Operation and Maintenance (O&M) Data specifically applicable to this contract and a complete and concise depiction of the provided equipment, product, or system. Organize and present information in sufficient detail to clearly explain O&M requirements at the system, equipment, component, and subassembly level. Include an index preceding each submittal. Submit in accordance with this section and Section 01 33 00, SUBMITTAL PROCEDURES.

1.1.1 Package Quality

Documents must be fully legible. Poor quality copies and material with hole punches obliterating the text or drawings will not be accepted.

1.1.2 Package Content

Data package content shall be as shown in the paragraph titled "Schedule of Operation and Maintenance Data Packages." Comply with the data package requirements specified in the individual technical sections, including the content of the packages and addressing each product, component, and system designated for data package submission.

1.1.3 Changes to Submittals

Manufacturer-originated changes or revisions to submitted data shall be furnished by the Contractor if a component of an item is so affected subsequent to acceptance of the O&M Data. Changes, additions, or revisions required by the Contracting Officer for final acceptance of submitted data, shall be submitted by the Contractor within 30 calendar days of the notification of this change requirement.

1.2 TYPES OF INFORMATION REQUIRED IN O&M DATA PACKAGES

1.2.1 Operating Instructions

Include specific instructions, procedures, and illustrations for the following phases of operation:

1.2.1.1 Safety Precautions

List personnel hazards and equipment or product safety precautions for all operating conditions.

1.2.1.2 Operator Prestart

Include procedures required to set up and prepare each system for use.

1.2.1.3 Startup, Shutdown, and Post-Shutdown Procedures

Provide narrative description for Startup, Shutdown and Post-shutdown operating procedures including the control sequence for each procedure.

1.2.1.4 Normal Operations

Provide narrative description of Normal Operating Procedures. Include Control Diagrams with data to explain operation and control of systems and specific equipment.

1.2.1.5 Emergency Operations

Include Emergency Procedures for equipment malfunctions to permit a short period of continued operation or to shut down the equipment to prevent further damage to systems and equipment. Include Emergency Shutdown Instructions for fire, explosion, spills, or other foreseeable contingencies. Provide guidance and procedures for emergency operation of all utility systems including required valve positions, valve locations and zones or portions of systems controlled.

1.2.1.6 Operator Service Requirements

Include instructions for services to be performed by the operator such as lubrication, adjustment, inspection, and recording gage readings.

1.2.1.7 Environmental Conditions

Include a list of Environmental Conditions (temperature, humidity, and other relevant data) that are best suited for the operation of each product, component or system. Describe conditions under which the item equipment should not be allowed to run.

1.2.2 Preventive Maintenance

Include the following information for preventive and scheduled maintenance to minimize corrective maintenance and repair.

1.2.2.1 Lubrication Data

Include preventative maintenance lubrication data, in addition to instructions for lubrication provided under paragraph titled "Operator Service Requirements":

a. A table showing recommended lubricants for specific temperature ranges and applications.

b. Charts with a schematic diagram of the equipment showing lubrication points, recommended types and grades of lubricants, and capacities.

c. A Lubrication Schedule showing service interval frequency.

1.2.2.2 Preventive Maintenance Plan and Schedule

Include manufacturer's schedule for routine preventive maintenance, inspections, tests and adjustments required to ensure proper and economical operation and to minimize corrective maintenance. Provide manufacturer's projection of preventive maintenance work-hours on a daily, weekly, monthly, and annual basis including craft requirements by type of craft.

For periodic calibrations, provide manufacturer's specified frequency and procedures for each separate operation.

1.2.3 Corrective Maintenance (Repair)

Include manufacturer's recommended procedures and instructions for correcting problems and making repairs.

1.2.3.1 Troubleshooting Guides and Diagnostic Techniques

Include step-by-step procedures to promptly isolate the cause of typical malfunctions. Describe clearly why the checkout is performed and what conditions are to be sought. Identify tests or inspections and test equipment required to determine whether parts and equipment may be reused or require replacement.

1.2.3.2 Wiring Diagrams and Control Diagrams

Wiring diagrams and control diagrams shall be point-to-point drawings of wiring and control circuits including factory-field interfaces. Provide a complete and accurate depiction of the actual job specific wiring and control work. On diagrams, number electrical and electronic wiring and pneumatic control tubing and the terminals for each type, identically to actual installation configuration and numbering.

1.2.3.3 Maintenance and Repair Procedures

Include instructions and alist of tools required to repair or restore the product or equipment to proper condition or operating standards.

1.2.3.4 Removal and Replacement Instructions

Include step-by-step procedures and a list required tools and supplies for removal, replacement, disassembly, and assembly of components, assemblies, subassemblies, accessories, and attachments. Provide tolerances, dimensions, settings and adjustments required. Instructions shall include a combination of text and illustrations.

1.2.3.5 Spare Parts and Supply Lists

Include lists of spare parts and supplies required for maintenance and repair to ensure continued service or operation without unreasonable delays. Special consideration is required for facilities at remote locations. List spare parts and supplies that have a long lead-time to obtain.

