9 RFP AtcJ3d1_Spec15011.pdf

SECTION 15011

15011-1

ZNRE 19-1069

SECTION 15011 - MECHANICAL GENERAL REQUIREMENTS

1. PART 1 GENERAL:

1.1. SECTION INCLUDES:

A. This guide specification covers the mechanical general requirements for all sections of

Division 15, "Mechanical." This guide specification can be applied to other divisions of the project specifications.

1.2. REFERENCES:

A. The following specifications and standards listed below form a part of this specification.

1) Air-Conditioning and Refrigeration Institute (ARI).

2) American National Standard Institute (ANSI).

3) American Society of Heating, Refrigerating, and Air-Conditioning

Engineers, Inc. (ASHRAE) Standards.

4) American Society of Sanitary Engineering (ASSE).

5) Associated Air Balance Council (AABC).

6) Construction Code of Pressure Vessels (Japanese Labor Ministry).

7) Federal Specifications (FS).

8) Japanese Industrial Standards (JIS).

9) Japanese Refrigerating and Air Conditioning Association (JRA).

10) Japan Pipe Fittings Association (MP) Standards.

11) Japan Steel Water Pipe Association (WSP) Standards.

12) Japan Water Works Association (JWWA) Standards.

13) Japan Industrial Safety and Health Association (JISHA).

14) National Environmental Balancing Bureau (NEBB).

15) National association of Corrosion Engineers (NACE).

16) National Fire Protection Association (NFPA).

17) National Sanitation Foundation (NSF).

18) National Standard Plumbing Code.

19) Sheet Metal and Air Conditioning Contractors National Association (SMACNA).

20) Standard of Society of Heating, Air Conditioning and Sanitary Engineers of Japan

(HASS).

21) Unified Facilities Criteria (UFC)

22) Underwriters Laboratories, Inc. (UL).

23) International Organization for Standardization (ISO)

15011-2

ZNRE 19-1069

B. 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.

C. ASTM (American Society for Testing and Materials)/ASTM B 117

D. CFR (Code of Federal Regulations)/ 29 CFR 1910, Occupational Safety and Health

Standards

1.3. GENERAL:

A. The drawings indicate the general arrangement. The contractor shall carefully examine the drawings and shall be responsible for the proper fitting of materials as indicated, without substantial alteration.

B. Verification of Dimensions and Condition: The Contractor shall be responsible for the proper dimensional relationship of his work to the building structure and to that of other trades involved. The Contractor shall visit the premises to familiarize himself with all details of the work and to verify all existing dimensions and condition in the field. The Contractor shall inform the Contracting Officer of any discrepancies found before performing any work.

C. Coordination: The Contractor shall be responsible for coordinating the work of all trades working in the area. Coordinate work with work of other trades so that all components will be installed in the proper place at the proper time, avoiding conflicts between other trades and improper space for servicing. Components improperly installed shall be removed and relocated or reinstall correctly as directed by the contracting officer’s designated representative at no additional cost to the government.

D. Drawings: Drawings show the general arrangement of all components. The contractor shall carefully study the structural and finish conditions affecting all his work and shall arrange such work accordingly as may be required to meet such conditions.

E. Protection of Fixtures, Materials, and Equipment: Fixtures and equipment shall be tightly covered and protected against dirt, water, and chemical or mechanical injury. At the completion of the work, the fixtures, materials, and equipment shall be thoroughly cleaned, adjusted and operated.

F. Brand Names and Manufactures: Reference to specific brand name and models of equipment is for the purpose of establishing minimum quality standards, identification and guidance and is not intended to limit selection to other manufacturers that are equal or exceed the specified items in terms of physical properties, including finish, durability, appearance, performance, and other factors. Other products may be submitted for evaluation and approval/disapproval by the contracting officer.

G. The contractor shall have all new materials and equipment required to complete the mechanical work approved [for each phase] and at the project site prior to beginning any demolition work.

H. Prior to installation, changes in piping, ductwork or equipment location up to 5 feet shall be made by the contractor without additional compensation as directed by the contracting officer to allow for field conditions.

I. The contractor shall provide all necessary fittings and components to provide a complete and usable system. Route all piping and ductwork to minimize the number of bends and elbows.

15011-3

ZNRE 19-1069

J. The contractor shall route all new ductwork and piping and build all duct transitions and offsets to avoid all obstructions such as structural members, electrical conduit, and piping at no additional cost to the government.

