Attachment 2 Specifications.docx

SPECIFICATIONS

PUMPED PRETREATMENT WASTE PIPING

PART 1 GENERAL

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.

ASME INTERNATIONAL (ASME)

ASME B16.5 (B16.5a) Pipe Flanges and Flanged Fittings NPS 1/2 thru NPS 24 ASME B16.9 Factory-Made Wrought Steel Buttwelding Fittings

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A 105 Carbon Steel Forgings for Piping Applications ASTM A 234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service ASTM F593-22 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs ASTM A 53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)

MSS SP-58 Pipe Hangers and Supports - Materials, Design and Manufacture MSS SP-69 Pipe Hangers and Supports - Selection and Application

1.2 DESCRIPTION

This Section covers all of the piping systems in the PPW (Pumped Pretreatment Waste) manholes including those marked "PPW", "Drain", and "Air Vent".

DOUBLE WALL CONTAINMENT FOR PRETREATMENT WASTE.

PART 2 PRODUCTS

2.1 Fluid Description

The liquid in the pipes mostly consists of wastewater from animals, laboratory services, and related substances. The liquid also includes chemicals that decontaminate the waste from the biological toxins. The liquid contains solids that tend to sludge and harden on rough surfaces. For design purposes, the specific gravity of the liquid shall be considered to be 1.15.

2.2 Design Basis

The maximum design conditions shall be 225 PSIG at 225 degrees F. Normal operating conditions are 60 PSIG at 105 degrees F.

2.3 Pipe

4-inch piping shall be stainless steel, A312-TP304L S/40s.

2-inch piping shall be stainless steel, A312-TP304L S/80s.

2.4 Joints

Joints 2 inches and smaller shall be socket welded except where threaded is specifically called out on a Contract Drawing detail (includes connections to casing system for level switches).

Joints 2-1/2 inches and larger shall be butt welded. All sizes shall be flanged where shown on the Contract Drawings or where required to connect to flanged valves, fittings, or equipment.

2.5 Fabrication and Erection

All piping shall be fabricated and erected per ASME B31.3 Process Piping Code. All welding shall be per Section 15216, WELDING PRESSURE PIPING.

2.6 Testing

Testing (including welding and hydrostatic) shall follow Section 15216, WELDING PRESSURE PIPING per ASME B31.3 Process Piping Code. Prefabricated spools shall be tested at 90 PSI prior to installation on site. All (100%) buttweld joints for "PPW" piping shall be tested per radiography. All (100%) socket weld joints for "PPW" piping shall be hydrostatically pressure tested at 90psi for one hour (by USDA staff) after final installation. Comment by Madson, Katherine - REE-ARS: I’m trying to make this more clear between they have to test and we have to test.

2.7 Flanges

Flanges and slip flanges shall be stainless steel, 4” flanges shall be A182-F304L S/40s 150# RF weld-necks and 2” flanges shall be stainless steel, A182-F304L S/80s 150# RF. Welding neck flanges shall be bored to match the same ID as the attached pipe. 4” slip flanges shall be allowed.

2.8 Fittings

Fittings 2 inches and smaller shall be 3000-pound socket-weld in accordance with ASME B16.11. Material shall conform to ASTM A 105. 2” fittings shall be butt-welded A403-WP304L S/40s.

Fittings 2-1/2 inches and larger shall be steel butt-weld type in accordance with ASME B16.9 with Schedule "XS" wall thickness. Material shall conform to ASTM A 234, Grade WPB.

Mitered branches are not allowed. Use regular "tee" fitting or forged fittings for reduction.

2.9 Bolting Materials

Bolting materials shall all be stainless steel, hexagonal head bolts with heavy hexagonal nuts conforming to ASTM F593-22.

2.10 Unions

Unions 1-1/2 inches and smaller shall be 3000 pound, threaded, with steel-to-steel seats. Material shall conform to ASTM A 105. Note that the use of unions shall be minimized as much as possible.

Unions 2 inches and larger shall be made with flanges.

2.11 Gaskets

Gaskets shall be Flexitallic spiral wound, Type 304 stainless steel with non-asbestos filler material and carbon steel outer ring. Gaskets shall be 1/16 inch thick and conform to the flange face on which they are used.

2.12 Valves

All stainless-steel valves 1-1/2 inches and smaller shall be Class 250, bronze body, one piece ball valves with stainless steel ball and Teflon seats.

All stainless-steel valves 2 inches and larger shall be ball valves with regular port, top entry, wedge seated ball style with Class 150 flanges. Body material shall be 316SS, seat shall be TFE, and trim shall be 316SS. Provide lockable lever hardware. Valves shall be McCanna Figure Number S151-S6-T-S6 or Velan Figure F-006T13-BAA.

2.13 Specialties

Hose end drain shall be that currently used on the site - creamery style, twist lock, gasketed connection.

2.14 Supports

Support all piping with standard manufactured supports per MSS SP-58 and MSS SP-69. Hardware shall be stainless steel.

PART 3 EXECUTION

3.1 INSTALLATION

Install piping and piping components to ensure proper and efficient operation of equipment and in accordance with manufacturer's printed instructions.

3.1.1 Water Piping

ASME B31.3.

3.2 PIPING SYSTEMS

3.2.1 Flanged Joints

Faced true, square, tight, and provided as indicated and where necessary for normal maintenance. Mate with valves and various equipment connections. Remove raised faces when used with flanges having a flat face.

3.2.2 Threaded Joints

Clean threads and apply suitable amount of Teflon tape or Teflon pipe dope prior to making joint.

