Atch 4 WAFB HVAC Design Guide.pdf

WHITEMAN AIR FORCE BASE

(MISSOURI)

PLUMBING AND HVAC DESIGN

REQUIREMENTS

March 2014

APPROVED FOR RELEASE (v1.0)

FA4525-15-R-0002 Attachment 7

Plumbing and HVAC Design Requirements Whiteman AFB, MO

TABLE OF CONTENTS

1.0 GENERAL INSTRUCTIONS 4

1.1. OBJECTIVE

1.2. DRAWING REQUIREMENTS

1.3. DESIGN CRITERIA

2.0 PLUMBING 6

2.1. APPLICABLE SPECIFICATIONS

2.2. WATER CLOSETS

2.3. URINALS

2.4. LAVATORIES

2.5. SHOWERS

2.6. FLOOR DRAINS

2.7. FREEZE PROOF WALL HYDRANTS

2.8. SHUTOFF VALVES

2.9. LAUNDRY ROOMS

2.10. DOMESTIC WATER TREATMENT

2.11. DOMESTIC WATER PIPING

2.12. DOMESTIC HOT WATER HEATING

3.0 HEATING, VENTILATING, AND AIR CONDITIONING (HVAC) 9

3.1. APPLICABLE SPECIFICATIONS

3.2. HVAC DESIGN PARAMETERS

3.3. UTILITIES

3.4. HVAC LOADS AND SYSTEM SIZING CALCULATIONS

3.5. VENTILATION

3.6. HUMIDITY CONTROL

3.7. AIR HANDLING UNITS

3.8. HEAT RECOVERY SYSTEMS

3.9. HVAC WATER TREATMENT PROCEDURES

3.10. STEAM AND HYDRONIC HOT WATER HEATING SYSTEMS

3.11. HYDRONIC CHILLED WATER SYSTEMS

3.12. GEOTHERMAL SYSTEMS

3.13. EQUIPMENT ACCESSIBILITY AND SAFETY CONSIDERATIONS

3.14. ANTI-TERRORISM AND FORCE PROTECTION (AT/FP) CONSIDERATIONS

3.15. NOISE AND VIBRATION CONTROL

3.16. DUCTWORK

3.17. TESTING, ADJUSTING, AND BALANCING (TAB)

3.18. CONSTRUCTION CONTRACTOR QUALITY CONTROL (QC)

3.19. COMMISSIONING

3.20. ELECTRICAL REQUIREMENTS

4.0 ENERGY MANAGEMENT AND HVAC CONTROLS 19

4.1. APPLICABLE SPECIFICATIONS

4.2. HVAC EQUIPMENT SELECTION METHODOLOGY

4.3. DIRECT DIGITAL CONTROLS (DDC) SYSTEM PERFORMANCE

5.0 APPENDIX – WATER TREATMENT PROCEDURES 22

5.1. DOMESTIC WATER SYSTEMS

5.2. HYDRONIC CHILLED/HOT WATER SYSTEMS

5.3. WARRANTY PERIOD

1.0 GENERAL INSTRUCTIONS

1.1. OBJECTIVE

The objective of this guide is to instruct in-house designers and Architect-Engineers (AEs) on the standards, policies, and basic requirements to be used in the preparation of plumbing and HVAC design analyses, drawings, cost estimates, and specifications for Military Construction projects assigned to the U.S. Army Engineer District, Kansas City (USACE) at Whiteman AFB, Missouri. Designers must be thoroughly familiar with the contents of this guide to efficiently design a military project at Whiteman AFB.

1.2. DRAWING REQUIREMENTS

1.2.1. All drawings shall have a project-specific drawing code entered into the drawing border. The USACE PM shall provide that drawing code to the AE.

1.2.2. All electronic copies of plans, specifications, design analysis, and other design submittals shall have file names that do not include the following special characters: \ / : * ? “ < > | # {

1.2.3. Plans submitted on electronic media must include one PDF file of the entire set or each volume.

1.3. DESIGN CRITERIA

As applicable to the scope, all projects shall be based upon, but not limited to the following most recent edition publications, codes and specifications. Any changes to criteria at or prior to 35% (Conceptual) design shall be incorporated; criteria changes after 35% design shall comply with the criteria in effect at the time the project was initiated. In the event of a conflict between criteria, the most stringent criterion shall be applied.

1.3.1. Industry Standards

1.3.1.1. Air Conditioning and Refrigeration Institute

ARI Air Conditioning and Refrigeration Institute Standard

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

ASHRAE 55 Thermal Environmental Conditions for Human Occupancy

ASHRAE 62.1 Ventilation for Acceptable Indoor Air Quality

ASHRAE 62.2 Ventilation and Acceptable Indoor Air Quality in Low-Rise Residential Buildings

ASHRAE 90.1 Energy Standard for Buildings Except Low-Rise Residential Buildings

ASHRAE 189.1 Standard for the Design of High-Performance Green Buildings

1.3.1.3. International Code Council

IBC International Building Code

IPC International Plumbing Code

1.3.1.4. Sheet Metal and Air Conditioning Contractors’ National Association

Architectural Sheet Metal Manual, 7th Edition

1.3.1.5. U.S. Green Building Council

LEED LEED Reference Guide for Green Building Design and Construction

1.3.2. Military Criteria

1.3.2.1. Public Laws

EISA Energy Independence and Security Act

EPAcT Energy Policy Act

1.3.2.2. Executive Orders

E.O. 13423 Strengthening Federal Environmental, Energy, and Transportation Management

E.O. 13514 Federal Leadership in Environmental, Energy, and Economic Performance

1.3.2.3. Standard Design Document (as applicable to the facility)

1.3.2.4. U.S. Air Force Regulations and Instructions

AFI 32-1023 Design and Constructing Military Construction Projects ETL (various) Engineering Technical Letters applicable to Air Force facility-type.

