Attachment 2_33 63 00.pdf

09-01-17

33 63 00-1

SECTION 33 63 00

STEAM ENERGY DISTRIBUTION

PART 1 - GENERAL

1.1 DESCRIPTION

A. This section specifies materials and procedures for construction of underground steam distribution and condensate return piping system, including manholes, outside the buildings. System shall be: walk through concrete tunnels concrete shallow trenches pre-engineered, direct-buried, drainable-dryable-testable (DDT).

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

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

GENERATION.

C. Definitions:

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

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

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

System: A factory-fabricated system.

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

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

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

1.2 RELATED WORK

A. Section 01 00 00, GENERAL REQUIREMENTS.

B. Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA AND SAMPLES.

C. Section 01 57 19, TEMPORARY ENVIRONMENTAL CONTROLS: Erosion and

Sediment Controls.

D. Section 01 74 19, CONSTRUCTION WASTE MANAGEMENT.

E. Section 01 81 13, SUSTAINABLE CONSTRUCTION REQUIREMENTS.

F. Section 01 91 00, GENERAL COMMISSIONING REQUIREMENTS.

G. SECTION 02 82 11, TRADITIONAL ASBESTOS ABATEMENT.

33 63 00-2

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

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

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

K. Section 13 05 41 SEISMIC RESTRAINT REQUIREMENTS FOR NON-STRUCTURAL

COMPONENTS: Bracing and concrete anchors.

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

GENERATION.

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

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

Engineered Direct-Buried Systems.

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

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

1.3 APPLICABLE PUBLICATIONS

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

B. American Association of State Highway and Transportation Officials

(AASHTO):

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

Primer

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

Concrete Box Sections for Culverts, Storm

Drains, and Sewers with Less Than 2 Feet of

Cover Subjected to Highway Loadings

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

Engineers (ASHRAE):

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

Low-Rise Residential Buildings

D. American Society of Mechanical Engineers (ASME):

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

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

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

33 63 00-3

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

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

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

Lag Screws (Inch Series)

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

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

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

ASME Boiler and Pressure Vessel Code -

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

Vessels, Division 1

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

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

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

Steel

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

Seamless

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

Forgings for Piping Applications

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

Steel Pipe for High-Temperature Service

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

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

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

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

Stainless-Steel Bolting for High Temperature or

High-Pressure Service and Other Special Purpose

Applications

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

Steel, and Stainless-Steel Nuts for Bolts for

High Pressure or High Temperature Service, or

Both

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

Wrought Carbon Steel and Alloy Steel for

Moderate and High Temperature Service

33 63 00-4

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

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

Applications

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

Carbon Steel and Austenitic Stainless-Steel

Pipe Nipples

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

Bronze Castings

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

Measurements and Thermal Transmission

Properties by Means of the Guarded-Hot-Plate

Apparatus

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

Performance of High-Temperature Thermal

Insulation

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

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

D-Load Culvert, Storm Drain, and Sewer Pipe

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

Sealants

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

Insulation

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

Characteristics of Building Materials

F. American Welding Society (AWS):

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

Performance Qualification

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

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

Processes

G. Federal Specifications (Fed. Spec.):

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

Basin, Manhole

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

33 63 00-5

H. Manufacturer’s Standardization Society (MSS):

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

Installation

I. Military Specifications (Mil. Spec.):

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

Machinery, Equipment and Systems, Requirements for

J. NACE International (NACE):

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

Submerged Metallic Piping Systems

K. National Fire Protection Association (NFPA):

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

Characteristics of Building Materials

L. Society for Protective Coatings (SSPC):

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

1.4 SUBMITTALS

A. Submittals, including number of required copies, shall be submitted in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, and

SAMPLES.

B. Information and material submitted under this section shall be marked

"SUBMITTED UNDER SECTION 33 63 00, STEAM ENERGY DISTRIBUTION”, with applicable paragraph identification.