3.2.3 Pipe Bends

Pipe bends shall have a uniform radius of at least five times the nominal pipe diameter. Pipe bends shall be free of any flattening, wrinkling, or thinning of pipe walls other than minor external surface distortions.

3.2.4 Reducing Fittings

Make branch connections with tees except that factory-made-forged-steel welding branch outlets or nozzles having integral reinforcements and conforming to ASME B31.3 may be provided when the nominal diameter of piping system branch does not exceed one nominal pipe size less than nominal size of piping segment containing fitting.

3.2.5 Insulation

Follow manufacturer’s installation instructions.

3.2.6 Pipe Hangers and Supports

Installation including spacing shall conform to ASME B31.3.

3.3 PPW PIPING AND ALL RELATED SYSTEMS IN PPW MANHOLES

3.3.1 Fabrication and Assembly of Piping and Components

Welding shall conform to ASME B31.3 and as specified herein. Piping shall follow general arrangement shown, cut accurately to measurements established for the work by the Contractor, and worked into place without springing or forcing. Piping and equipment within manholes shall be entirely out of the way of electrical conduit, and manhole entrance.

Provide adequate clearance from walls, ceilings, and floors to permit welding of joints; at least 6 inches for pipe sizes 4 inches and less, 10 inches for pipe sizes over 4 inches, and in corners provide sufficient clearance to permit the welder to work between pipe and one wall. Provide for expansion and contraction of pipelines. Make changes in size of water lines with reducing fittings. Protect materials and equipment from weather. Do not miter pipe to form elbows, or notch straight runs to form full-sized tees, or utilize any similar construction. Except where shown otherwise, run vertical piping plumb and straight and parallel to walls. Plug or cap open ends of mains during shutdown periods. Do not leave lines open at any place where foreign matter might accidentally enter.

3.3.1.1 Valves

a. Install valves as indicated, according to manufacturer's written instructions.

b. Install valves with unions or flanges at each piece of equipment arranged to allow servicing, maintenance, and equipment removal without system shutdown.

c. Locate valves for easy access and provide separate support where necessary.

d. Install valves in horizontal piping with stem at or above the center of the pipe.

e. Install valves in a position to allow full stem movement.

3.4 FIELD INSPECTIONS

Prior to initial operation examine and inspect piping systems for conformance to plans and specifications, ASME B31.3. Equipment, material, or work rejected because of defects or nonconformance with plans, specifications, and ANSI Codes for pressure piping shall be corrected as directed by the Contracting Officer Representative.

3.5 FIELD TESTS

After completion of piping installation and prior to initial operation, conduct tests on piping system. Furnish materials and equipment required for tests. Correct defects disclosed by test. Perform test after installation and prior to acceptance in presence of the Contracting Officer Representative and subject to his approval.

3.5.1 PPW Manhole Piping

Hydrostatically test in accordance with requirements of ASME B31.3. Test piping system at 1-1/2 times the design pressure with water not exceeding 100 degrees F. Before tests, remove or isolate apparatus in new system and existing piping system which may be damaged. Repair leaks by tightening or renewing pipe or fittings. Do not caulk joints. Install a calibrated, test pressure gage in system to observe loss in pressure. Maintain required test pressure for a sufficient amount of time to enable an inspection of joints and connections. The minimum time shall be 60 minutes. Correct defects disclosed by test.

-- End of Section --

WELDING PRESSURE PIPING

PART 1 GENERAL

1.1 REFERENCES

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

ASME INTERNATIONAL (ASME)

ASME B31.1 (2001) Power Piping ASME B31.3 (2002) Process Piping ASME B31.4 (2002) Piping Transportation Systems for Liquid Hydrocarbons and Other Liquid ASME B31.5 (2001) Refrigeration Piping and Heat Transfer Components ASME BPVC SEC I (2001) Boiler and Pressure Vessel Code; Section I, Power Boilers ASME BPVC SEC II-C (2001) Boiler and Pressure Vessel Code; Section II, Materials, Part C - Specifications for Welding Rods, Electrodes and Filler Metals ASME BPVC SEC V (2001) Boiler and Pressure Vessel Code; Section V, Nondestructive Examination ASME BPVC SEC IX (2001) Boiler and Pressure Vessel Code; Section IX, Welding and Brazing Qualifications

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ASNT RP SNT-TC-1A (2001) Recommended Practice

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 (1998) Standard Symbols for Welding, Brazing and Nondestructive Examination AWS A3.0 (2001) Standard Welding Terms and Definitions AWS D1.1/D1.1M (2002) Structural Welding Code - Steel AWS D10.9 (1980) Qualification of Welding Procedures and Welders for Piping and Tubing AWS QC1 (1996) AWS Certification of Welding Inspectors AWS Z49.1 (1999) Safety in Welding, Cutting and Allied Processes

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards 29 CFR 1926 Safety and Health Regulations for Construction

1.2 RELATED REQUIREMENTS

Section 15050, BASIC MECHANICAL MATERIALS AND METHODS, applies to this section with the additions and modifications specified herein.

1.3 DEFINITIONS

AWS A3.0 and applicable ANSI piping documents.

1.4 SUBMITTALS

Submit the following in accordance with Section 01330, SUBMITTAL PROCEDURES.

SD-02 Shop Drawings Welding pressure piping; G SD-07 Certificates Welding procedures qualification; G Nondestructive examination (NDE) procedures; G NDE personnel certification procedures; G Inspector certification; G Submit inspector certification and NDE personnel certification for record.

SD-11 Closeout Submittals Weld identifications; G

1.5 QUALITY ASSURANCE

1.5.1 Welding Pressure Piping

Show location, length, and type of welds, and indicate post weld heat treatment and nondestructive testing as required.