1.3.2.5. Unified Facilities Criteria

UFC 1-200-01 General Building Requirements

UFC 1-200-02 High Performance and Sustainable Building Requirements

UFC 3-310-04 Seismic Design for Buildings

UFC 3-400-02 Engineering Weather Data

UFC 3-401-01 Mechanical Engineering

UFC 3-410-01 Heating, Ventilating, and Air Conditioning

UFC 3-410-02 Lonworks Direct Digital Control for HVAC and Other Local Building Systems

UFC 3-420-01 Plumbing Systems

UFC 3-440-01 Active Solar Preheat Systems

UFC 3-450-01 Noise and Vibration Control

UFC 4-010-01 DoD Minimum Antiterrorism Standards for Buildings

UFC 4-010-02 DoD Minimum Standoff Distances for Buildings (FOUO)

2.0 PLUMBING

2.1. APPLICABLE SPECIFICATIONS

2.1.1. The UFGS Guide Specification 22 00 00, ‘Plumbing, General Purpose,’ shall be used to specify the plumbing systems in all contracts.

2.1.2. Other UFGS Guide specifications that may be used as applicable to the project scope include, but are not limited to, the following:

22 31 00 Water Softeners, Cation-Exchange (Sodium Cycle) 22 33 30.00 10 Solar Water Heating Equipment

2.1.3. All guide specifications shall be edited and tailored for each project to remove irrelevant requirements. The edits shall be consistent with the specific design requirements outlined in this document. No deviations or substitutions shall be inserted in the guide specification in material and installation requirements unless approved by Base CE in advance.

2.2. WATER CLOSETS

2.2.1. Dual-volume (heavy, light) flush valve type, floor-mounted elongated bowl with solid antimicrobial plastic elongated open seat front, no lid,1.6 gallons per flush, Class A or better.

2.2.2. Provide hard-wired sensor equipped with manual override flush.

2.3. URINALS

2.3.1. Wall-mounted vitreous china, ultra low-flush valve type shall be provided. Washout and waterless types shall not be permitted.

2.3.2. Provide hard-wired sensor equipped with manual override flush.

2.4. LAVATORIES

2.4.1. Unless otherwise specified, sinks shall be wall-mounted vitreous china with integral bowl and countertop, 19" x 17", with heavy-duty, 2-handle, 4" center set faucet, with wrist blade handles and 0.50 gpm. One sink shall have a gooseneck spigot in each latrine. All other sink requirements shall utilize a design which includes a solid surfacing vanity countertop with solid surfacing under-mount lavatories. At least one sink shall be ADA compliant as required by the standard building design requirements or by the building occupants.

2.4.2. All automatic lavatory water sensors, flush sensors or other automatic sensors shall be hard-wired - no solar or battery-powered devices shall be permitted.

2.5. SHOWERS

2.5.1. Shower heads rated for 1.5 gpm flow, mounted 75 inches above finished floor, heavy duty type.

2.5.2. Shower drains sized to accommodate 150 percent of the maximum shower head flow, minimum 2 inches.

2.6. FLOOR DRAINS

2.6.1. Provide floor drains in latrines, laundry rooms, janitor’s closets, drying areas, showers and other areas expected to need regular drainage. All drains shall have screw-down brass/bronze covers with corrosion-resistant screws.

2.6.2. Avoid trap primers – if required, the preference is to use an elastomeric flexible tube that sits watertight inside the drain and automatically opens to permit water flow, from intermittent drip to fire-hose type flows and stays open when water is flowing but rolls up closed when the water stops.

2.7. FREEZE PROOF WALL HYDRANTS

2.7.1. All exterior HVAC units shall be provided with an exterior freeze-proof wall hydrant within 40 feet of the HVAC unit.

2.7.2. Provide freeze proof wall hydrants around the exterior building perimeter in a manner such that all areas adjacent to the building can be reached with a 50-foot hose.

2.8. SHUTOFF VALVES

Provide shut off valves in water supply to all plumbing fixtures. In addition, main piping runs to more than five plumbing fixtures shall also be provided with isolation valves.

2.9. LAUNDRY ROOMS

Designers shall confirm with USACE and BASE C/E what dryers will be used and ensure that the dryer connection requirements are clear and complete in the design documents (including the FF&E). Connection requirements shall address manifold connections, flex hose connections, and venting connections. Gas lines and combustion air for gas dryers shall be provided per NFPA 54.

2.10. DOMESTIC WATER TREATMENT

Water softeners, when required for the project, shall not be located in mechanical rooms.

2.11. DOMESTIC WATER PIPING

2.11.1. Provide backflow preventer at domestic water entrance, per Missouri Department of Natural Resources (MDNR).

2.11.2. Cleanouts shall be installed at base of all waste/vent stacks and elsewhere as required by IPC (Code).

2.11.3. Whiteman AFB has experienced problems with cavitations and pipe erosion in the domestic piping systems on base. Cavitations are a product of excessive velocity through under-sized piping. The water hardness found at Whiteman AFB only adds to the problem. Maximum velocities shall be 6 fps for domestic cold water, 4 fps for domestic hot water less than 140º F, and 2 fps for domestic hot water greater than 140º F. Pump-driven hot water recirculation lines shall be positively limited to 4 fps using a balancing device and TAB.

2.11.4. Domestic water piping insulation shall be flexible elastic cellular type.

2.11.5. Designer shall determine piping expansion and show anchor and expansion loop requirements, as necessary.

2.12. DOMESTIC HOT WATER HEATING

Domestic hot water shall be generated by condensing type gas water heaters, or tank & tube or flat plate heat exchanger type systems using condensing type boilers, or steam tankless water heaters. Aluminum heat exchangers shall not be used. Water shall be stored at 140 degrees F and mixed down to 110 degrees F for use. Provide properly sized expansion tank.