C. Contractor shall make all necessary field measurements and investigations to assure that the equipment and assemblies will meet contract requirements and will fit the space available.

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

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

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

F. Installing Contractor shall provide lists of previous installations for selected items of equipment. Contact persons who will serve as

33 63 00-6 references, with telephone numbers and e-mail addresses shall be submitted with the references. COMMON WORK RESULTS FOR PLUMBING", with applicable paragraph identification.

G. Manufacturers’ Literature and Data including: Full item description and optional features and accessories of the complete system including, but not limited to, dimensions, weights, materials, applications, standard compliance, model numbers, size and capacity. Submit as one package for pipes, fittings and appurtenances, including jointing materials, insulation, hangars, expansion and power set fasteners, and other miscellaneous items.

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

I. Coordination/Shop Drawings:

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

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

1:32 (3/8 inch equal to one foot). Clearly identify and dimension the proposed locations of the principal items of equipment. The drawings shall clearly show the proposed locations and adequate clearance for all equipment, controls, piping, pumps, valves and other items. All equipment requiring service shall be provided with an access door sized for the complete removal of device, component, or servicing of the equipment. Access for service and access for removal of components may be separate as necessary. Provide detailed coordination/shop drawings and loading calculations for all piping systems. The drawings should include all lockout/tagout points for all energy/hazard sources for each piece of equipment. Coordinate lockout/tagout procedures and practices with local VA requirements.

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

J. Complete operating and maintenance manuals including wiring diagrams, technical data sheets, information for ordering replacement parts, and troubleshooting guide:

33 63 00-7

1. Include complete list indicating all components of the systems.

2. Include complete diagrams of the internal wiring for each item of equipment.

3. Diagrams shall have their terminals identified to facilitate installation, operation and maintenance.

K. Completed System Readiness Checklist provided by the Commissioning

Agent and completed by the contractor, signed by a qualified technician and dated on the date of completion, in accordance with the requirements of Section 33 08 00, COMMISSIONING OF SITE UTILITY

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

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

SYSTEMS.

1.5 QUALITY ASSURANCE

A. Products Criteria:

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

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

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

3. The products and execution of work specified in Division 33 shall conform to the referenced codes and standards as required by the specifications. Local codes and amendments shall be enforced, along with requirements of local utility companies. The most stringent requirements of these specifications, local codes, or utility company requirements shall always apply. Any conflicts shall be brought to the attention of the COR.

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

33 63 00-8

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

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

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

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

C. Welding Qualifications: Before any welding is performed, contractor shall submit a certificate certifying that welders comply with the following requirements:

1. Qualify welding processes and operators for piping according to ASME

BPVC Section IX, AWS Z49.1 and AWS B2.1/B2.1M.

2. Comply with provisions in ASME B31.9 ASME B31.1.

3. Certify that each welder and welding operator has passed AWS qualification tests for welding processes involved and that certification is current and recent. Submit documentation to the

COR.

4. All welds shall be stamped according to the provisions of the

American Welding Society.

D. ASME Compliance: Comply with ASME B31.9 ASME B31.1 for materials, products, and installation. Safety valves and pressure vessels shall bear appropriate ASME labels.

1.6 DELIVERY, STORAGE AND HANDLING

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

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

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

Both inside and outside shall be cleaned before painting or placing equipment in operation. Protect direct-buried system coatings from

33 63 00-9 ultraviolet light (sunlight). Existing equipment worked on by the

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

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

1.7 AS-BUILT DOCUMENTATION

A. Submit manufacturer’s literature and data updated to include submittal review comments and any equipment substitutions.

B. Submit operation and maintenance data updated to include submittal review comments, VA approved substitutions and construction revisions shall be in electronic version on CD or DVD inserted into a three-ring binder. All aspects of system operation and maintenance procedures, including applicable piping isometrics, wiring diagrams of all circuits, a written description of system design, control logic, and sequence of operation shall be included in the operation and maintenance manual. The operations and maintenance manual shall include troubleshooting techniques and procedures for emergency situations.