1.5.2 Procedures

Develop and qualify procedures for welding metals included in the work. Do not start welding until welding procedures, welders, and welding operators have been qualified. Perform qualification testing by an approved testing laboratory, or by the Contractor if approved by the Contracting Officer in accordance with the qualified procedures. Notify the Contracting Officer Representative at least 24 hours in advance of the time and place of the tests. When practicable, perform the qualification tests at or near the work site. Maintain current records of the test results obtained in welding procedure, welding operator/welder performance qualifications, and nondestructive examination (NDE) procedures. These records shall be readily available at the site for examination by the Contracting Officer Representative. Qualify the procedures for making transition welds between different materials or between plates or pipes of different wall thicknesses. ANSI Piping requirements for branch connections may be used in lieu of detailed designs. Unless otherwise specified, the choice of welding process shall be the responsibility of the Contractor.

1.5.2.1 Previous Qualifications

Welding procedures, welders, and welding operators previously qualified by test may be accepted for the work without requalification provided that the following conditions are fulfilled:

a. Copies of welding procedures, procedure qualification test records, and welder and welding operator performance qualification test records are submitted and approved in accordance with the paragraph entitled "Submittals."

b. Testing was performed by an approved testing laboratory or technical consultant or by the Contractor's approved quality control organization.

c. The welding procedures, welders, and welding operators were qualified in accordance with ASME BPVC SEC IX or AWS D10.9, AR-2 level; and base materials, filler materials, electrodes, equipment, and processes conformed to the applicable requirements of this specification.

d. The requirements of paragraph entitled "Welder and Welding Operator Performance Qualification" for renewal of qualification were met, and records showing name of employer and period of employment using the process for which qualified are submitted as evidence of conformance.

1.5.2.2 Performance

The Contractor shall be responsible for the quality of joint preparation, welding, and examination. Clearly identify and record materials used in the welding operations. The examination and testing defined in this specification are minimum requirements. Provide additional examination and testing as necessary to achieve the quality required.

1.5.3 Welding Procedures Qualification

Qualification of the welding procedures for each group of materials to be welded is required as indicated in ASME BPVC SEC IX. Record in detail and qualify the "Welding Procedure Specifications" for every welding procedure proposed. Qualification for each welding procedure shall conform to the requirements of ANSI Standards and to this specification. The welding procedures shall specify end preparation for welds, including cleaning, alignments, and root openings. Preheat, interpass temperature control, and post heat treatment of welds shall be as required by ANSI Piping documents, unless otherwise indicated or specified. Describe the type of backing rings or consumable inserts, if used, and, if they are to be removed, the removal process. Welding procedure qualifications shall be identified individually and referenced on the shop drawings or suitably keyed to the contract drawings.

1.5.4 Welder and Welding Operator Performance Qualification

Qualify each welder and welding operator assigned to work covered by this specification by performance tests using equipment, positions, procedures, base metals, and electrodes or bare filler wires from the same specification, classification, or group number that will be encountered on his assignment. Welders or welding operators who make acceptable procedure qualification tests will be considered performance-qualified for the welding procedure used. Determine performance qualification in accordance with ASME BPVC SEC IX, ANSI Piping Standards and as specified.

1.5.5 Renewal of Qualification

Requalification of a welder or welding operator shall be required under one or any combination of the following conditions:

a. When a welder or welding operator has not used the specific welding process for a period of 3 months. The period may be extended to 6 months if the welder has been employed on another welding process.

b. There is specific reason to question the welder's ability to make welds that will meet the requirements of the specifications.

c. The welder or welding operator was qualified by an employer other than those firms performing work under this contract and a qualification test has not been taken within the preceding 12 months. Renewal of qualification under this condition need be made on only a single test joint or pipe of any thickness, position, or material to reestablish qualification for any thickness, position, or material for which the welder or welding operator had qualified previously.

1.5.6 Qualification of Inspection and (NDE) Personnel

Qualification of Inspection and Nondestructive Examination (NDE) Personnel:

Qualify inspection and nondestructive examination personnel in accordance with the following requirements:

1.5.6.1 Inspector Certification

Qualify welding inspectors in accordance with AWS QC1.

1.5.6.2 NDE Personnel Certification Procedures

Certify NDE personnel and establish a written procedure for the control and administration of NDE personnel training, examination, and certification. Base procedures on appropriate specific and general guidelines of training and experience recommended by ASNT RP SNT-TC-1A, Supplement A-Radiographic Supplement B-Magnetic particle and Supplement D-Liquid Penetrant.

1.5.6.3 Welding Procedures and Qualifications

a. Specifications and Test Results: Submit copies of the welding procedure specifications and procedure qualification test results for each type of welding required. Approval of any procedure does not relieve the Contractor of the responsibility for producing acceptable welds. Submit this information on the forms printed in ASME BPVC SEC IX or their equivalent.

b. Certification: Before assigning welders or welding operators to the work, submit their names, together with certification that each individual is performance qualified as specified. Do not start welding work prior to procedure qualification. The certification shall state the type of welding and positions for which each is qualified, the code and procedure under which each is qualified, date qualified, and the firm and individual certifying the qualification tests.

1.5.7 Symbols

Conform to AWS A2.4.

1.5.7.1 Weld Identifications

Submit a list of the welders' names and symbol for each welder. To identify welds, submit written records indicating the location of welds made by each welder or welding operator.

1.5.8 Safety

Conform to AWS Z49.1, 29 CFR 1910-SUBPART Q, "Welding, Cutting, and Brazing," 29 CFR 1926-SUBPART J, "Welding and Cutting."

1.6 ENVIRONMENTAL

Do not perform welding when the quality of the completed weld could be impaired by the prevailing working or weather conditions. The Contracting Officer Representative will determine when weather or working conditions are unsuitable for welding.