3.0 HEATING, VENTILATION, AND AIR CONDITIONING (HVAC)

3.1. APPLICABLE SPECIFICATIONS

3.1.1. The UFGS Guide Specification 23 00 00, ‘Air Supply, Distribution, Ventilation, and Exhaust Systems,’ shall be used to specify the HVAC systems in all contracts.

3.1.2. Other UFGS Guide specifications that may be used as applicable to the project scope include, but are not limited to, the following:

23 05 93 Testing, Adjusting, and Balancing for HVAC 23 07 00 Thermal Insulation for Mechanical Systems 23 08 00 Commissioning of HVAC Systems 23 09 23.13 20 BACnet Direct Digital Control Systems for HVAC 23 11 25 Facility Gas Piping 23 23 00 Refrigerant Piping 23 52 00 Heating Boilers 23 64 10 Water Chillers, Vapor Compression Type 23 64 26 Chilled, Chilled-Hot, and Condenser Water Piping System 33 51 15 Natural-Gas / Liquid Petroleum Gas Distribution

3.1.3. All guide specifications shall be edited and tailored for each project to remove irrelevant requirements. The edits shall be consistent with the specific design requirements outlined in this document. No deviations or substitutions shall be inserted in the guide specification in material and installation requirements unless approved by Base CE in advance.

3.2. HVAC DESIGN PARAMETERS

3.2.1. Site Outdoor Design Conditions for Whiteman AFB

As directed by UFC 3-410-01, Whiteman AFB, MO (ASHRAE Climate Zone 4A), weather data shall be selected with outdoor design conditions as follows:

1.0% Occurrence/Cooling Design Dry Bulb 97 degrees F 1.0% Occurrence/Cooling Design MCWB 76 degrees F 99.0% Occurrence/Heating Design Dry Bulb 7 degrees F

3.2.2. General Indoor Design Conditions

As directed by UFC 3-410-01, general indoor design conditions shall be as follows:

TABLE I: INDOOR DESIGN DATA

Area Type Summer

Temperature Winter

Temperature Humidity (% RH)1

(degrees F) (degrees F) Nom. Tol.

General Indoor Design Temperature 78 68 50% N/A Communication Rooms2 72 72 50% ± 5% Aircraft Hangars Ventilation 55 N/A N/A Mechanical and Electrical Rooms Ventilation 40 N/A N/A Toilets and Showers Ventilation 68 N/A N/A Vestibules – Exterior Entrances N/A 55 N/A N/A

Table I ‘Indoor Design Data’ Notes:

1. General dehumidification shall be performed by using air handling unit cooling coils to pre-treat the outside air to the minimum space dew point condition and selecting the cold deck supply air temperature to maintain space relative humidity.

2. All Communications Rooms shall have dedicated and independent air conditioning units.

The space shall be conditioned and pressurized in accordance with the requirements of I3A.

3.2.3. Ensure that all heating and cooling equipment provided is listed by the manufacturer to handle the specified outdoor summer and winter entering air temperatures on a design day.

All outdoor cooling equipment (i.e. chillers, condensers, condensing units) shall be selected to provide the design capacity at 105 degrees F ambient outdoor temperature. All equipment shall be supplied by the manufacturer with protective devices to assure equipment is not damaged should entering air conditions exceed manufacturer limits.

3.3. UTILITIES

3.3.1. Missouri Gas Energy is the privatized utility supplying natural gas to the Installation’s gas distribution system. The Air Force purchases natural gas from Missouri Gas Energy and maintains all distribution mains and laterals. Designer shall be responsible for verifying the available gas pressures and capacities at the site and evaluating the impact of the new system on the existing gas infrastructure. Designer shall coordinate location of new gas meter and anticipated gas service requirements with Base CE during design.

3.3.2. The Installation is the local electric utility provider. Designer shall be responsible for verifying the available electric capacity at the site and evaluating the impact of the new system on the existing electric infrastructure. Designer shall coordinate location of new electric meter and anticipated electric service requirements with Base CE during design.

3.3.3. The installation has a central steam distribution system. Unless the project site is remotely located from the central steam plant, utilizing the Installation’s steam system for facility heating is preferred. Consult with Base C/E prior to hydronic system design for review and approval

3.4. HVAC LOADS AND SYSTEM SIZING CALCULATIONS

3.4.1. Capacities of heating and cooling systems shall be based on load calculations of individual spaces as well as block loads. All mechanical calculations shall be performed in accordance with ASHRAE methods as computed using a HVAC loads computer program.

3.4.2. Safety factors for heating and cooling loads shall be in accordance with requirements of UFC 3-410-01.

3.5. VENTILATION

3.5.1. Mechanical ventilation for human occupancy shall be provided in strict accordance with ASHRAE Standard 62.

3.5.2. Exhaust rates for shower/drying areas shall be increased above ASHRAE Std. 62.1 to provide 10 air exchanges per hour.

3.5.3. Laundry areas shall have modulating outdoor air dampers to provide tempered make up air depending on number of dryers in operation.

3.5.4. Designs shall comply with ASHRAE 62.1 minimum requirements for separation of fresh air intakes.

3.5.4.1. Provide a minimum of 3 feet of vertical separation distance between fresh air intakes and combustion vents and exhaust louvers.

3.5.4.2. Provide a minimum of 15 feet of horizontal separation distance between fresh air intakes and combustion vents and all exhaust louvers.

3.6. HUMIDITY CONTROL

3.6.1. To prevent mold formation in buildings, air conditioning systems must be designed to maintain space humidity at 50 percent, generally by performing dehumidification by pre-treating the outside air to the space dew point conditions, and removing the latent moisture and controlling the building’s moisture content through the use of cooling coils in air handling units.

3.6.2. Include the following considerations in the design of the air conditioning systems:

3.6.2.1. Avoid over-sizing of cooling equipment.

3.6.2.2. Supply air temperatures shall be calculated using the space sensible heat ratios required to maintain an indoor design condition of 50 percent relative humidity.