K. All pipes shall be square with the building and all risers and drops plumb. Grades, offsets, and swings shall be done in the most economical manner. All necessary building equipment and maintenance clearances shall be maintained.

L. The contractor shall provide temporary heating if the outside air temperature falls bellow

60 degrees F and temporary cooling if the outside air temperature rises above 85 degrees F between demolition and installation of new HVAC systems which is the same or greater capacity of the existing one throughout the replacement work at no additional cost to the government.

1.4. MATERIALS AND EQUIPMENT:

A. Materials and equipment shall conform to the respective publications and other requirements specified below. Other materials and equipment shall be as specified elsewhere herein and as shown on the drawings. Capacities of all equipment and material shall be not less than indicated on the drawings. Material and equipment shall be the products of a manufacturer regularly engaged in the manufacture of the products. Where two or more units of the same class of equipment are required, these units shall be products of a single manufacturer;

however, the component parts of the system need not be the products of the same manufacturer.

Materials and equipment used for this project shall not contain any asbestos. Materials and equipment used for this (these) project(s) shall be compatible with existing materials and equipment where interface occurs.

1) Plumbing: Plumbing material used shall be "lead free". "Lead free" when used with respect to pipes and pipe fittings refers to pipes and pipe fittings containing not more than

8.0 percent lead. When used with respect to solders and flux it refers to solders and flux containing not more than 0.2 percent lead.

2) Manufacture Warranty: Items of mechanical equipment shall be essentially duplicate equipment 0.5 ton below split type air conditioners, except three (3)-year warranty equipment that have been in satisfactory use for at least 2 years. A three (3)-year warranty shall be provided for equipment, split single package air conditioners, fan coil units, pumps, chillers, air handling units and heat generators. A five (5)-year warranty shall be provided for bathtub and apron refinishment materials and construction. Each warranty shall be provided by equipment manufacture or regular distributor. Any equipment warranty written by the Contractor shall not be acknowledged. [However, if neither equipment manufacture nor regular distributor can not provide any warranty owning to

Government required modification of the equipment, minimum (1)-year Contractor provided warranty will be acknowledged.]

3) Manufacture Equipment: HVAC equipment shall be recommended, registered and authorized by Japanese Public Architecture Construction Association.

4) Painting: All equipment shall be factory painted by manufacture. Outdoor installed equipment shall be painted in color #207(U19-80F) [09-30D on roof only Fed. Spec.

10219] of the Japan Paint Industrial Association(JPIA). Exposed interior installed equipment (include ceiling diffuse, register, grille, damper, access door, panel, metal casing and cabinet, etc.) shall be painted adjacent wall and/or ceiling color, if required color is not indicated. Concealed area, attic space or mechanical room installed equipment may be painted manufacture standard color. Non-metal parts may not be painted. Field

15011-4

ZNRE 19-1069

painting for the equipment shall not be approved. If required color is not manufacture standard color, equipment shall be painted in original method (in principle, baking finish for metal surface).

1.5. APPLICATION:

A. Apply this guide specification to other divisions of the project specification as required;

delete the Divisions which are not appropriate, and change punctuation if necessary. Be sure that the appropriate section which has mechanical equipment has the following paragraph:

B. "1.3 GENERAL: Section 15011, "Mechanical General Requirements" applies to this section, with the additions and modifications specified herein.”

C. This section applies to [certain sections of Division 1, "General Requirements"; and] all sections of Division 15, "Mechanical" of this specification, including modifications and additions specified in each individual section.

D. The contractor shall be prepared and provided Qualification of Mechanical General

(Drawing and Construction Control) in each Construction projects for approved submittals.

1.6. POSTED OPERATING INSTRUCTIONS:

A. Furnish approved operating instructions for each principal item of equipment as specified in each individual section for the use of the operation and maintenance personnel. The operating instructions shall include wiring diagrams, control diagrams, and control sequence for each principal item of equipment. Operating instructions shall be printed or engraved, and shall be framed under glass or in approved laminated plastic and posted where directed. Operating instructions shall be attached to or posted adjacent to each principal item of equipment and include directions for start up, proper adjustment, operating, lubrication, shutdown, safety precautions, procedure in the event of equipment failure, and other areas as recommended by the manufacturer of each item of equipment. Operating instructions exposed to the weather shall be made of weatherproof materials or shall be suitably enclosed to be weather protected.