1.7 DELIVERY AND STORAGE

Deliver filler metals, electrodes, fluxes, and other welding materials to the site in manufacturers' original packages and store in a dry space until used. Label and design packages properly to give maximum protection from moisture and to assure safe handling.

PART 2 PRODUCTS

2.1 WELDING MATERIALS

Comply with ASME BPVC SEC II-C. Welding equipment, electrodes, welding wire, and fluxes shall be capable of producing satisfactory welds when used by a qualified welder or welding operator using qualified welding procedures.

PART 3 EXECUTION

3.1 WELDING

Do not deviate from applicable codes, approved procedures, and approved shop drawings without prior written approval from the Contracting Officer Representative. Materials or components with welds made off the site will not be accepted if the welding does not conform to the requirements of this specification unless otherwise specified. Assign each welder or welding operator an identifying number, letter, or symbol that shall be used to identify his welds. Each welder or welding operator shall apply his mark adjacent to his weld using an approved rubber stamp or felt-tipped marker with permanent, weatherproof ink or other approved methods that do not deform the metal. For seam welds, place identification marks adjacent to the welds at 3-foot intervals. Confine identification by die stamps or electric etchers to the weld reinforcing crown, preferably in the finished crater.

3.2 WELDING OPERATORS

Perform welding in accordance with qualified procedures using qualified welders and welding operators.

3.3 SUPPORTS

Welding of hangers, supports, and plates to structural members shall conform to AWS D1.1/D1.1M.

3.4 EXAMINATIONS AND TESTS

Visual and nondestructive examinations shall be performed by the Contractor to detect surface and internal discontinuities in completed welds. Visually examine welds Radiographic, Liquid penetrant, or Magnetic particle, examination shall be required as indicated in Tables IV and V attached to this section or in accordance with other sections where detailed requirements are specified. Random NDE testing applies to ASME B31.1 piping unless specified otherwise. When examination and testing indicates defects in a weld joint, a qualified welder shall repair the weld in accordance with the paragraph entitled "Corrections and Repairs" of this section.

3.4.1 Random NDE Testing

When radiographic, liquid penetrant, or magnetic particle, examination is required, test a minimum of 10 percent of the total length or number of piping welds. Randomly select the welds examined but include an examination of welds made by each welding operator or welder. If random testing reveals that a weld fails to meet minimum quality requirements, examine an additional 10 percent of the welds in that same group. If the additional welds examined meet the quality requirements, the entire group of welds represented shall be accepted and the defective welds shall be repaired. If any of the additional welds examined also fail to meet the quality requirements, that entire group of welds shall be rejected. Remove and reweld rejected welds or examine rejected welds 100 percent and remove and reweld defects.

3.4.2 Visual Examination

Visually examine welds as follows:

a. Before welding -- for compliance with requirements for joint preparation, placement of backing rings or consumable inserts, alinement and fit-up, and cleanliness.

b. During welding -- for conformance to the qualified welding procedure.

c. After welding -- for cracks, contour and finish, bead reinforcement, undercutting, overlap, and size of fillet welds.

3.4.3 Nondestructive Examination

NDE shall be in accordance with written procedures. Procedures for radiographic, liquid penetrant or magnetic particle, tests and methods shall conform to ASME BPVC SEC V. The approved procedure shall be demonstrated to the satisfaction of the Contracting Officer's QA personnel.

In addition to the information required in ASME BPVC SEC V, the written procedures shall include:

a. Timing of the nondestructive examination in relation to the welding operations.

b. Safety precautions.

3.4.4 Examinations and Tests by the Government

Examinations and tests will conform to paragraphs "Visual Examination" and "Nondestructive Examination" of this section, except that destructive tests may be required also. When destructive tests are made, qualified welders or welding operators shall make repairs using welding procedures which will develop the full strength of the members cut. Welding shall be subject to examination and tests in the mill, shop, and field.

3.5 ACCEPTANCE STANDARDS

3.5.1 Visual

The following indications are unacceptable:

a. Cracks--external surface.

b. Undercut on surface which is greater than 1/32 inch deep provided that the remaining wall thickness is not less than the minimum design thickness.

c. Weld reinforcement:

(1) ASME B31.1, conform to Table I.

TABLE I

REINFORCEMENT OF GIRTH AND LONGITUDINAL BUTT WELDS

Greater than Less Than 750°F 350°F-750°F 350°F Thickness of Base Metal, _________ ___________ _______ inches inch inch inch Up to 1/8, incl. 1/16 3/32 3/16 Over 1/8 to 3/16, incl. 1/16 1/8 3/16

TABLE I

REINFORCEMENT OF GIRTH AND LONGITUDINAL BUTT WELDS

Maximum Thickness of Reinforcement for Design Temperature Greater than Less Than 750°F 350°F-750°F 350°F Thickness of Base Metal, _________ ___________ _______ inches inch inch inch Over 3/16 to 1/2, incl. 1/16 5/32 3/16 Over 1/2 to 1, incl. 3/32 3/16 3/16 Over 1 to 2, incl. 1/8 1/4 1/4 Over 2 5/32 The greater of ¼ in. or 1/8 times the width of the weld in inches.

NOTES:

1. For double welded butt joints, this limitation on reinforcement given above shall apply separately to both inside and outside surfaces of the joint.

2. For single welded butt joints, the reinforcement limits given above shall apply to the outside surface of the joint only.

3. The thickness of weld reinforcement shall be based on the thickness of the thinner of the materials being joined.

4. The weld reinforcement thicknesses shall be determined from the higher of the abutting surfaces involved.

5. Weld reinforcement may be removed if so desired.

(2) ASME B31.3, conform to Table II.