3.6.2.3. Size cooling coils for the greater of the cooling load calculated at the design dry bulb temperature condition or the design humidity condition.

3.6.2.4. Where fan coil units are used, provide a non-permeable wall covering behind the unit.

3.6.2.5. For all unitary systems, provide ventilation air from a separate dedicated air handling unit.

Outside air shall not be conditioned by the unitary system.

3.6.2.6. DX systems shall not be equipped with additional dehumidification controls, unless such measures are supplied as an integral component to the system by the manufacturer.

3.7. AIR HANDLING UNITS

3.7.1. All air handling units shall be equipped with adjustable outside air intake dampers and economizer controls.

3.7.2. Units shall be equipped with freezestats with manual reset capability. Manual reset capability can be accomplished through the DDC system by a manual software reset by the user.

3.7.3. When there is the potential for air stratification, air handling units utilizing outside and return air damper mechanisms shall have air-blending devices installed.

3.7.4. Ball or butterfly valve-type isolation valves shall be provided on each air handler coil. Gate valves are not preferred.

3.7.5. The maximum face velocity across filters shall not exceed 300 fpm.

3.7.6. Hydronic coils shall be drainable and shall be selected based on a spacing no closer than 10 fins per inch.

3.7.7. Ultraviolet (UV) modules provided by the manufacturer as an integral component of the air handling unit for additional air filtration/treatment are preferred for dormitory and headquarters facilities (new and existing).

3.8. HEAT RECOVERY SYSTEMS

3.8.1. Heat recovery systems are encouraged for maximizing energy savings.

3.8.2. Preferred heat recovery approach is flat plate heat exchanger. Desiccant heat wheels are not preferred by the Installation.

3.9. HVAC WATER TREATMENT PROCEDURES

3.9.1. Water treatment shall be performed on all water systems in accordance with the procedures outlined in the Appendix.

3.10. STEAM AND HYDRONIC HOT WATER HEATING SYSTEMS

3.10.1. Where steam is available or accessible to the facility, steam in conjunction with steam-to-hot water exchangers shall be utilized for hydronic hot water heating.

3.10.1.1. Steam or air (non-powered) steam pushers shall be utilized for steam systems. Electric pumps are not permissible.

3.10.1.2. Steam pressure reducing valves (PRVs) shall be selected as a complete assembly from the manufacturer.

3.10.2. Boilers shall be modular high-efficiency condensing type and capable of operating at minimum 90 percent efficiency, with boiler return water temperature up to 140 degrees F or a 30 degree temperature difference.

3.10.2.1. If boilers are equipped with aluminum heat exchangers, the DDC system shall monitor the pH level of the water and provide an alarm when the pH concentration reaches the boiler manufacturer’s recommended limits. The hydronic systems shall avoid the use of dissimilar materials (all copper piping preferable).

3.10.2.2. Boilers with pulse burners shall not be permitted due to their additional maintenance requirements.

3.10.2.3. A minimum of two units shall be used, sized at two-thirds of the building’s total heating load.

Consider available space when selecting boilers. Venting and combustion air intakes shall be per manufacturer’s recommendations.

3.10.3. Air separators shall be combination air/dirt coalescing type separators with auto-vent included.

3.10.4. Chemical feeders shall be dual-purpose type with chemical feeding and cleaning filters.

3.10.5. All triple duty valves shall include check, isolation, and balancing valves integral to the assembly.

3.10.6. A vent shall be provided with isolation valves at the highest point of the heating system.

3.10.7. Heating systems shall have dedicated piping separate from the chilled water system.

3.10.7.1. Hot water heating piping shall not be directly connected to the potable water system. Make up water shall be provided by a feed water tank system. Relief points in the hot water system shall be piped to the feed water tank for recovery.

3.10.7.2. Piping materials on hot water systems shall be Schedule 40 black steel or Type L copper.

Steam piping shall be Schedule 80 black steel.

3.10.7.3. Grooved piping shall not be allowable for the hot water heating systems.

3.10.7.4. Designer shall determine piping expansion and show anchor and expansion loop requirements, as necessary.

3.10.8. Glycol feeders shall be installed on hot water systems where applicable.

3.11. HYDRONIC CHILLED WATER SYSTEMS

3.11.1. Freeze protection shall be provided for all closed loop hydronic systems (chilled, load, source, or condenser) with 35% propylene glycol (food grade).

3.11.2. Air separators shall be combination air/dirt coalescing type separators with auto-vent included.

3.11.3. Chemical feeders shall be dual-purpose type with chemical feeding and cleaning filters.

3.11.4. Chillers shall be air-cooled; the type of chiller (i.e. scroll, screw, etc.) selected shall be based upon the most appropriate energy-efficient unit for the design cooling load of the facility. All chiller units shall be equipped with multiple compressors and circuits.

3.11.4.1. Screw compressors shall be equipped with soft- start features. Scroll compressors shall be equipped with across-the-line starters.

3.11.4.2. Provide 5-year extended warranty for the compressors

3.11.4.3. Unit will have low ambient temperature controls to 0 degrees F.

3.11.4.4. Condenser coils shall have louvered covers (hail guards), and all other accessible areas will have 2 x 2 wire guards.

3.11.4.5. Unit shall be mounted on the isolation mounts provided by the manufacturer.

3.11.4.6. Unit will be mounted on a minimum 6-inch structural concrete equipment pad.

3.11.4.7. Unit shall utilize a 0 ozone depletion refrigerant such as R-410A.

3.11.4.8. Unit shall be equipped with a factory-provided BACnet Card.

3.11.4.9. Ball or butterfly valve-type isolation valves shall be provided on each chiller. Gate valves are not preferred.