1.2.4 Corrective Maintenance Work-Hours

Include manufacturer's projection of corrective maintenance work-hours including requirements by type of craft. Corrective maintenance that requires completion or participation of the equipment manufacturer shall be identified and tabulated separately.

1.2.5 Appendices

Provide information required below and information not specified in the preceding paragraphs but pertinent to the maintenance or operation of the product or equipment. Include the following:

1.2.5.1 Parts Identification

Provide identification and coverage for all parts of each component, assembly, subassembly, and accessory of the end items subject to replacement. Include special hardware requirements, such as requirement to use high-strength bolts and nuts. Identify parts by make, model, serial number, and source of supply to allow reordering without further identification. Provide clear and legible illustrations, drawings, and exploded views to enable easy identification of the items. When illustrations omit the part numbers and description, both the illustrations and separate listing shall show the index, reference, or key number that will cross-reference the illustrated part to the listed part. Parts shown in the listings shall be grouped by components, assemblies, and subassemblies in accordance with the manufacturer's standard practice.

Parts data may cover more than one model or series of equipment, components, assemblies, subassemblies, attachments, or accessories, such as typically shown in a master parts catalog.

1.2.5.2 Warranty Information

List and explain the various warranties and include the servicing and technical precautions prescribed by the manufacturers or contract documents in order to keep warranties in force. Include warranty information for primary components such as the compressor of air conditioning system.

1.2.5.3 Personnel Training Requirements

Provide information available from the manufacturers that is needed for use in training designated personnel to properly operate and maintain the equipment and systems.

1.2.5.4 Testing Equipment and Special Tool Information

Include information on test equipment required to perform specified tests and on special tools needed for the operation, maintenance, and repair of components.

1.2.5.5 Contractor Information

Provide a list that includes the name, address, and telephone number of the General Contractor and each Subcontractor who installed the product or equipment, or system. For each item, also provide the name address and telephone number of the manufacturer's representative and service organization most convenient to the project site. Provide the name, address, and telephone number of the product, equipment, and system manufacturers.

1.3 SCHEDULE OF OPERATION AND MAINTENANCE DATA PACKAGES

Furnish the O&M data packages specified in individual technical sections.

Separate packages shall be provided for Building 154 work and the new WWPTP. The required information for each O&M data package is as follows:

1.3.1 Data Package 1

a. Safety precautions

b. Maintenance and repair procedures

c. Warranty information

d. Contractor information

e. Spare parts and supply list

1.3.2 Data Package 2

b. Normal operations

c. Environmental conditions

d. Lubrication data

e. Preventive maintenance plan and schedule

f. Maintenance and repair procedures

g. Removal and replacement instructions

h. Spare parts and supply list

i. Parts identification

j. Warranty information

k. Contractor information

1.3.3 Data Package 3

b. Normal operations

c. Emergency operations

d. Environmental conditions

e. Lubrication data

f. Preventive maintenance plan and schedule

g. Troubleshooting guides and diagnostic techniques

h. Wiring diagrams and control diagrams

i. Maintenance and repair procedures

j. Removal and replacement instructions

k. Spare parts and supply list

l. Parts identification

m. Warranty information

n. Testing equipmetn and special tool information

o. Contractor informtion

1.3.4 Data Package 4

b. Operator prestart

c. Startup, shutdown, and post-shutdown procedures

d. Normal operations

e. Emergency operations

f. Operator service requirements

g. Environmental conditions

h. Lubrication data

i. Preventive maintenance plan and schedule

j. Troubleshooting guides and diagnostic techniques

k. Wiring diagrams and control diagrams

l. Maintenance and repair procedures

m. Removal and replacement instructions

n. Spare parts and supply list

o. Corrective maintenance man-hours

p. Parts identification

q. Warranty information

r. Personnel training requirements

s. Testing equipment and special tool information

t. Contractor information

1.3.5 Data Package 5

b. Operator prestart

c. Start-up, shutdown, and post-shutdown procedures

d. Normal operations

e. Environmental conditions

f. Preventive maintenance plan and schedule

g. Troubleshooting guides and diagnostic techniques

h. Wiring and control diagrams

i. Maintenance and repair procedures

j. Spare parts and supply list

k. Testing equipments and special tools

l. Warranty information

m. Contractor information

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

-- End of Section --

108285A 108285A June 23, 2009 11:21 AM

SECTION VERIFICATION REPORT

This report lists all Sections that are referenced in other Sections,but that are not in the Job or Master.

HINT: Double-clicking a Section number will open the Section in the Editor.

SECTION SUBPART SECTION REFERENCED

ALL SECTIONS HAVE BEEN VERIFIED

Section Verification Report

SECTION 23 03 00.00 20

BASIC MECHANICAL MATERIALS AND METHODS

01/07

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM B 117 (2007a) Standing Practice for Operating Salt Spray (Fog) Apparatus

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C2 (2007; Errata 2007; INT 2008) National Electrical Safety Code

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2007; Errata 2008) Standard for Motors and Generators

NEMA MG 10 (2001; R 2007) Energy Management Guide for Selection and Use of Fixed Frequency Medium AC Squirrel-Cage Polyphase Induction Motors

NEMA MG 11 (1977; R 2007) Energy Management Guide for Selection and Use of Single Phase Motors

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2007) National Electrical Code - 2008 Edition

1.2 QUALITY ASSURANCE

1.2.1 Material and Equipment Qualifications

Provide materials and equipment that are standard products of manufacturers regularly engaged in the manufacture of such products, which are of a similar material, design and workmanship. Standard products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year use shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2 year period.