Notes on all special systems or devices shall be included. A list of recommended spare parts (manufacturer, model number, and quantity) shall be furnished. Information explaining any special knowledge or tools the owner will be required to employ shall be inserted into the

As-Built documentation.

C. The installing contractor shall maintain as-built drawings of each completed phase for verification; and, shall provide the complete set at the time of final systems certification testing. Should the installing contractor engage the testing company to provide as-built or any portion thereof, it shall not be deemed a conflict of interest or breach of the ‘third party testing company’ requirement. Provide record drawings as follows:

1. Red-lined, hand-marked drawings are to be provided, with one paper copy and a scanned PDF version of the hand-marked drawings provided on CD or DVD.

33 63 00-10

2. As-built drawings are to be provided, with a copy of them on AutoCAD version provided on CD or DVD. The CAD drawings shall use multiple line layers with a separate individual layer for each system.

3. As-built drawings are to be provided, with a copy of them in three-dimensional Building Information Modeling (BIM) software version provided on CD or DVD.

D. The as-built drawings shall indicate the location and type of all lockout/tagout points for all energy sources for all equipment and pumps to include breaker location and numbers, valve tag numbers, etc.

Coordinate lockout/tagout procedures and practices with local VA requirements.

E. Certification documentation shall be provided to COR 21 working days prior to submitting the request for final inspection. The documentation shall include all test results, the names of individuals performing work for the testing agency on this project, detailed procedures followed for all tests, and provide documentation/certification that all results of tests were within limits specified. Test results shall contain written sequence of test procedure with written test results annotated at each step along with the expected outcome or setpoint. The results shall include all readings, including but not limited to data on device (make, model and performance characteristics), normal pressures, switch ranges, trip points, amp readings, and calibration data to include equipment serial numbers or individual identifications, etc.

1.8 COORDINATION

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

1.9 UTILITY LOCATION SERVICES

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

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

PART 2 - PRODUCTS

2.1 STEEL PIPES AND FITTINGS

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

33 63 00-11

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

1. Material Group: 1.1.

2. End Connections: Butt welding.

3. Facings: Raised face.

C. Steel Welding Fittings: ASME B16.9 ASTM A234/A234M, seamless or welded.

1. Welding Filler Metals shall comply with AWS D10.12M/D10.12 for welding materials appropriate for wall thickness and chemical analysis of steel pipe being welded.

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

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

1. For flat-face, Class 125 flanges.

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

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

2.2 PRE-ENGINEERED, FACTORY-FABRICATED, DIRECT-BUIRED, DRAINABLE-DRYABLE-

TESTABLE (DDT) SYSTEMS

A. Complete factory-fabricated steam and condensate piping system with carrier pipes, carrier pipe insulation with jackets and banding, air space, 6 mm (1/4 inch) thick steel casing, fusion-bonded epoxy casing coatings, cathodic protection, accessories. Do not locate condensate pipes in casings that contain steam pipes.

B. All components of system shall be suitable for carrier pipe pressures and temperatures as follows:

1. Steam System: 1035 kPa (150 psig); 185 degrees C (366 degrees F).

2. Condensate System: 345 kPa (50 psig); 154 degrees C (310 degrees F).

C. Steam Carrier Pipes and Condensate Carrier Pipes: No piping joints are allowed in factory-fabricated straight sections of pre-engineered direct-buried systems.

D. Carrier Pipe Insulation:

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

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

33 63 00-12

2. Section A: Steam temperature is _____degrees C (_____ degrees F), steam pressure is ____ kPa (psig). Pumped condensate temperature is

93 degrees C (200 degrees F). Drip return temperature is 100 degrees

C (212 degrees F).

3. Section B: Steam temperature is _____degrees C (_____degrees F), steam pressure is ____ kPa (psig). Pumped condensate temperature is

93 degrees C (200 degrees F). Drip return temperature is 100 degrees

C (212 degrees F).