3.11.5. All triple duty valves shall include check, isolation, and balancing valves integral to the assembly.

3.11.6. A vent shall be provided with isolation valves at the highest point of the chilled water system.

3.11.7. Chilled water systems shall have dedicated piping separate from the heating system.

3.11.7.1. Chilled water piping shall not be directly connected to the potable water system. Make up water shall be provided by a feed water tank system. Relief points in the chilled water system shall be piped to the feed water tank for recovery.

3.11.7.2. Piping materials on chilled water systems shall be Schedule 40 black steel, Type L copper, or Schedule 80 PVC.

3.11.7.3. Grooved piping shall not be allowable on the chilled water systems downstream of the chiller(s).

3.11.8. All condensate shall be properly drained to open drains or discharged to an approved area outdoors. In accordance with UFC 1-200-02 and ASHRAE 189.1, condensate recovery systems shall be evaluated and provided if life cycle cost effective.

3.11.8.1. Designer shall determine piping expansion and show anchor and expansion loop requirements, as necessary.

3.11.9. Glycol feeders shall be installed on chilled water systems where applicable.

3.12. GEOTHERMAL SYSTEMS

3.12.1. Geothermal systems, such as ground-source heat pump (GSHP) systems, are permissible if they are appropriately suited to the facility and site and designed in a manner to minimize additional maintenance.

3.12.2. Well fields located beneath existing or planned parking lots and existing or planned structures shall not be permitted.

3.12.3. All valve vaults shall be accessible and located above-ground.

3.12.4. All geothermal equipment, such as pumps and centralized heat pumps, shall be located in the mechanical room. Distributed heat pumps shall not be permitted.

3.12.5. Freeze protection shall be provided for all geothermal with 35% propylene glycol (food grade).

3.13. EQUIPMENT ACCESSIBILITY AND SAFETY CONSIDERATIONS

3.13.1. All heating and cooling systems shall be installed in accordance with NFPA 90A and B.

3.13.2. All mechanical equipment with rotating parts shall be equipped with guards provided by the equipment manufacturer.

3.13.3. Air handling units shall be located inside of the building within a designated mechanical room.

No mechanical units, such as air handling units, exhaust/relief fans, condensing units, and chillers, shall be permitted on the roof. Rooftop air handling units installed at grade-level may be permitted in special situations upon approval by the Installation.

3.13.4. Mechanical HVAC equipment requiring regular maintenance shall not be placed in normally occupied restricted access areas.

3.13.5. All mechanical equipment located more than 18 inches above a 10-foot ceiling or located above a ceiling greater than 10 feet AFF shall have a catwalk for maintenance access.

Catwalk design and location shall be submitted to Base C/E for review and approval.

3.13.6. All hydronic pumps shall be located inside a mechanical room space.

3.13.7. Underground chilled water, hydronic hot water heating, and refrigerant lines shall not be permitted.

3.13.8. Provide identification labels on all piping (i.e. hydronic chilled/water, condensate, and refrigerant supply and returns) throughout the facility. All ductwork in the mechanical room shall be labeled.

3.13.9. All geothermal equipment, such as pumps and centralized heat pumps, shall be located in the mechanical room. Distributed heat pumps shall not be permitted.

3.13.10. Any equipment producing condensation located above the ceiling shall be equipped with secondary condensate drain pans.

3.13.11. All ground-mounted mechanical equipment shall be installed on appropriately designed concrete equipment pads with a minimum thickness of 4 inches. Equipment pads with floor drains shall have a minimum thickness of 6 inches.

3.13.12. All equipment layouts shall be carefully coordinated to ensure manufacturer’s recommended service and performance clearances are maintained. A minimum 4-foot work area shall be provided for maintenance of chillers, condensing units, pumps, boilers, and terminal units.

Specific clearances include, but are not limited to, the following:

Chiller airflow clearances.

Boiler access panels and piping (including hydronic and flue vent as well as tube removal where applicable).

Air handling unit fan, coil, and filter removal.

Terminal unit control panel, piping, fan, and filter (as applicable). Terminal units shall not be located more than 18 inches above a ceiling (or no more than 10 feet above finished floor in spaces without a suspended ceiling). Piping or cable trays shall not be permitted to be routed beneath the unit. VAV terminal units shall not be equipped with filters.

Provide appropriately sized access panels for any equipment located above a hard ceiling.

Provide access to all control devices, cleanouts, and gas fittings.

3.13.13. All isolation valves shall be located in accessible areas. Isolation valves located in a concealed wall or ceiling shall be provided with access panels.

3.13.14. Freezestats shall be mounted on the air handling unit, or in another location approved by Base CE if locating it on the unit makes it difficult to access.

3.14. ANTI-TERRORISM AND FORCE PROTECTION (AT/FP) CONSIDERATIONS

3.14.1. The design and installation of all HVAC equipment shall comply with the latest requirements of UFC 4-010-01.

3.14.2. The following minimum force protection measures shall be provided:

Outside air intake height shall be minimum 10 feet above finished grade.

Class 1A low-leakage motorized control dampers at all duct penetrations of the building envelope.

Emergency shutdown switch interlocked with all fans and dampers. Location of switch shall be coordinated with Installation.

Screens over the top of chillers and condensing units shall not be permitted.

3.15. NOISE AND VIBRATION CONTROL

3.15.1. All HVAC equipment shall be selected to prohibit objectionable noise transmittance or vibration into occupied areas.

3.15.2. The air supply and distribution system shall target a nose criteria rating of NC30.

3.15.3. All construction activities and project phasing, including system start-ups and shutdowns shall be coordinated with the Installation and End User and sequenced in a manner to minimize disruptions to the occupants.

3.16. DUCTWORK

3.16.1. The systems shall be installed in accordance with guidelines of ARI and ductwork of Class I flex ducting and in accordance with ASHRAE standards. All ductwork installation and construction shall meet current SMACNA Standards.