1.2.2 Alternative Qualifications

Products having less than a two-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturer's factory or laboratory tests, can be shown.

1.2.3 Service Support

The equipment items shall be supported by service organizations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. These service organizations shall be reasonably convenient to the equipment installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.

1.2.4 Manufacturer's Nameplate

Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.

1.2.5 Modification of References

In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction", or words of similar meaning, to mean the Contracting Officer.

1.2.5.1 Definitions

For the International Code Council (ICC) Codes referenced in the contract documents, advisory provisions shall be considered mandatory, the word "should" shall be interpreted as "shall." Reference to the "code official" shall be interpreted to mean the "Contracting Officer." For Navy owned property, references to the "owner" shall be interpreted to mean the "Contracting Officer." For leased facilities, references to the "owner" shall be interpreted to mean the "lessor." References to the "permit holder" shall be interpreted to mean the "Contractor."

1.2.5.2 Administrative Interpretations

For ICC Codes referenced in the contract documents, the provisions of Chapter 1, "Administrator," do not apply. These administrative requirements are covered by the applicable Federal Acquisition Regulations (FAR) included in this contract and by the authority granted to the Officer in Charge of Construction to administer the construction of this project.

References in the ICC Codes to sections of Chapter 1, shall be applied appropriately by the Contracting Officer as authorized by his administrative cognizance and the FAR.

1.3 DELIVERY, STORAGE, AND HANDLING

Handle, store, and protect equipment and materials to prevent damage before and during installation in accordance with the manufacturer's recommendations, and as approved by the Contracting Officer. Replace damaged or defective items.

1.4 ELECTRICAL REQUIREMENTS

Furnish motors, controllers, disconnects and contactors with their respective pieces of equipment. Motors, controllers, disconnects and contactors shall conform to and have electrical connections provided under Section 26 05 00.00 40 COMMON WORK RESULTS FOR ELECTRICAL. Furnish internal wiring for components of packaged equipment as an integral part of the equipment. Extended voltage range motors will not be permitted.

Controllers and contactors shall have a maximum of 120 volt control circuits, and shall have auxiliary contacts for use with the controls furnished. When motors and equipment furnished are larger than sizes indicated, the cost of additional electrical service and related work shall be included under the section that specified that motor or equipment.

Power wiring and conduit for field installed equipment shall be provided under and conform to the requirements of Section 26 05 00.00 40 COMMON WORK

RESULTS FOR ELECTRICAL.

1.5 ELECTRICAL INSTALLATION REQUIREMENTS

Electrical installations shall conform to IEEE C2, NFPA 70, and requirements specified herein.

1.5.1 New Work

Provide electrical components of mechanical equipment, such as motors, motor starters (except starters/controllers which are indicated as part of a motor control center), control or push-button stations, float or pressure switches, solenoid valves, integral disconnects, and other devices functioning to control mechanical equipment, as well as control wiring and conduit for circuits rated 100 volts or less, to conform with the requirements of the section covering the mechanical equipment. Extended voltage range motors shall not be permitted. The interconnecting power wiring and conduit, control wiring rated 120 volts (nominal) and conduit, the motor control equipment forming a part of motor control centers, and the electrical power circuits shall be provided under Division 26, except internal wiring for components of package equipment shall be provided as an integral part of the equipment. When motors and equipment furnished are larger than sizes indicated, provide any required changes to the electrical service as may be necessary and related work as a part of the work for the section specifying that motor or equipment.

1.5.2 Modifications to Existing Systems

Where existing mechanical systems and motor-operated equipment require modifications, provide electrical components under Division 26.

1.5.3 High Efficiency Motors

1.5.3.1 High Efficiency Single-Phase Motors

Unless otherwise specified, single-phase fractional-horsepower alternating-current motors shall be high efficiency types corresponding to the applications listed in NEMA MG 11.

1.5.3.2 High Efficiency Polyphase Motors

Unless otherwise specified, polyphase motors shall be selected based on high efficiency characteristics relative to the applications as listed in NEMA MG 10. Additionally, polyphase squirrel-cage medium induction motors with continuous ratings shall meet or exceed energy efficient ratings in accordance with Table 12-6C of NEMA MG 1.

1.6 INSTRUCTION TO GOVERNMENT PERSONNEL

When specified in other sections, furnish the services of competent instructors to give full instruction to the designated Government personnel in the adjustment, operation, and maintenance, including pertinent safety requirements, of the specified equipment or system. Instructors shall be thoroughly familiar with all parts of the installation and shall be trained in operating theory as well as practical operation and maintenance work.

Instruction shall be given during the first regular work week after the equipment or system has been accepted and turned over to the Government for regular operation. The number of man-days (8 hours per day) of instruction furnished shall be as specified in the individual section. When more than 4 man-days of instruction are specified, use approximately half of the time for classroom instruction. Use other time for instruction with the equipment or system.