4. Allowable Carrier Pipe Insulation Type and Minimum Insulation

Thickness:

TABLE 1

Minimum Pipe Insulation Thickness mm (inches)

For Steam 110 to 2800 kPa (16 to 406 psig) gauge

Nominal Pipe Diameter mm (inches)

Pre-Formed Mineral Wool

Calcium Silicate

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Notes:

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

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

TABLE 2

Minimum Pipe Insulation Thickness mm (inches)

33 63 00-13

For Steam Less than 110 kPa (16 psig) gauge, Condensate Return

Nominal Pipe Diameter mm (inches)

Pre-Formed Mineral Wool Calcium Silicate

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Notes:

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

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

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

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

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

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

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

33 63 00-14

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

150 - 1170 (6 – 46) 6.35 (0.250)

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

I. Vent Riser Pipes: ASTM A53/A53M, Schedule 40, galvanized, extending through top of manhole and terminate 300 mm (12 inches) above grade with 180-degree bend. Provide stainless steel insect screen at pipe opening.

J. Gland seals are prohibited because of the possibility of water entering the system through the gland seal from a flooded manhole.

K. Provide continuous 25 mm (1 inch) minimum air space between carrier pipe insulation and casing.

L. Casing coating shall be dual layers of fusion-bonded epoxy, inner green-colored layer minimum thickness 0.5 mm (0.020 inch), outer black-colored layer minimum thickness 0.25 mm (0.010 inch). Rated by coating manufacturer for continuous service for at least 25 years at minimum temperature of 110 degrees C (230 degrees F) and having a coefficient of expansion similar to that of steel. Coating shall be applied in accordance to recommendations of coating manufacturer including surface preparation. Factory-inspect for holidays and make repairs as necessary.

M. Coating of end plates and casing sections extending in manholes shall be zinc-rich coating that conforms to AASHTO M300-03-UL, Type IA except that volatile organic compounds shall not exceed 0.34 kg per liter (2.8 pounds per gallon). The zinc rich coating shall be applied in accordance with the recommendations of the coating manufacturer including surface preparation. No additional top coat shall be applied.

N. Carrier pipe guides and supports shall be maximum spacing 3000 mm (10 feet) on centers, no greater than 1500 mm (5 feet) from pipe ends, minimum of three guides per elbow section. Designed to permit thermal expansion without damage, provide proper pipe guiding and support, and to allow horizontal movement in two directions as necessary at expansion loops and bends. Design of guides and supports must permit

33 63 00-15 continuous drainage of water in bottom of casing. Pipe insulation shall extend through the pipe guides and supports and be protected by steel sleeves. Design of guides and supports shall be such that no metal-to-metal contact exists between the casing and the carrier pipe.

Insulation or non-metallic material used to ensure no metal to metal contact shall be designed to not be compressed by the weight of the carrier pipe when full of water.

O. Anchor plates shall be ASTM A36/A36M steel, welded to carrier pipe and casing, 15 mm (1/2 inch) minimum thickness, passages for air flow and water drainage through the annular air space in the system. Coated with same coating material as the casing. Locate 900 to 1500 mm (3 to 5 feet) from piping entrance to manhole or building wall. Walls of manholes and buildings cannot be utilized as anchor points.

P. Field connection of casing sections shall be steel section conforming to casing specification, welded to casing sections, coated on all surfaces with system manufacturer’s coating field repair compound, and covered with a 1.3 mm (0.05 inch) minimum thickness polyethylene shrink sleeve designed for a service temperature exceeding 80 degrees C (176 degrees F).

Q. Manhole and building wall penetrations shall provide steel leak plates welded to wall sleeves or to casings. Where a wall sleeve is utilized, allow sufficient annular space between the sleeve and the casing and install a watertight seal, rated for 121 degrees C (250 degrees F) minimum. Manhole and building walls cannot be used as anchor points.