3.16.2. The length of flex ducting shall be limited to 5 feet.

3.16.3. Internal duct insulation shall not be permitted.

3.17. TESTING, ADJUSTING, AND BALANCING (TAB)

3.17.1. Test and balance air and hydronic systems, using a firm certified for testing and balancing by the Associated Air Balance Council (AABC), National Environmental Balancing Bureau (NEBB), and Testing, Adjusting, and Balancing Bureau (TABB).

3.17.2. Perform TAB in accordance with the requirements of the standard under which the TAB Firm’s qualifications are approved, i.e., AABC MN-1, NEBB TABES, or SMACNA HVAC TAB unless otherwise specified herein.

3.17.3. All recommendations and suggested practices contained in the TAB Standard shall be considered mandatory.

3.17.4. All HVAC control loops shall be custom-tuned on-site to establish proportional and integral constants. Leaving controllers at their default factory proportional and integral constants for TAB and commissioning is not permissible.

3.17.5. Use the provisions of the TAB Standard, including checklists, report forms, etc., as nearly as practicable to satisfy the Contract requirements.

3.17.6. Use the TAB Standard for all aspects of TAB, including qualifications for the TAB Firm and Specialist and calibration of TAB instruments.

3.17.7. Where the instrument manufacturer calibration recommendations are more stringent than those listed in the TAB Standard, adhere to the manufacturer’s recommendations.

3.17.8. All quality assurance provisions of the TAB Standard, such as performance guarantees, shall be part of this Contract.

3.17.9. For systems or system components not covered in the TAB Standard, the TAB Specialist shall develop TAB procedures.

3.17.10. Where new procedures, requirements, etc., applicable to the Contract requirements have been published or adopted by the body responsible for the TAB Standard used (AABC, NEBB, or TABB), the requirements and recommendations contained in these procedures and requirements are mandatory.

3.17.11. Submit final TAB reports indicating initial airflow, final airflow, initial temperature, and final temperature of each conditioned space for Governmental review and approval. Seasonal reports shall include parameters during summer when the outside air temperature is within 10 percent of the summer design conditions, and during the winter when the outside air temperature is within 10 percent of the winter design conditions.

3.18. CONSTRUCTION CONTRACTOR QUALITY CONTROL (QC)

3.18.1. All mechanical construction activities shall be reviewed by a mechanical quality control representative designated by the general contractor or mechanical subcontractor.

3.18.2. The designated mechanical QC representative shall submit documentation to the COR verifying all HVAC systems and their components have been properly installed and tested prior to commencement of functional performance testing by the commissioning agent.

3.19. COMMISSIONING

3.19.1. Commissioning of the installed HVAC systems shall commence only after all systems have been installed, as verified by the contractor or subcontractor’s designated mechanical QA representative, and TAB of the systems completed.

3.19.2. Commission all HVAC systems and equipment, including controls, and all systems requiring commissioning for LEED Fundamental Commissioning (EA Prerequisite 1), in accordance with ASHRAE UFC 1-200-02 and requirements of the LEED Reference Manual. All HVAC control loops shall be custom-tuned on-site to establish proportional and integral constants.

Leaving controllers at their default factory proportional and integral constants for TAB and commissioning is not permissible.

3.19.3. The sampling techniques discussed in ASHRAE Guidelines 0 and 1.1 shall not be utilized.

Refer to the functional performance testing checklists in UFGS Guide Specification 23 08 23.

3.19.4. Commission 100 percent of the HVAC controls and major equipment (including but not limited to air handling units, boilers, chillers, pumps, unitary and computer/server room equipment, and exhaust/relief fans). Full commissioning of heating and cooling systems shall be shall be performed in winter and summer conditions, respectively, to demonstrate in-season performance. A minimum representative sample of 50% of the terminal units shall be commissioned.

3.19.5. The Contractor shall hire the Commissioning Authority (CxA), certified as a CxA by AABC, NEBB, or TABB, as described in ASHRAE Guideline 1.1. The CA shall be an independent contractor and not an employee or subcontractor of the Contractor or any other subcontractor on this Project, including the design professionals (i.e., the DOR or their firm[s]).

3.19.6. The Contracting Officer’s Representative shall act as the Owner’s representative in performance of duties spelled out under OWNER in Annex F of ASHRAE Guideline 0.

3.20. ELECTRICAL REQUIREMENTS

3.20.1. Each chiller shall have an external disconnect.

3.20.2. Each air handling unit fan motor shall have an external disconnect.

3.20.3. Phase protection (i.e. under voltage, over voltage, phase loss, and phase reversal) for all HVAC mechanical equipment (e.g. pumps, chillers, fan motors) shall be provided and its status provided on the DDC system.

4.0 ENERGY MANAGEMENT AND HVAC CONTROLS

4.1. APPLICABLE SPECIFICATIONS

4.1.1. The UFGS Guide Specification 23 09 23.13 20, ‘BACnet Direct Digital Control Systems,’ shall be used to specify the energy management and HVAC controls systems in all contracts.

4.1.2. All guide specifications shall be edited and tailored for each project to remove irrelevant requirements. The edits shall be consistent with the specific design requirements outlined in this document. No deviations or substitutions shall be inserted in the guide specification in material and installation requirements unless approved by Base CE in advance.

4.2. HVAC EQUIPMENT SELECTION METHODOLOGY

4.2.1. In accordance with UFC 1-200-02 and ASHRAE 189.1, design the buildings, including the building envelope, HVAC systems, service water heating, power, and lighting systems to achieve an energy consumption that is at least 30 percent below the consumption of a baseline building meeting the minimum requirements of ANSI/ASHRAE/IESNA Standard 90.1 (2010) Appendix G. The selection of solutions and technologies to achieve the above energy performance requirements shall be evaluated using life cycle cost analysis. Life-cycle Cost Analyses shall follow the requirements set forth in 10 CFR Part 436 and utilize an approved automated calculation tool such as BLCC5. Cyclical and annual maintenance costs used shall come from ASHRAE recommendations or other similar Industry Standard sources.