When significant changes or modifications in the equipment or system are made under the terms of the contract, provide additional instruction to acquaint the operating personnel with the changes or modifications.

1.7 ACCESSIBILITY

Install all work so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install concealed valves, expansion joints, controls, dampers, and equipment requiring access, in locations freely accessible through access doors.

3.1 PAINTING OF NEW EQUIPMENT

New equipment painting shall be factory applied or shop applied, and shall be as specified herein, and provided under each individual section.

3.1.1 Factory Painting Systems

Manufacturer's standard factory painting systems may be provided subject to certification that the factory painting system applied will withstand 125 hours in a salt-spray fog test, except that equipment located outdoors shall withstand 500 hours in a salt-spray fog test. Salt-spray fog test shall be in accordance with ASTM B 117, and for that test the acceptance criteria shall be as follows: immediately after completion of the test, the paint shall show no signs of blistering, wrinkling, or cracking, and no loss of adhesion; and the specimen shall show no signs of rust creepage beyond 0.125 inch on either side of the scratch mark.

The film thickness of the factory painting system applied on the equipment shall not be less than the film thickness used on the test specimen. If manufacturer's standard factory painting system is being proposed for use on surfaces subject to temperatures above 120 degrees F, the factory painting system shall be designed for the temperature service.

3.1.2 Shop Painting Systems for Metal Surfaces

Clean, pretreat, prime and paint metal surfaces; except aluminum surfaces need not be painted. Apply coatings to clean dry surfaces. Clean the surfaces to remove dust, dirt, rust, oil and grease by wire brushing and solvent degreasing prior to application of paint, except metal surfaces subject to temperatures in excess of 120 degrees F shall be cleaned to bare metal.

Where more than one coat of paint is specified, apply the second coat after the preceding coat is thoroughly dry. Lightly sand damaged painting and retouch before applying the succeeding coat. Color of finish coat shall be aluminum or light gray.

a. Temperatures Less Than 120 Degrees F: Immediately after cleaning, the metal surfaces subject to temperatures less than 120 degrees F shall receive one coat of pretreatment primer applied to a minimum dry film thickness of 0.3 mil, one coat of primer applied to a minimum dry film thickness of one mil; and two coats of enamel applied to a minimum dry film thickness of one mil per coat.

b. Temperatures Between 120 and 400 Degrees F: Metal surfaces subject to temperatures between 120 and 400 degrees F shall receive two coats of 400 degrees F heat-resisting enamel applied to a total minimum thickness of 2 mils.

c. Temperatures Greater Than 400 Degrees F: Metal surfaces subject to temperatures greater than 400 degrees F shall receive two coats of 600 degrees F heat-resisting paint applied to a total minimum dry film thickness of 2 mils.

SUBMITTAL VERIFICATION REPORT

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Section Submittal Discrepancies

Sections that do not cite Submittal Items in both the Submittal Article and elsewhere in the text, that cite invalid Classifications, or that contain Submittal Descriptions or Classifications outside the Submittal Article:

SECTION SUBPART SUBMITTAL DISCREPANCY

Discrepancies Between Submittal Articles and Submittal Procedures Section

Submittal Descriptions from Section Submittal Articles that differ from Descriptions in the Submittal Procedures Section (01 33 00, 01330, or 01300), or that are missing from the Submittal Procedures Section:

STANDARD DESCRIPTION

SECTION SUBPART INVALID DESCRIPTION

All the Submittal Descriptions in Sections processed match.

Submittal Verification Report

REFERENCE TITLE REPORT

This report lists Reference Identifiers with conflicting Reference Titlesin two or more Section Reference Articles.

SECTION REFERENCE REFERENCE TITLE

ALL REFERENCES HAVE BEEN VERIFIED

Reference Title Report

SECTION 23 05 15

COMMON PIPING FOR HVAC

02/09

AMERICAN WELDING SOCIETY (AWS)

AWS WHB-2.9 (2004) Welding Handbook; Volume Two - Welding Processes

ASME INTERNATIONAL (ASME)

ASME A112.18.1 (2005) Standard for Plumbing Fixture Fittings

ASME B1.20.7 (1991; R 2008) Standard for Hose Coupling Screw Threads (Inch)

ASME B16.1 (2005) Standard for Gray Iron Threaded Fittings; Classes 125 and 250

ASME B16.25 (2007) Standard for Buttwelding Ends

ASME B16.3 (2006) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.39 (1998; R 2006) Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300

ASME B16.5 (2003) Standard for Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24

ASME B16.9 (2007) Standard for Factory-Made Wrought Steel Buttwelding Fittings

ASME B31.3 (2008) Process Piping

ASME B40.100 (2005) Pressure Gauges and Gauge Attachments

ASME BPVC SEC IX (2007; Addenda 2008) Boiler and Pressure Vessel Code; Section IX, Welding and Brazing Qualifications

ASTM A 126 (2004) Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

ASTM A 183 (2003) Standard Specification for Carbon Steel Track Bolts and Nuts

ASTM A 197/A 197M (2000; R 2006) Standard Specification for Cupola Malleable Iron