TABLE II

Wall Thickness, Inches Height, Inches Less than or equal to 1/4 Less than or equal to 1/16 Greater than 1/4, is less Less than or equal to 1/8 than or equal to 1/2 Greater than 1/2, is less Less than or equal to 5/32 than or equal to 1 Greater than 1 Less than or equal to 3/16

NOTES:

1. Wall thickness is the nominal wall thickness of the thinner of components joined by butt weld.

2. Height: For "Normal Service" and "Severe Cyclic" conditions, use the listed value. For "Category D Fluid Service," use twice the listed value. Measure from surfaces of adjacent components. The lesser of the two measurements, in any plane through the weld, shall not exceed the applicable value at right. Weld metal shall merge smoothly into component surfaces.

(3) ASME B31.4, conform to Table I for under 350 degrees F.

(4) ASME B31.5, conform to Table III.

TABLE III

Pipe Wall Thickness, inches Reinforcement Thickness, inches.

1/4 and under 1/16 Over 1/4 through 1/2 3/32 Over 1/2, through 1 1/8 Over 1 3/16

d. Lack of fusion on surface.

e. Incomplete penetration (applies only when inside surface is readily accessible).

f. Convexity of fillet weld surface greater than 10 percent of longest leg plus 0.03 inch.

g. Concavity in groove welds.

h. Concavity in fillet welds greater than 1/16 inch.

i. Fillet weld size less than indicated or greater than 1 1/4 times the minimum specified fillet leg length.

3.5.2 Magnetic Particle Examination

The following relevant indications are unacceptable:

a. Any cracks and linear indications.

b. Rounded indications with dimensions greater than 3/16 inch.

c. Four or more rounded indications in a line separated by 1/16 inch or less edge-to-edge.

d. Ten or more rounded indications in any 6 square inches of surface, with the major dimension of this area not to exceed 6 inches, with the area taken in the most unfavorable location relative to the indications being evaluated.

3.5.3 Liquid Penetrant Examination

Indications whose major dimensions are greater than 1/16 inch shall be considered relevant. The following relevant indications are unacceptable:

a. Any cracks or linear indications.

b. Rounded indications with dimensions greater than 3/16 inch.

c. Four or more rounded indications in a line separated by 1/16 inch or less edge-to-edge.

d. Ten or more rounded indications in any 6 square inches of surface, with the major dimension of this area not to exceed 6 inches, with the area taken in the most unfavorable location relative to the indications being evaluated.

3.5.4 Radiography

Welds that are shown by radiography to have any of the following discontinuities are unacceptable:

a. Any type of crack or zone of incomplete fusion or penetration.

b. Any other elongated indication which has a length greater than:

(1) 1/4 inch for t up to 3/4 inch, inclusive;

(2) 1/3 t for t from 3/4 inch to 2 1/4 inches, inclusive;

(3) 3/4 inch for t over 2 1/4 inches where t is the thickness of the thinner portion of the weld.

("t" pertains to the thickness of the weld being examined. If a weld joins two members having different thickness at the weld, "t" is the thinner of these two thicknesses.)

c. Any group of indications in line that have an aggregate length greater than t in a length of 12t, except where the distance between the successive indications exceeds 6L where L is the longest indication in the group.

d. Porosity in excess of that shown acceptable in Appendix A-250, Acceptance Standard for Radiographically Determined Rounded Indications in Welds, ASME BPVC SEC I.

3.6 CORRECTIONS AND REPAIRS

Remove defects and replace welds as specified in ASME B31.1, unless otherwise specified. Repair defects discovered between weld passes before additional weld material is deposited. Wherever a defect is removed, and repair by welding is not required, the affected area shall be blended into the surrounding surface eliminating sharp notches, crevices, or corners. After defect removal is complete and before rewelding, reexamine the area by the same test methods which first revealed the defect to ensure that the defect has been eliminated. After rewelding, reexamine the repaired area by the same test methods originally used for that area. For repairs to base material, the minimum examination shall be the same as required for butt welds. Indication of a defect shall be regarded as a defect unless reevaluation by NDE or by surface conditioning shows that no unacceptable indications are present. The use of foreign material to mask, fill in, seal, or disguise welding defects will not be permitted.

TABLE IV

EXAMINATIONS AND TESTS FOR VARIOUS MATERIALS AND SERVICES

Examinations or Tests Required Magnetic Particle Material or or Liquid Application Visual Radiographic Penetrant High-alloy austenitic or nickel steels or nickel alloys for cryogenic service and vacuum service

a. Tack welds Yes No No No

b. Root passes Yes No Yes No

c. Intermediate passes Yes No No No

d. Completed weld Yes 100 percent Yes(PT only) Yes for for NPS over wall thickness 1 1/4 inches 1/2 inch and over 60 percent for NPS 1 1/4 inches and less

High-alloy austenitic or nickel steels or nickel alloys for other than cryogenic or vacuum service

a. Tack welds Yes No No No

b. Root passes Yes No No

c. Intermediate passes Yes No No

d. Completed weld Yes Random Yes(PT only)

Stainless steel to carbon steel

a. Completed weld Yes Yes Yes(PT only) Carbon steel piping systems

a. Tack welds Yes No No

b. Root passes Yes No No

c. Intermediate passes Yes No No

d. Completed weld Yes Random No

TABLE V

MANDATORY MINIMUM NONDESTRUCTIVE EXAMINATIONS FOR ASME B31.1 PIPING

Temperatures over Temperatures between All others 750 degrees F and 350 degrees F and at all pressures. 750 degrees F inclusive and at all pressures over 1052 psig gage Buttwelds RT for NPS over RT for over 2 inch Visual for (Girth and 2 inches MT or PT NPS with thickness all sizes Longitudinal) for NPS 2 inches over 3/4 inch. and and less. Visual for all thicknesses.

sizes with thickness 3/4 inch or less.