R. Provide sacrificial anode type cathodic protection system with dielectric isolation devices and test stations for all systems. Design system for 25 years of service, assume two percent bare metal. System shall comply with NACE SP0169.

S. Provide embossed brass or stainless-steel tag hung by a brass or stainless-steel chain at each end of each casing or insulated piping in the manholes and buildings. The tag shall identify system manufacturer’s name, date of installation, government contract, and manufacturer’s project number.

T. All branch piping connections must be located in manholes.

U. Ensure the DDT manufacturer is responsible for the complete design of the DDT system, including, but not limited to, the product to be supplied, fabrication, installation, supervision, and testing of the

33 63 00-16 system within the design parameters established by the contract documents, and in compliance with the detailed design. The complete design of the system shall be sealed by a Professional Engineer in the employ of the DDT manufacturer.

V. Furnish thermal expansion calculations for the steam and condensate piping using the design characteristics indicated in this section and installation temperature no higher than the ambient temperature at the site: degrees C ( degrees F).

W. DDT manufacturer shall submit a complete description of the design and assembly of the system, materials of construction and field installation instructions. Include sufficient system details to show that the specified minimum insulation thickness has been met. A detailed design layout of the system (plan and elevation views) showing size, type, elevations and location of each component to be used in the system, the design and location of anchors, pipe guides, pipe supports, expansion loops, Z-bends, L-bends, end seals, leak plates, joint locations, pipe and insulation thickness and sizes, types, and movements, connection to manhole and building wall penetrations, and including, if applicable, details of transition point to aboveground or other type systems. Detailed design layout drawings shall be stamped by a registered Professional Engineer.

X. Expansion Loops and Bends: Pipe-stress and system-expansion calculations for each expansion compensation elbow using a finite element computer generated 3-dimensional analysis (FEA). Demonstrate with calculations that pipe stresses from temperature changes are within the allowable requirements in ASME B31.1 and that the anchors and the guides will withstand the resultant forces. Detailed design layout drawings shall include all analysis node points. As a minimum, computer analysis results shall include node stresses, forces, moments and displacements. Calculations shall be stamped by a registered

Professional Engineer in the employ of the DDT manufacturer.

Y. Reinforced Concrete Manholes: Not less than 200 mm (8 inches) thick.

Pour monolithically where possible. Place waterproof membrane between mud slab and bottom concrete slab, and continue up sides to top of sidewalls. Joints between manhole walls and casings or concrete trench sections shall be watertight. Steel manholes or prefabricated concrete manholes are prohibited.

33 63 00-17

Z. Accessories for Manholes: Cast iron manhole frames and solid covers, not less than 711 mm (28 inches) clear openings. Unless otherwise shown on the drawings, frames and covers shall be as follows:

1. For non-traffic applications:

a. Fed. Spec. A-A-60005 NOT1, Frame Type IV, Size 28

b. Fed. Spec. A-A-60005 NOT1, Cover Type E, Size 28, cast identification “STEAM”.

2. For traffic applications:

a. Fed. Spec. A-A-60005 NOT1, Frame Type I, Style A, Size 27A.

b. Fed. Spec. A-A-60005 NOT1, Cover Type A, Size 27A, cast identification “STEAM”.

3. Manhole steps shall be standard, cast iron.

AA. Manhole Ventilation: As indicated on Drawings. Construct ventilation ducts of galvanized steel sheet metal and in accordance with ASHRAE Handbook recommendations for low pressure ducts. Gravity ventilators shall be factory-fabricated of aluminum or galvanized steel and arranged as indicated on drawings. Ventilating pipes shall be standard weight black steel and installed as shown on drawings.

BB. Drainage as shown on drawings. Provide a 600 mm (24 inches) square by 600 mm (24 inches) deep sump pit in each manhole where indicated on drawings. Provide larger sump pit if necessary to accommodate required electric sump pumps.