ASTM A 234/A 234M (2007) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM A 307 (2007b) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A 53/A 53M (2007) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A 563 (2007a) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A 6/A 6M (2008a) Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling

ASTM B 117 (2007a) Standing Practice for Operating Salt Spray (Fog) Apparatus

ASTM B 62 (2002) Standard Specification for Composition Bronze or Ounce Metal Castings

ASTM C 920 (2008) Standard Specification for Elastomeric Joint Sealants

ASTM D 2000 (2008) Standard Classification System for Rubber Products in Automotive Applications

ASTM E 1 (2007) Standard Specification for ASTM Liquid-in-Glass Thermometers

ASTM F 104 (2003) Standard Classification System for Nonmetallic Gasket Materials

FLUID SEALING ASSOCIATION (FSA)

FSA-0017 (1995e6) Standard for Non-Metallic Expansion Joints and Flexible Pipe Connectors Technical Handbook

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2002) Standard for Pipe Hangers and Supports - Materials, Design and Manufacture

MSS SP-67 (2002a; R 2004) Standard for Butterfly

Valves

MSS SP-69 (2003; R 2004) Standard for Pipe Hangers and Supports - Selection and Application

MSS SP-70 (2006) Standard for Cast Iron Gate Valves, Flanged and Threaded Ends

MSS SP-71 (2005) Standard for Gray Iron Swing Check Valves, Flanged and Threaded Ends

MSS SP-72 (1999) Standard for Ball Valves with Flanged or Butt-Welding Ends for General Service

MSS SP-85 (2002) Standard for Cast Iron Globe & Angle Valves, Flanged and Threaded Ends

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-C-18480 (Rev B; Notice 1) Coating Compound, Bituminous, Solvent, Coal-Tar Base

MIL-DTL-17813 (Rev G) Military Standard for Expansion Joints, Pipe, Metallic Bellows

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

CID A-A-1922 (Rev A; Notice 1) Shield, Expansion (Caulking Anchors, Single Lead)

CID A-A-1923 (Rev A; Notice 1) Shield, Expansion (Lag, Machine and Externally Threaded Wedge Bolt Anchors)

CID A-A-55614 (Basic; Notice 1) Shield, Expansion (Non-Drilling Expansion Anchors)

CID A-A-55615 (Basic; Notice 1) Shield, Expansion (Wood Screw and Lag Bolt Self-Threading Anchors

FS A-A-1924 (1995, R 2001-Rev A) Standard for Shield, Expansion; (Self Drilling Tubular Expansion Shell Bolt Anchors)

FS A-A-1925 (Rev A; Notice 1) Shield, Expansion (Nail Anchors)

1.2 GENERAL REQUIREMENTS

Submit Records of Existing Conditions consisting of the results of Contractor's survey of work area conditions and features of existing structures and facilities within and adjacent to the jobsite. Commencement of work constitutes Contractor's acceptance of the existing conditions.

Submit Fabrication Drawings for pipes, valves and specialties consisting of fabrication and assembly details to be performed in the factory.

Submit Material, Equipment, and Fixture Lists for pipes, valves and specialties including manufacturer's style or catalog numbers, specification and drawing reference numbers, warranty information, and fabrication site information. Provide a complete list of construction equipment to be used.

Submit Manufacturer's Standard Color Charts for pipes, valves and specialties showing the manufacturer's recommended color and finish selections.

Include with Listing of Product Installations for piping systems identification of at least 5 units, similar to those proposed for use, that have been in successful service for a minimum period of 5 years. Include in the list purchaser, address of installation, service organization, and date of installation.

Submit Record Drawings for pipes, valves and accessories providing current factual information including deviations and amendments to the drawings, and concealed and visible changes in the work.

Submit Connection Diagrams for pipes, valves and specialties indicating the relations and connections of devices and apparatus by showing the general physical layout of all controls, the interconnection of one system (or portion of system) with another, and internal tubing, wiring, and other devices.

Submit Coordination Drawings for pipes, valves and specialties showing coordination of work between different trades and with the structural and architectural elements of work. Detail all drawings sufficiently to show overall dimensions of related items, clearances, and relative locations of work in allotted spaces. Indicate on drawings where conflicts or clearance problems exist between various trades.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for Contractor Quality Control approval. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-01 Preconstruction Submittals

Submit Material, Equipment, and Fixture Lists for construction equipment to be used.

SD-02 Shop Drawings

Submit the following for pipes, valves and specialties showing conformance with the referenced standards contained within this section.

Record Drawings

Connection Diagrams

Coordination Drawings

Fabrication Drawings

Submit Installation Drawings for pipes, valves and specialties in accordance with the paragraph entitled, "Pipe Installation," of this section.

SD-03 Product Data

Submit equipment and performance data for the following items consisting of corrosion resistance, life expectancy, gage tolerances, and grade line analysis.

Submit Manufacturer's catalog data for the following items:

Pipe and Fittings

Piping Specialties

Miscellaneous Materials

Supporting Elements

SD-04 Samples

Submit Manufacturer's Standard Color Charts in accordance with paragraph entitled, "General Requirements," of this section.