Welded Branch RT for NPS over RT for branch over Visual for Connections 2-inch MT or PT 4-inch NPS and all sizes (Size indicated for NPS 2-inch thickness of branch and is Branch Size) and less. over 3/4 inch. thicknesses.

Visual for all sizes with branch thickness 3/4 inch.

or less.

Fillet, Socket PT or MT for Visual for all sizes Visual for Welds all sizes and and thicknesses. all sizes and thicknesses. thicknesses.

NOTES:

1. Thickness refers to pressure boundary wall thickness (such as pipe wall, fitting wall, or nozzle wall thickness).

2. All welds must be given a visual examination in addition to type of specific nondestructive examination specified.

3. NPS-Nominal Pipe Size.

4. RT-Radiographic examination; MT-magnetic particle examination; PT-liquid penetrant examination.

5. RT of branch welds shall be performed before any nonintegral reinforcing material is applied.

6. The thickness of buttwelds is defined as the thicker of the two abutting ends after end preparation.

7. Temperatures and pressures shown are design.

8. In lieu of radiography of welded branch connections when required above, liquid penetrant or magnetic particle examination is acceptable and, when used, shall be performed at the lesser of one-half of the weld thickness or each 1/2 inch of weld thickness and all accessible final weld surfaces.

9. For nondestructive examination of the pressure retaining component, refer to the standards listed in applicable code or the manufacturing specifications.

-- End of Section --

This product selection guide is written according to the Construction Specifications Institute (CSI) Format, including Master Format, Section Format, and Page Format, contained in the CSI Manual of Practice.

This specification is only a guide listing various coating system options and should not be used as a final specification. Tnemec is not liable in any way for revisions to or use of this product guide specification by any end user.

A qualified design professional should review and edit the document to suit project requirements. Coordinate this section with other specification sections and the drawings.

To finalize this specification, please contact your local Tnemec consultant listed at www.tnemec.com or by calling 1-800-TNEMEC-1.

Delete all "Specifier Notes" when editing this section.

SECTION 09 96 72 – FLUID APPLIED INSULATIVE COATINGS

GENERAL

DESCRIPTION OF WORK

Section includes a spray-applied insulative coating including primer, insulative coating and topcoat for the following applications:

Applied to steel penetrating the exterior envelope, from 18 inches outboard of the face of the wall to 18 inches inside the face of metal framing.

Applied to the interior of aluminum window frames, on top of exposed framing.

Applied to concrete slab edges.

RELATED SECTIONS

Section 05 12 00 Structural Metal Framing Section 05 50 00 Metal Fabrications

REFERENCES

American Institute of Steel Construction (AISC) AISC 303-05 Section 10 – Erection and storage of coated material during shipment and site handling shall be protected to minimize field touch up.

American Society of Testing and Materials (ASTM) ASTM D638 - Standard Test Method for Tensile Strength ASTM D695 - Standard Test Method for Compressive Strength ASTM D790 - Standard Test Method for Flexural Strength ASTM D4624/ISO 4624 - Standard Test Method for Bond Strength ASTM D2240 - Standard Test Method for Determining Durometer Hardness ASTM E84 - Surface Burning Characteristics ASTM C 1057 - Safe to Touch Association of the American Walls and Ceilings Industries (AWCI) The Society of Protective Coatings (SSPC) SSPC SP-6: Commercial Blast Cleaning Standard SSPC PA-1: Shop, Field, and Maintenance Painting of Steel.

SSPC PA-2: Procedure for Determining Conformance to Dry Coating Thickness Requirements.

SYSTEM DESCRIPTION

The liquid applied thermal break acrylic material shall be applied at the required thickness specified by the manufacturer in order to mitigate thermal bridging. In no case shall the K-value of the liquid applied thermal break be more than 0.040 W/mK.

SUBMITTALS

Product Data: Submit product data including manufacturers technical data indicating product performance characteristics, performance and limitation criteria.

Manufacturer’s Instructions: Submit manufacturer written installation instructions.

Applicator Qualifications: Submit applicators current certification as a manufacturer trained applicator.

Performance Documentation: Submit published design listings for insulation value ratings and product thickness. Include evidence that the liquid applied thermal break testing was sponsored by the manufacturer and that the material tested was produced at the manufacturers facility under the supervision of technical personnel.

QUALITY ASSURANCE

Manufacturer:

Company specializing in manufacturing product in this section with a minimum of 2 years documented experience in manufacturing insulative technology.

Applicator: Company specializing in applying the work of this section with documented experience and trained by the manufacturer.

Fluid Applied Thermal Break Acrylic system shall be the complete system from a sole source consisting of primer, acrylic thermal break material and topcoat. All materials shall be LEED 2009 compliant.

Mock-up:

Minimum thirty days prior to application in any area, provide mock-up Samples of thermal break materials in accordance with the following requirements:

Provide minimum two square feet on representative substrate, where directed by the Engineer, for each different thickness and finish of required for the work.

Provide mock-up areas that comply with thickness, density application, finish texture, and color.

Inspect mock-up areas within one hour of application for variance due to shrinkage, temperature, and humidity.

Where shrinkage and cracking are evident, adjust mixture and method of application as necessary to meet required installation, finish, and color requirements.

Continue to provide mock-up areas until acceptable areas are produced.