4.2.2. The construction shall provide a system based on a building life cycle of 40 years, with a minimum in-service component lifespan of 25 years for major repairs or operating expenses.

4.2.3. The Contractor shall purchase Energy Star or FEMP designated products. The term “Energy Star product” means a product that is rated for energy efficiency under an Energy Star program. The term “FEMP designated product” means a product that is designated under the Federal Energy Management Program of the Department of Energy as being among the highest 25 percent of equivalent products for energy efficiency. In the case of an electric motor of 1 to 500 horsepower, the Contractor shall select only a premium efficient motor.

4.3. DIRECT DIGITAL CONTROLS (DDC) SYSTEM PERFORMANCE

4.3.1. Basic Function

4.3.1.1. The construction shall provide a building control system that controls the indoor environment, manages energy and fuel consumption, monitors packaged equipment controls, and integrates fire alarm and security functions. The system shall have the capability such future upgrades and expansion as scheduling preventative maintenance and controlling interior and exterior lighting systems.

4.3.1.2. The construction shall provide a temperature sensor for each HVAC thermal zone to communicate with the DDC system and maintain the required space conditions. Push-button occupant override capability shall only be provided in select areas specifically identified by the Installation. All sensor locations shall be coordinated with the space interior furnishings and placed in a manner to ensure precise and accurate readings.

4.3.1.3. The construction will provide monitoring of all major HVAC equipment.

4.3.1.4. Where control and instrumentation elements also must function as elements defined within another element group, the construction will meet the requirements of both element groups.

4.3.2. Design Documentation Requirements

4.3.2.1. Indicate occupancy types, with special HVAC requirements clearly identified.

4.3.2.2. Plans shall depict zoning, equipment locations, and air distribution.

4.3.3. Operation and Maintenance

4.3.3.1. The construction shall connect to and integrate with the existing Installation Energy Management Control System (EMCS), which is a Johnson Controls “Metasys” system, unless otherwise specified. Integration shall include, at minimum, the complete monitoring and control of the installed systems, as well as the ability the upload and download controller programs between the control systems.

4.3.3.2. The controls system shall have the capability for future expansion by a minimum of 20% more than the number of controls points required for the design.

4.3.3.3. The construction shall locate the field panels in mechanical rooms.

4.3.3.4. The construction shall locate the central controller in a mechanical room.

4.3.3.5. The construction will provide a system which has multiple layers of secured access to data and program information.

4.3.3.6. The construction will provide field panels which are independent and do not need the central controller to continue functioning.

4.3.3.7. All software and network tools shall be installed on the existing Base C/E workstations located in Building 709. Software install shall be validated at the project site with a Base C/E representative. Software provided shall be the same version used to configure DDC hardware. All passwords shall be provided to the Base C/E.

4.3.3.8. Programming of the new controls system for a facility, including labels, set points, graphics, schedulers, shall be accomplished in a manner consistent with the existing controls systems for ease of operation. Sample graphics and layouts shall be obtained from Base C/E.

4.3.4. System Requirements

4.3.4.1. BacNet open protocol shall be used for all network management including addressing and binding of network variables.

4.3.4.2. The building level systems shall have a stand-alone architecture where failure of a single controller shall not impact more than one system.

4.3.4.3. Control sequence logic shall reside in DDC hardware in the building. The building control network shall not be dependent upon connection to a Utility Monitoring and Control System (UMCS) for performance of control sequences in this Specification. The hardware shall, to the greatest extent practical, perform the sequences without reliance on the building network.

4.3.4.4. The hardware shall be installed such that individual control equipment can be replaced by similar control equipment from other equipment manufacturers with no loss of system functionality.

4.3.4.5. The hardware installed shall be readily available by the Air Force’s procurement methods.

4.3.4.6. The DDC web client server software shall be an open BacNet scalable enterprise software that can collect and manage data from building level BacNet networks and Legacy systems across multiple facilities, and shall communicate with the existing base EMCS.

4.3.4.7. The M&C software shall allow for graphical navigation between systems, graphical representations of systems, access to real-time data for systems, ability to override points in a system, access to all monitoring and control functions.

4.3.4.8. The DDC building level network interface (BPOC) shall have web services capabilities.

Building level network interface shall provide access to all data points.

4.3.4.9. The DDC system shall incorporate a labeled HVAC ventilation shutdown switch located in a common area served by the equipment.

5.0 APPENDIX – WATER TREATMENT PROCEDURES

5.1. DOMESTIC WATER SYSTEMS

After operational tests are complete, the entire domestic hot- and cold-water distribution system shall be disinfected. System shall be flushed, before introducing chlorinating material. The chlorinating material shall be hypochlorites or liquid chlorine. Water chlorination procedure shall be in accordance with AWWA M20. The chlorinating material shall be fed into the water piping system at a constant rate at a concentration of at least 50 parts per million. The chlorine residual shall be checked at intervals to ensure that the proper level is maintained. Chlorine application shall continue until the entire main is filled. The water shall remain in the system for a minimum of 24 hours. Each valve in the system being disinfected shall be opened and closed several times during the contact period to ensure its proper disinfection. Following the 24-hour period, no less than 25 ppm chlorine residual shall remain in the system. Water tanks shall be disinfected by the addition of chlorine directly to the filling water. Following a 6 hour period, no less than 50 ppm chlorine residual shall remain in the tank. If after the 24 hour and 6 hour holding periods, the residual solution contains less than 25 ppm and 50 ppm chlorine respectively, flush the piping and tank with potable water, and repeat the above procedures until the required residual chlorine levels are satisfied. The system including the tanks shall then be flushed with clean water until the residual chlorine level is reduced to less than one part per million. During the flushing period each valve and faucet shall be opened and closed several times. Samples of water in disinfected containers shall be obtained from several locations selected by the Contracting Officer. The samples of water shall be tested for total coliform organisms in accordance with AWWA EWW. Disinfection shall be repeated until tests indicate the absence of coliform organisms (zero mean coliform density per 100 milliliters) in the samples for at least 2 full days.