SD-05 Design Data

Submit design analysis and calculations for the following items consisting of surface resistance, rates of flow, head losses, inlet and outlet design, required radius of bend, and pressure calculations. Also include in data pipe size, shape, and dimensions, as well as temperature ratings, vibration and thrust limitations minimum burst pressures, shut-off and non-shock pressures and weld characteristics.

Pipe and Fittings

Piping Specialties

SD-06 Test Reports

Submit test reports on the following tests in accordance with paragraph entitled, "Piping Installation," of this section.

Hydrostatic Tests

Valve-Operating Tests

Drainage Tests

Non-Destructive Electric Tests

System Operation Tests

SD-07 Certificates

Submit Listing of Product Installations for piping systems verifying proper qualifications.

Submit Records of Existing Conditions by the Contractor prior to start.

Submit Certificates for the following in accordance with paragraph entitled, "Pipe Installation," of this section.

Surface Resistance

Shear and Tensile Strengths

Temperature Ratings

Bending Tests

Flattening Tests

Transverse Guided Weld Bend Tests

SD-10 Operation and Maintenance Data

Submit Operation and Maintenance Manuals in accordance with paragraph entitled, "Operation and Maintenance," of this section.

1.4 QUALITY ASSURANCE

1.4.1 Material and Equipment Qualifications

Provide materials and equipment that are standard products of manufacturers regularly engaged in the manufacture of such products, which are of a similar material, design and workmanship. Standard products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year use shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2 year period.

1.4.2 Alternative Qualifications

Products having less than a two-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturer's factory or laboratory tests, can be shown.

1.4.3 Service Support

The equipment items shall be supported by service organizations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. These service organizations shall be reasonably convenient to the equipment installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.

1.4.4 Manufacturer's Nameplate

Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.

1.4.5 Modification of References

In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction", or words of similar meaning, to mean the Contracting Officer.

1.4.5.1 Definitions

For the International Code Council (ICC) Codes referenced in the contract documents, advisory provisions shall be considered mandatory, the word "should" shall be interpreted as "shall." Reference to the "code official" shall be interpreted to mean the "Contracting Officer." For Navy owned property, references to the "owner" shall be interpreted to mean the "Contracting Officer." For leased facilities, references to the "owner" shall be interpreted to mean the "lessor." References to the "permit holder" shall be interpreted to mean the "Contractor."

1.4.5.2 Administrative Interpretations

For ICC Codes referenced in the contract documents, the provisions of Chapter 1, "Administrator," do not apply. These administrative requirements are covered by the applicable Federal Acquisition Regulations (FAR) included in this contract and by the authority granted to the Officer in Charge of Construction to administer the construction of this project.

References in the ICC Codes to sections of Chapter 1, shall be applied appropriately by the Contracting Officer as authorized by his administrative cognizance and the FAR.

1.5 DELIVERY, STORAGE, AND HANDLING

Handle, store, and protect equipment and materials to prevent damage before and during installation in accordance with the manufacturer's recommendations, and as approved by the Contracting Officer. Replace damaged or defective items.

1.6 INSTRUCTION TO GOVERNMENT PERSONNEL

When specified in other sections, furnish the services of competent instructors to give full instruction to the designated Government personnel in the adjustment, operation, and maintenance, including pertinent safety requirements, of the specified equipment or system. Instructors shall be thoroughly familiar with all parts of the installation and trained in operating theory as well as practical operation and maintenance work.

Give instruction during the first regular work week after the equipment or system has been accepted and turned over to the Government for regular operation. The number of man-days (8 hours per day) of instruction furnished shall be as specified in the individual section. When more than 4 man-days of instruction are specified, use approximately half of the time for classroom instruction. Use other time for instruction with the equipment or system.

When significant changes or modifications in the equipment or system are made under the terms of the contract, provide additional instruction to acquaint the operating personnel with the changes or modifications.

1.7 ACCESSIBILITY

Install all work so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install concealed valves, expansion joints, controls, dampers, and equipment requiring access, in locations freely accessible through access doors.

2.1 PIPE AND FITTINGS

2.1.1 Type BCS, Black Carbon Steel

Pipe 1/8 through 12 inches shall be Schedule 40 black carbon steel, conforming to ASTM A 53/A 53M.

Pipe 1/8 through 10 inches shall be Schedule 40 seamless or electric-resistance welded black carbon steel, conforming to ASTM A 53/A 53M, Type E, Grade B (electric-resistance welded). Grade A should be used for permissible field bending, in both cases.

Fittings 2 inches and under shall be 150-pounds per square inch, gage (psig) working steam pressure (wsp) banded black malleable iron screwed, conforming to ASTM A 197/A 197M and ASME B16.3.

Unions 2 inches and under shall be 250 pounds per square inch, wsp female, screwed, black malleable iron with brass-to-iron seat, and ground joint, conforming to ASME B16.39.

Fittings 2-1/2 inches and over shall be Steel butt weld, conforming to ASTM A 234/A 234M and ASME B16.9 to match pipe wall thickness.