Acceptable areas shall constitute standard of acceptance for method of application, thickness, finish texture, and color requirements, for fluid applied thermal break material applications.

DELIVERY, STORAGE AND HANDLING

Delivery: Deliver materials in manufacturers’ original, sealed, undamaged container with identification label intact. Packaged materials shall bear the appropriate labels, seals.

Storage: Materials shall be stored in strict accordance with manufacturers documented instructions.

Documentation: All batch number, product identification and quantities shall be recorded on appropriate QC documents. A copy of the transport document and manufacturers conformance certificate shall be attached to the material delivery on site.

PROJECT/SITE CONDITIONS

Project Environmental Requirements: Substrate and air temperature shall be in accordance with the manufacturers’ requirements.

Protect work area from windblown dust and rain. Protect adjacent areas from over spray of material.

Provide ventilation in areas to receive work of this section during application and minimum 24 hours after application.

Temperature and Humidity Requirements: Maintain air temperature and relative humidity in areas where products will be applied for a time period before during and after application as recommended by manufacturer.

Do not apply Fluid Applied Acrylic Thermal Break when temperature of substrate and/or surrounding ambient air temperature is below 45° F. Temporary protection and heat shall be maintained at this minimum temperature for 24 hours before, during and 24 hours after material application.

Steel substrate temperature shall be a minimum of 5° F (3° C) above the dew point of the surrounding air for a period of 24 hours prior, during the application of the material and 24 hour cure period.

If necessary for job schedule, the General Contractor shall provide enclosures and heat to maintain proper temperatures and humidity levels in the application areas.

The relative humidity of the application area shall not exceed a maximum of 85% 24 hours prior, during and 24 hours after the application of the material. The relative humidity shall not exceed 75% throughout the application and curing of the decorative top coat finish.

WARRANTY

Provide a manufacturer’s warranty and applicators workmanship warranty under the provisions detailed in AIA MasterSpec®, current edition.

PRODUCTS

0. FLUID APPLIED INSULATION COATING GENERAL

Materials Compatibility:

Provide shop and field primers, and finish-coat materials that are compatible with one another and with the substrates indicated under conditions of service and application, as demonstrated by manufacturer based on testing and field experience.

Provide products of same manufacturer for each coat in a coating system.

MANUFACTURERS

Products specified are manufactured by Tnemec Company Incorporated. Local Representative: Josh Brady (402)689-7848 josh@moderncoatingsolutions.com Materials specified herein shall not preclude consideration of equivalent or superior materials. Suggested equivalent materials or other substitutions shall be submitted to specifier for consideration in compliance with substitution procedures in Section 01 25 00 of this Project Manual and include the following:

Submittals shall be provided no later than (10) days after Owner/Owner’s Agent letter of Notice to Proceed.

Requests for substitution shall include evidence of satisfactory past performance in similar environment.

Substitutions will not be considered that change the number of coats or do not meet specified dry film thicknesses.

Manufacturer’s certified test reports showing the substitute product(s) performance as outlined in Paragraph 2.15 shall be submitted.

After second submittal, Architect/Engineer/ Owner or Owner’s Agent hourly rates will be charged to review further submittals.

Bidders desiring to use coatings other than those specified shall submit those with their proposal based on the specified materials, together with the information required in Paragraph 1.5 above, and indicate the sum which will be added to or deducted from the base bid should alternate materials be accepted.

PRIMERS

HydroLink Water-based Epoxy :

Inorganic Hybrid Water-Based Epoxy:

Tnemec Series 1224 EPOXOLINE WB® VOC Content: 1 grams/liter Color: 1288 Off-White Requirements:

Adhesion to Steel (ASTM D4541): No less than 1,150 psi.

Fire Testing (UL 263 ASTM E 119): Any UL Classified spray-applied fire resistive materials having a maximum average density of 19.5 pcf. Including W.R. Grace Monokote MK-6/HY and Isolatek (Cafco) Blaze-Shield II (Type II).

Salt Fog Corrosion (ASTM B117): No cracking or delamination of film. No more than 1/64” rust creepage at scribe and no more than 3% rusting on plane after 10,250 hours exposure.

Slip Coefficient & Tension Creep: Meets AISC requirements of a Class B surface with a mean slip coefficient no less than 0.57.

THERMAL INSULATING COATING

Fluid Applied Acrylic Insulation Coating Tnemec Series 971 Aerolon® Acrylic VOC Content: 1.9 grams/liter Solids by Volume: 76 percent.

Colors: 1278 Insulation Yellow Requirements:

Abrasion (ASTM D4060): No more than 50.2 mg loss after 1,000 cycles.

Cyclic Salt Fog/UV Exposure (ASTM D5894): No blistering, cracking, rusting or delamination of film after 5,000 hours.

Humidity Resistance (ASTM D4585): No blistering, cracking, rusting, or delamination after 2,000 hours.

Immersion (ASTM D870): No blistering, cracking, rusting, or delamination after six months continuous tap water immersion.

Surface Burning Characteristics (ASTM E84): Class A Thermal Conductivity (ASTM C518): No greater than 0.0356 W/m-°K or 0.2468 BTU-in/ft2-hr-°F.

NORSOK M-501 ISO 20340: Passed 25 cycles.

EXECUTION

EXAMINATION

Do not begin installation until substrates have been properly prepared.

If substrate preparation is the responsibility of another installer, notify Architect of unsatisfactory preparation before proceeding.

All surfaces to receive the specified Tnemec Series 971 Aerolon® shall follow the manufacturer’s printed instructions and be clean, dry and free of oil, grease, loose mill scale, dirt, dust or other foreign substances which would impair bond of the material to the substrate.