CC. Electric Sump Pumps with Automatic Controls and High-Water Alarm:

1. Type: High temperature submersible duplex pumps and automatic controls.

2. Service: Continuous operation at required flows and pressures while completely submerged at 93 degrees C (200 degrees F). All pumps and pump controls shall have demonstrated 200,000 cycles of operation while totally submerged in 93 degrees C (200 degrees F) water.

3. Capacity and Pressure: Pumps shall be capable of passing 10 mm (3/8 inch) spheres.

4. Pumps: Epoxy-coated cast iron casing, cast iron impeller, stainless steel shaft, carbon/ceramic shaft seal, stainless steel hardware, permanently lubricated bearings, screened inlets. Schedule 80 discharge pipe protected from corrosion.

5. Motors: Non-overloading at all points on the pump performance curve.

Include overload protection.

33 63 00-18

6. Controls: Automatic alternating lead-lag, with damp-proof electrical service. Mount non-submerged control components in a NEMA 4 enclosure on adjacent wall or dedicated galvanized steel support stand.

7. High Water Alarm Switch: Set at level below lowest steam or condensate pipe in the manhole. Switch shall activate weatherproof red alarm light mounted above grade as shown. Provide contacts and connect to for future connection to engineering control center.

2.3 TUNNELS (WALK THROUGH)

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

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

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

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

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

E. Waterproof manholes and below grade ventilation ducts.

2.4 CONCRETE SHALLOW TRENCHES

A. Cast-in-Place Trench: Reinforced concrete with minimum thickness 200 mm

(8 inches).

1. Trench Covers in Grass or Sidewalk Areas: Precast reinforced concrete sections, set to existing grade, flat and true at all points of contact on trench wall; trench and cover to form a watertight envelope when assembled.

2. Trench Covers in Pavement: Precast reinforced concrete sections per

AASHTO M273-11-UL, set to existing pavement, flat and true at all points of contact on trench wall; trench and cover to form a watertight envelope when assembled.

3. Waterproofing: Apply to all below grade portions of the trench.

4. Gaskets and Sealants: ASTM C920, 6 mm (1/4 inch) thick neoprene pads with a minimum width of 50 mm (2 inches) between covers and tops of

33 63 00-19 walls; elastomeric sealants that are available as a one or two component system. Asphaltic sealants are prohibited. Sealants must resist 50 percent total joint movement. Non-sagging sealant must be used for vertical joints. Self-leveling sealant must be used for trench top butt joints.

2.5 STEAM PIPING

A. Pipe: ASTM A53/A53M, steel, seamless, Grade B ASTM A106/A106M, Grade B, electric resistance welded, Schedule 40 Schedule 80. Grade F, furnace butt-welded pipe is prohibited. Use Schedule 80 pipe and fittings for threaded joints.

B. Joints:

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

2. In tunnels, manholes, and open areas: Butt weld pipe sizes 65 mm (2-

1/2 inches) and greater; thread or socket weld pipe sized 50 mm (2 inches) and less. Use Schedule 80 pipe and fittings for threaded joints.

C. Fittings:

1. Butt welded joints: ASTM A234/A234M or ASME B16.9, steel, Grade B, same schedule as adjoining pipe. All elbows shall be long radius unless otherwise indicated. Tees shall be full size or reducing as required, having interior surfaces smoothly contoured.

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

Schedule 80 pipe only.

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

D. Flanges and Bolts: ASME B16.5, weld neck, forged steel ASTM A105/A105M, pressure class 1035 kPa (150 psig). Bolts shall be high strength ASTM

A193/A193M, Class 2, Grade B7. Nuts shall be ASTM A194/A194M.

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

2.6 STEAM CONDENSATE PIPING

A. Pipe: ASTM A53/A53M, seamless, Grade B ASTM A106/A106M, Grade B ASTM

A53/A53M electric resistance welded, Grade B, Schedule 80. Grade F, furnace butt-welded pipe is prohibited. Use Schedule 80 pipe and fittings for threaded joints.