Flanges 2-1/2 inches and over shall be 150-pound forged-steel conforming to ASME B16.5, welding neck to match pipe wall thickness.

2.1.2 Type GCS-DWV, Galvanized Steel Drain, Waste and Vent

Pipe (all sizes) shall be Schedule 40 seamless galvanized carbon steel, conforming to ASTM A 53/A 53M, Grade A.

Furnace butt weld pipe is acceptable for sizes less than 2 inches.

Fittings shall be galvanized, coated, screwed, cast iron, recessed pattern drainage fittings, conforming to ASTM A 126.

Use long radius fittings wherever space permits. Short-turn tees, branches, and ells may be used for vent piping and connections of branch lines to battery fixtures, except wall-hung water closets.

2.1.3 Grooved Pipe Couplings and Fittings

Provide housing for all couplings, fabricated in two or more parts, of black, ungalvanized malleable iron castings. Coupling gasket shall be molded synthetic rubber, conforming to ASTM D 2000. Coupling bolts shall be oval-neck, track-head type, with hexagonal heavy nuts conforming to

ASTM A 183.

Fabricate all pipe fittings used with couplings of black, ungalvanized malleable iron castings. Where a manufacturer's standard-size malleable iron fitting pattern is not available, approved fabricated fittings may be used.

Fabricate fittings from Schedule 40 or 0.75-inch wall ASTM A 53/A 53M, Grade B seamless steel pipe; long radius seamless welding fittings with wall thickness to match pipe, conforming to ASTM A 234/A 234M and ASME B16.9.

2.2 PIPING SPECIALTIES

2.2.1 Dielectric Connections

Dissimilar pipe metals shall be electrically insulated from each other by couplings, unions, or flanges commercially manufactured for that purpose and rated for the service pressure and temperature.

2.2.2 Expansion Vibration Isolation Joints

Single or multiple arch-flanged expansion vibration isolation joints shall be constructed of steel-ring reinforced chloroprene-impregnated cloth materials. Design joint to absorb the movement of the pipe sections in which installed with no detrimental effect on the pipe or connected equipment. Back flanges with ferrous-metal backing rings. Provide control rod assemblies to restrict joint movement. All nonmetallic exterior surfaces of the joint shall be coated with chlorosulphinated polyethylene.

Provide grommets in limit bolt hole to absorb noise transmitted through the bolts.

Joints shall be suitable for continuous-duty working temperature of at least 250 degrees F.

Fill arches with soft chloroprene.

Joint, single-arch, movement limitations and size-related, pressure characteristics shall conform to FSA-0017.

2.2.3 Metallic Expansion Joints

Expansion joints shall be metallic-bellows-type, conforming to MIL-DTL-17813.

Design and construct joints to absorb all of the movements of the pipe sections in which installed, with no detrimental effect on pipe or supporting structure.

Rate, design, and construct joints for pressures to 125 psig and temperatures to 500 degrees F.

Joints shall have a designed bursting strength in excess of four times their rated pressure.

Joints shall be capable of withstanding a hydrostatic test of 1.5 times their rated pressure while held at their uncompressed length without leakage or distortion that may adversely affect their life cycle.

Life expectancy shall be not less than 10,000 cycles.

Movement capability of each joint shall exceed calculated movement of piping by 100 percent.

Bellows and internal sleeve material shall be AISI Type 304, 304L, or 321 corrosion-resistant steel.

End connections shall require no field preparation other than cleaning.

Butt weld end preparation of expansion joints shall conform to the same codes and standards requirements as applicable to the piping system materials at the indicated joint location.

Flanges of flanged-end expansion joints shall conform to the same codes and standard requirements as are applicable to companion flanges specified for the given piping system at the indicated joint location.

Joints, 2-1/2 inches and smaller, shall have internal guides and limit stops.

Joints, 3 inches and larger, shall be provided with removable external covers, internal sleeves, and purging connection. Sleeves shall be sized to accommodate lateral clearance required, with minimum reduction of flow area, and with oversized bellows where necessary. When a sleeve requires a gasket as part of a locking arrangement, the gasket shall be provided by the manufacturer. Joints without purging connection may be provided;

however, remove these from the line prior to, or not installed until, cleaning operations are complete.

Cylindrical end portion of the reinforced bellows element shall be provided with a thrust sleeve of sufficient thickness to bring that portion within applicable code-allowable stress. Sleeve shall provide 360 degrees support for the element and end-reinforcing ring.

Expansion joints shall have four, equidistant, permanent tram points clearly marked on each joint end. Locate points to prevent obliteration during installation. Distance between tram points indicating installed lengths shall be included in shop drawings. Overall dimension after joint installation shall be subject to approval.

Each expansion joint shall have adjustable clamps or yokes provided at quarter points, straddling the bellows. Overall joint length shall be set by the manufacturer to maintain joints in manufacturer's recommended position during installation.

Permanently and legibly mark each joint with the manufacturer's name or trademark and serial number; the size, series, or catalog number; bellows material; and directional-flow arrow.