Other corrections of the surfaces to receive the Fluid Applied Insulation Coating material shall be the responsibility of the Contractor, at no additional cost to the Owner.

Application of the primer, Series 971 Aerolon®, and topcoat shall not commence until the contractor, applicator and inspector have examined the surfaces to receive the primer and determined the surfaces are acceptable to receive the primer and Aerolon®. Commencement of application means acceptance of substrate.

Verify that substrate and workspace temperature and humidity conditions are in accordance with manufacturers recommendations.

SURFACE PREPARATION

Prepare surfaces in accordance with manufacturer's instructions.

Provide masking, drop cloths or other suitable coverings to prevent overspray onto surfaces not intended to be coated with thermal break coating.

Weld spatter and defects shall be ground smooth prior to commencement of primer and fluid applied thermal break material.

Primer shall not be applied to prepared substrate until the area has been adequately vented to remove all airborne dust. Prior to the application of any coating material, the blast products, dust and debris shall be removed by vacuuming.

Steel Substrates: Remove rust and loose mill scale.

Fabrication defects:

Correct steel and fabrication defects revealed by surface preparation.

Remove weld spatter and slag.

Round sharp edges and corners of welds to a smooth contour.

Smooth weld undercuts and recesses.

Grind down porous welds to pinhole-free metal.

Remove weld flux from surface.

Ensure surfaces are dry.

Remove visible oil, grease, dirt, dust, mill scale, rust, paint, oxides, corrosion products, and other foreign matter in accordance with SSPC-SP 6/NACE 3, unless otherwise specified.

** NOTE TO SPECIFIER ** Surface Profile should be 2 to 3 mils.

Abrasive Blast-Cleaned Surfaces: Coat abrasive blast-cleaned surfaces with primer before visible rust forms on surface. Do not leave blast-cleaned surfaces uncoated for more than 8 hours.

Shop Primer: Prepare shop primer to receive field coat in accordance with manufacturer's instructions.

Concrete Surfaces (where thermal break is needed):

Grind all surfaces to receive primer.

Apply Series 1224 Epoxoline WB.

APPLICATION

Apply coatings in accordance with manufacturer's instructions.

Mix and thin coatings, including multi-component materials, in accordance with manufacturer's instructions.

Keep containers closed when not in use to avoid contamination.

Do not use mixed coatings beyond pot life limits.

Use application equipment, tools, pressure settings, and techniques in accordance with manufacturer's instructions.

Uniformly apply coatings at spreading rate required to achieve specified DFT.

Apply coatings to be free of film characteristics or defects that would adversely affect performance or appearance of coating systems.

Apply primer at thickness recommended by manufacturer.

Apply Series 971 Aerolon® Thermal Insulative Coating as specified in Section 3.8 Coating Schedule.

Apply topcoat at thickness recommended by the manufacturer.

Final Dry Film Thickness (DFT) shall be measured with a dry film thickness gauge.

The steel deck is not to be sprayed unless otherwise indicated.

REPAIR

Materials and Surfaces Not Scheduled to Be Coated: Repair or replace damaged materials and surfaces not scheduled to be coated.

Damaged Coatings: All patching and repair to material, due to damage by other trades, shall be performed under this section and paid for by the trade responsible for the damage. Patching shall be performed by applicators certified by the manufacturer and applied in accordance with the manufacturer application instructions.

Coating Defects: Repair in accordance with manufacturer's instructions coatings that exhibit film characteristics or defects that would adversely affect performance or appearance of coating systems.

FIELD QUALITY CONTROL

The Owner will engage an independent testing laboratory inspect and verify the application of material in accordance with the provisions Tnemec Company.

Material inspection and testing shall be performed 24 hours after completion of final application coat.

The results of the above tests shall be made available to all parties at the completion of each pre-designated area and approval.

In-place material not in compliance with the specified thickness requirements shall be corrected prior to final acceptance.

The dry film thickness (DFT) of the applied material shall be measured with a non-destructive coating thickness gage after material has completely cured. All measurements shall be documented in writing and furnished to the Owner.

Manufacturer's Technical Services: Coordinate with coating manufacturer's technical service department or independent sales representative for current technical data and instructions.

CLEANING AND PROTECTION

Remove overspray materials from surfaces not required to be thermally protected.

Protect surfaces of coating systems from damage during construction.

Touch-up, or repair damaged products before Substantial Completion.

ONE-YEAR INSPECTION

** NOTE TO SPECIFIER ** Specify the one-year inspection of coating systems as required for the specific application. Delete the following paragraphs if the inspection is not required.

Owner will set date for one-year inspection of coating systems.

Inspection shall be attended by Owner, Contractor, Architect, and manufacturer's representative.

Repair deficiencies in coating systems as determined by Architect in accordance with manufacturer’s instructions.

FLUID APPLIED INSULATION COATING SCHEDULE

Steel Members Penetrating Exterior Building Envelope/Inside Face of Metal Framing/Concrete Slab Edges/Aluminum Window Frames, Condensation Control:

**SPECIFIER NOTE** Series 971 Aerolon: A minimum of 100 mils is required for thermal break condensation control. Vary color (white/yellow) on each lift to see previous coat. Subsequent coats shall be applied until final DFT is achieved.

Fluid Applied Thermal Break System, Mio-Zinc MCU Primer:

0. Surface Preparation: SSPC-SP6/NACE 3, If conditions will not permit this, Series 1224 may be applied to SSPC-SP2 or SP3 Hand or Power Tool Cleaned surfaces.

0. First Coat (Shop or Field): Series 1224 EPOXOLINE WB, DFT of 4.0 to 6.0 mils per coat.

Second Coat (Shop or Field): Series 971 Aerolon…