33 63 00-20

B. Joints:

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

2. In tunnels, manholes, and open areas: Butt weld pipe sizes 65 mm (2-

1/2 inches) and greater. For system pressures of 103 kPa (15 psi) or less, thread or socket weld pipe sizes 50 mm (2 inches) and less.

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

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

C. Fittings:

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

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

Schedule 80 pipe and fittings only.

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

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

(297 psig) steel.

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

2.7 EXPANSION LOOPS AND BENDS

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

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

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

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

33 63 00-21

2.8 EXPANSION JOINTS

A. Provide factory-built or field-fabricated guides located along the pipelines to restrain lateral pipe motion and direct the axial pipe movement into the expansion joints.

B. Minimum Service Requirements:

1. Pressure containment:

a. Steam service 35 to 200 kPa (5 to 29 psig): Rated 345 kPa (50 psig) at 148 degrees C (298 degrees F).

b. Steam service 214 to 850 kPa (31 to 123 psig): Rated 1035 kPa

(150 psig) at 186 degrees C (366 degrees F).

c. Steam service 869 to 1035 kPa (126 to 150 psig): Rated 1380 kPa

(200 psig) at 194 degrees C (381 degrees F).

d. Condensate service: Rated 690 kPa (100 psig) at 154 degrees C

(309 degrees F).

2. Number of full reverse cycles without failure: Minimum 1000.

3. Movement: Allowed as recommended safety factor of the manufacturer.

C. Internally pressurized bellows shall have:

1. ASTM A240/A240M, multiple corrugations, Type 304 or 321 stainless steel.

2. Internal stainless-steel sleeve running the entire length of bellows.

3. External steel equalizing rings for services exceeding 345 kPa (50 psig).

4. Welded ends, flanged ends for 50 mm (2 inches) and greater pipes.

5. External tie rods: Design to withstand pressure thrust force upon anchor failure if one or both anchors for the joint are at change in direction of pipeline and integral external cover.

D. Externally pressurized bellows shall have:

1. ASTM A240/A240M, multiple corrugations, Type 304 stainless steel.

2. Internal and external guides integral with joint.

3. Design for external pressurization of bellows to eliminate squirm.

4. Welded ends, flanged ends for 50 mm (2 inches) and greater pipes.

5. Include threaded connection at bottom, 25 mm (1 inch) minimum, for drain or drip point and integral external cover and internal sleeve.

E. Slip type joints shall include:

1. Steel construction, except guides.

2. Base with integral anchor.

33 63 00-22

3. Internally and externally guided steel slip, chrome plated to reduce corrosion, ground to reduce friction.

4. Guides shall be non-ferrous, non-corroding, low friction, designed to prevent scoring or binding of the slip.

5. Welded ends, flanged ends for 50 mm (2 inches) and greater pipes.

6. Limit stop to prevent slip disengagement if pipe anchor fails.

7. Semi plastic, self-lubricating, injectable packing contained between sealing rings.

8. Injection devices to allow addition of packing under full line pressure. Provide one-year supply of packing.

9. Threaded connection at bottom, 25 mm (1 inch) minimum, for drain or drip point.

10. Bolted packing gland permitting replacement of all packing and all sealing rings without removing joint from the line.

F. Nameplate: Stamped brass or stainless-steel nameplate indicating on each expansion joint the manufacturer, the allowable movement, flow direction, design pressure and temperature, date of manufacture, and identifying the expansion joint by the identification number on the contract drawings.

G. Guides: Provide factory-built guides along the pipeline to permit axial movement only and to restrain lateral and angular movement. Guides must be designed to withstand the axial and lateral forces determined by stress analyses and water hammer calculations. Field-built guides may be used if detailed on the contract drawings. Optimum guide locations must conform to recommendations of expansion joint manufacturer and shall be determined through results of the stress analyses.