5.2. HYDRONIC CHILLED/HOT WATER SYSTEMS

5.2.1. Air and Dirt Separator Tanks

External air and dirt separation tank shall have an internal design suitable for creating the required vortex and subsequent air and dirt separation. Tank shall be steel, constructed, tested, and stamped in accordance with ASME BPVC SEC VIII D1 for a working pressure of 125 psig. Tank shall have tangential inlets and outlets connections, threaded for 50 mm 2 inches and smaller and flanged for sizes 2 1/2 inches and larger. Air released from a tank shall be to the atmosphere. Tank shall be provided with a blow-down connection. Sizing shall be provided by manufacturer, match system and be submitted for Government review/approval.

5.2.2. Water Treatment Systems

Water treatment is required. The use of chemical-treatment products containing hexavalent chromium (Cr) is prohibited.

5.2.3. Chilled and Condenser Water

Water to be used in the chilled water systems shall be treated to maintain the conditions recommended by this specification as well as the recommendations from the manufacturers of the condenser and evaporator coils. Chemicals shall meet all required federal, state, and local environmental regulations for the treatment of evaporator coils and direct discharge to the sanitary sewer.

5.2.4. Glycol Solution

A 35 percent concentration by volume of food grade propylene glycol shall be provided in the chilled water. The glycol shall be tested in accordance with ASTM D 1384 with less than 0.5 mils penetration per year for all system metals. The glycol shall contain corrosion inhibitors.

Silicate based inhibitors shall not be used. The solution shall be compatible with pump seals, other elements of the system, and water treatment chemicals used within the system.

5.2.5. Flushing

Isolate expansion tank from flushing. The Contractor shall flush the chilled water system in building to include dead/no flow points. The Contractor shall open all system water valves and flush, clean strainers and provide flexible hoses on fan coils and air handlers prior to flushing the closed system. The chemical treatment and services shall be provided over a 1 year period and shall meet the requirements of this specification as well as the recommendations from the manufacturers of the condenser and evaporator coils.

5.2.5.1. Pre-Cleaning Phase

5.2.5.1.1. While system is circulating, Contractor shall establish multiple points of water loss throughout (lowest, middle, highest) the closed system. It is critical water loss is established in the lower elevation of the closed system. Water loss streams should be established to maintain a minimum continuous positive flow.

5.2.5.1.2. Contractor shall pull strainers; blow out separators, dead-headed piping, low flow and/or isolated flows areas.

5.2.5.2. Cleaning Phase

5.2.5.2.1. While system is circulating, Contractor shall add the following products via pumping them into the system.

AC-6160 (or approved equal) – 1 gallon per 100 gallons of system volume AC-7112 (or approved equal) – 1 gallon per 1,000 gallons of system volume

5.2.5.2.2. Contractor shall circulate the cleaning solution for 72 hours.

5.2.5.3. Post-Cleaning Phase

5.2.5.3.1. Following the 72 hour cleaning phase, while system is circulating, Contractor shall establish multiple points of water loss throughout (lowest, middle, highest) the closed system. It is critical water loss is established in the lower elevation of the closed system. Water loss streams should be established to maintain a minimum continuous positive flow.

5.2.5.3.2. Contractor shall pull strainers; blow out separators, dead-headed piping, low flow and/or isolated flows.

5.2.5.3.3. After 48 hours of flushing, water cleanliness shall be measured. Targeted bulk water total iron level is less than 0.50 ppm.

5.2.5.3.4. Once the bulk water iron level has written confirmation to be less than 0.50 ppm, the Pre- Glycol Addition Phase will be initiated.

5.2.5.4. Pre-Glycol Addition Phase

5.2.5.4.1. Following completion of the Post-Cleaning Phase, a 10% by volume of inhibited propylene glycol should be added and circulated for 48 hours.

5.2.5.4.2. After 48 hours of circulating, water cleanliness shall be measured. Targeted bulk water total iron level is less than 0.50 ppm.

5.2.5.4.3. Once the bulk water iron level has been confirmed to be less than 0.50 ppm, the Glycol Addition Phase will be initiated.

5.2.5.4.4. After 48 hours of circulation, should iron levels rise above the 0.50 ppm targeted level, while system is circulating, multiple points of water loss should be established throughout (lowest, middle, highest) the closed system. It is critical water loss is established in the lower elevation of the closed system. Water loss streams should be established to maintain a minimum continuous positive flow. Strainers, separators, dead-headed piping, low flow and/or isolated flows must be blown out. After 48 hours of flushing, water cleanliness shall be measured. Targeted bulk water total iron level is less than 0.50 ppm.

5.2.5.4.5. Once the bulk water iron level has been confirmed to be less than 0.50 ppm, the Glycol Addition Phase will be initiated.

5.2.5.5. Glycol Addition Phase

Contractor shall add Glycol within 24 hours of the written confirmation. The targeted inhibited propylene glycol % by volume (minimum of 20% by volume) should be added to the closed system. If the targeted inhibited propylene glycol % by volume is below 30%, additional inhibitor is to be added to bring inhibitor level to the inhibitor level of a 30-35% by volume inhibited propylene glycol solution. Written analysis of the final inhibitor level must be provided to the customer for review and confirmation that the targeted DDP levels are within targeted range.

5.3. WARRANTY PERIOD

The Contractor shall maintain water treatment during the one year warrantee period and provide a report at the end of the one year verifying system treatment is acceptable. Each equipment shall be inspected for problems due to corrosion, scale, and biological growth. If the equipment is found not to conform to the manufacturers recommended conditions, and the water treatment company recommendations have been followed; the water treatment company shall provide all chemicals and labor for cleaning or repairing the equipment as required by the manufacturer's recommendations.