2.2.4 Hose Faucets

Construct hose faucets with 1/2 inch male inlet threads, hexagon shoulder, and 3/4 inch hose connection, conforming to ASME A112.18.1. Hose-coupling screw threads shall conform to ASME B1.20.7.

Vandalproof, atmospheric-type vacuum breaker shall be provided on the discharge of all potable water lines.

2.2.5 Pressure Gages

Pressure gages shall conform to ASME B40.100 and to requirements specified herein. Pressure-gage size shall be 3-1/2 inches nominal diameter. Case shall be corrosion-resistant steel, conforming to any of the AISI 300 series of ASTM A 6/A 6M, with an ASM No. 4 standard commercial polish or better. Equip gages with adjustable red marking pointer and damper-screw adjustment in inlet connection. Service-pressure reading shall be at midpoint of gage range. All gages shall be Grade B or better and be equipped with gage isolators.

2.2.6 Sight-Flow Indicators

Sight-flow indicators for pressure service on 3-inch ips and smaller shall be constructed of bronze with specially treated single- or double-glass sight windows and have a bronze, nylon, or tetrafluoroethylene rotating flow indicator mounted on an AISI Type 316 corrosion-resistant steel shaft. Body may have screwed or flanged end. Assembly shall be pressure-and temperature-rated for the applied service. Flapper flow-type indicators are not acceptable.

2.2.7 Sleeve Couplings

Sleeve couplings for plain-end pipe shall consist of one steel middle ring, two steel followers, two chloroprene or Buna-N elastomer gaskets, and the necessary steel bolts and nuts.

2.2.8 Thermometers

Thermometers shall conform to ASTM E 1, except for being filled with a red organic liquid. Thermometers shall be an industrial pattern armored glass model, (well-threaded and seal-welded). Thermometers installed 6 feet or higher above the floor shall have an adjustable angle body. Scale shall be not less than 7 inches long. Case face shall be manufactured from manufacturer's standard polished aluminum or AISI 300 series polished corrosion-resistant steel. Thermometer range shall be 0 - 800 degrees F.

Provide thermometers with nonferrous separable wells. Provide lagging extension to accommodate insulation thickness.

2.2.9 Line Strainers, Water Service

Strainers shall be Y-type with removable basket. Strainers in sizes 2-inch ips and smaller shall have screwed ends. In sizes 2-1/2-inch ips and larger, strainers shall have flanged ends. Body working-pressure rating shall exceed maximum service pressure of system in which installed by at least 50 percent. Body shall have cast-in arrows to indicate direction of flow. All strainer bodies fitted with screwed screen retainers shall have straight threads and gasketed with nonferrous metal. Strainer bodies 2-1/2-inches and larger, fitted with bolted-on screen retainers, shall have offset blowdown holes. All strainers larger than2-1/2-inches shall be fitted with manufacturer's standard ball-type blowdown valve. Body material shall be cast bronze conforming to ASTM B 62. Where system material is nonferrous, metal strainer body material shall be nonferrous

Minimum free-hole area of strainer element shall be equal to not less than

3.4 times the internal area of connecting piping. Strainer screens shall have perforations not to exceed 0.045-inch. Strainer screens shall have finished ends fitted to machined screen chamber surfaces to preclude bypass flow. Strainer element material shall be AISI Type 316 corrosion-resistant steel.

2.3 VALVES

2.3.1 Ball and Butterfly Valves

Ball valves shall conform to MSS SP-72 for Figure 1D, three piece body and shall be rated for service at not less than 175 psig at 200 degrees F.

Valve bodies in sizes 2 inches and smaller shall be screwed-end connection-type constructed of Class A copper alloy. Valve bodies in sizes 2-1/2 inches and larger shall be flanged-end connection type, constructed of Class D material. Balls and stems of valves 2 inches and smaller shall be manufacturer's standard with hard chrome plating finish. Balls and stems of valves 2-1/2 inches and larger shall be manufacturer's standard Class C corrosion-resistant steel alloy with hard chrome plating. Balls of valves 6 inches and larger may be Class D with 900 Brinell hard chrome plating. Valves shall be suitable for flow from either direction and shall seal equally tight in either direction. Valves with ball seals held in place by spring washers are not acceptable. All valves shall have adjustable packing glands. Seats and seals shall be tetrafluoroethylene.

Butterfly valves shall conform to MSS SP-67. Valves shall be wafer type for mounting between specified flanges and shall be rated for 150-psig shutoff and nonshock working pressure. Bodies shall be cast ferrous metal conforming to ASTM A 126, Class B, and to ASME B16.1 for body wall thickness. Seats and seals shall be of the resilient elastomer type designed for field removal and replacement.

2.3.2 Drain, Vent, and Gage Cocks

Drain, vent, and gage cocks shall be lever handle, ground key type, with washer and screw, constructed of polished ASTM B 62 bronze, and rated 125-psi wsp. End connections shall be rated for specified service pressure.

Pump vent cocks, and where spray control is required, shall be UL umbrella-hood type, constructed of manufacturer's standard polished brass.

Cocks shall be 1/2-inch ips male, end threaded, and rated at not less than 125 psi at 225 degrees F.

2.3.3 Gate Valves (GAV)

Gate…