2.9 BALL JOINTS

A. Factory built devices, inserted in pipe line offsets in groups of two or three as shown to absorb cyclical pipe movement which results from thermal expansion and contraction.

B. Minimum service requirements shall be rated 1725 kPa (250 psig), 232 degrees C (450 degrees F), continuous on steam and condensate.

C. Submit independent certification that similar units have passed the following tests with no leaks.

1. Low Pressure Leakage Test: Minimum 41 kPa (6 psig) saturated steam for 60 days.

33 63 00-23

2. Life Cycle Flex Test: Minimum 8000 flex cycles at 1725 kPa (250 psig) saturated steam.

3. Thermal Cycling Test: Minimum 100 cycles from atmospheric pressure to operating pressure and back to atmospheric pressure with saturated steam.

4. Environmental Shock Test: MIL-S-901.

5. Vibration Test: Test for 170 hours on each of three mutually perpendicular axes at 25 to 125 Hz; 1 to 2 mm (0.04 to 0.08 inch) double amplitude on a single ball joint and on a three-ball joint offset.

D. Joints:

1. ASME B31.1, forged carbon steel with welded ends. Standard weight pipe wall thickness.

2. Minimum angular movement capability: 15 degrees and 360 degrees rotational movement.

3. Gaskets: Non-asbestos.

4. Packing injection devices, if provided: Allow injection under full line pressure. Provide one-year supply of packing.

2.10 VALVES

A. Gate Valves (ASTM A126):

1. Type 101:

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

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

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

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

2. Type 102 is not used.

3. Type 103:

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

b. Forged steel body, Class B, rated for 850 kPa (123 psig) saturated steam, 1380 kPa (200 psig) WOG, bronze or bronze face

33 63 00-24 wedge and seats, 850 kPa (123 psig) ASME flanged ends, OS&Y, rising stem, bolted bonnet, renewable seat rings.

4. Type 104:

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

b. Forged steel body, rated for 1380 kPa (200 psig) saturated steam, 2758 kPa (400 psig) WOG, bronze wedges and Monel or stainless-steel seats, threaded ends, rising stem, union bonnet.

5. Type 105 is not used.

6. Type 106:

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

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

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

B. Globe Valves (ASTM A126):

1. Type 201:

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

b. Carbon steel body, rated 1035 kPa (150 psig) at 260 degrees C

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

2. Type 202 is not used.

3. Type 203:

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

b. Steel body, rated for 850 kPa (123 psig) saturated steam, 1380 kPa (200 psig) WOG, bronze or bronze-faced disc (Teflon or composition facing permitted) and seat, 850 kPa (123 psig) ASME flanged ends, OS&Y, rising stem, bolted bonnet, renewable seat rings.

4. Type 204:

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

33 63 00-25

b. ASTM B61, Forged steel body, rated for 1380 kPa (200 psig) saturated steam, 2758 kPa (400 psig) WOG, hardened stainless steel disc and seat, threaded ends, rising stem, union bonnet, renewable seat rings.

C. Check Valves (ASTM A126):

1. Type 401:

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

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

2. Type 402 is not used.

3. Type 403:

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

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

4. Type 404:

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

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

D. Ball Valves (ASTM A126):

1. Type 501 is not used.

2. Type 502:

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

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

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

3. Type 503 is not used.

33 63 00-26

4. Type 504:

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

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

2.11 STEAM PRESSURE REDUCING VALVES

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

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

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

D. Construction:

1. Main Valve:

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

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

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

(250 psig) ASME flanged ends, globe body valve and seat shall be replaceable, Type 316 stainless steel and include stainless steel stem.

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

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

1500 mm (5 feet) elevation above adjacent floor, and 1500 mm (5 feet) distance in any direction. Inlet and outlet piping for steam pressure reducing valves shall be Schedule 80 minimum for required distance to achieve required levels or sound attenuators shall be applied.

33 63 00-27

E. Direct Digital Control PRV Valves: May be furnished in lieu of steam operated valves.