Operating instructions shall not fade when exposed to sunlight and shall be secured to prevent easy removal or peeling.

1.7. INSTRUCTION TO GOVERNMENT PERSONNEL:

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

Instruction shall be given during the first regular work week after the equipment or system has been accepted and turned over to the Government for regular operation. Instruction with the each equipment and other system on the job training shall be held a minimum 2 times as necessary operating and maintenance shops and number of man-days (7 hours) of instruction furnished shall be as specified in other section. When more than 4 man-days of instruction are specified, approximately half of the time shall be used for classroom instruction. All other time shall be used for instruction with the equipment or system. When significant changes or modifications in the equipment or system are made under the term of the contract, additional instruction shall be provided to acquaint the operating personnel with the changes or modifications.

15011-5

ZNRE 19-1069

1.8. DELIVERY AND STORAGE:

A. Equipment and materials shall be handled, stored, and protected to prevent damage before and during installation in accordance with the manufacturer's recommendations, and as approved by the Contracting Officer. Damaged or defective items shall be replaced.

1.9. STANDARD PRODUCTS/SERVICE AVAILABILITY:

A. Materials and Equipment: Materials and equipment shall be standard products of a manufacturer regularly engaged in the manufacture of such products, which are of a similar material, design and workmanship. The standard products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year use shall include applications of equipment and materials under similar circumstances and of similar size.

B. Experience Required: The 2-year experience must be satisfactorily completed by a product which has been sold or is offered for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures.

C. Alternative Service Record: Products having less than a 2-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturer's factory or laboratory tests, can be shown.

D. Service Support: The equipment items shall be supported by service organizations. The

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

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

1.10. SAFETY REQUIREMENTS:

A. Equipment Safety:

1) The designer should show on the drawings the details and locations of catwalks, ladders, and guard rails.

2) Belts, pulleys, chains, gears, couplings, projecting setscrews, keys, rotating parts, and other power transmission apparatus, located so that any person can come in close proximity thereto, shall be fully enclosed or properly guarded in accordance with 29 CFR

1910, Part 219, "Mechanical Power-Transmission Apparatus." Points of operation, ingoing nip points, and machinery producing flying chips and sparks shall be guarded in accordance with the applicable portions of 29 CFR 1910, Subpart O, "Machinery and

Machine Guarding." Provide positive means of locking out equipment so that it cannot be accidentally started during maintenance procedures. High-temperature equipment and piping so located as to endanger personnel or create a fire hazard shall be properly guarded or covered with insulation of a type as specified. Catwalks, maintenance platforms, and guardrails shall be provided where required for safe operation and maintenance of equipment. Provide ladders or stairways to reach catwalks and maintenance platforms.

Ensure that access openings leading to equipment are large enough to carry through routine maintenance items such as filters and tools.

15011-6

ZNRE 19-1069

B. Warning Sign: Provide a permanent placard or other sign at the entrance to all confined spaces contained in the equipment. The sign shall warn personnel not to enter the space until the atmosphere inside has been tested and all systems have been deenergized.

1.11. ELECTRICAL REQUIREMENTS:

A. Electrical components of mechanical equipment and systems such as motors, starters, and controls shall be provided under this Division and shall be as specified herein and as necessary for complete and operable systems. Extended voltage range motors will not be permitted.

Interconnecting wiring for components of packaged equipment shall be provided as an integral part of the equipment. All interconnecting power wiring and conduit for field erected equipment and all control wiring and conduit shall be as specified in Division 16. Motor control equipment forming part of motor control centers or switchgear assemblies and all necessary conduit and wiring connecting such assemblies, centers, or other power sources to mechanical equipment shall conform to Division 16.

2. PART 2 PRODUCTS: ( Not used )

3. PART 3 EXECUTION:

3.1. FACTORY PAINTING AND PLATING:

A. Factory applied painting plating of equipment shall be as specified herein, and provided under each individual section.

B. Factory Painting and Plating System: Manufacturer's standard factory painting and plating systems may be provided subject to certification that the factory painting and plating system applied will withstand 125 hours in a salt-spray fog test, except that equipment located outdoors shall withstand 500 hours, and air conditioning equipment shall withstand 960 hours in a salt spray fog test. Salt spray fog test shall be in accordance with ASTM B-117, JRA 9002, JIS K-

5400 and JIS Z-2371. Immediately after completion of the test, the paint shall show no signs of blistering, wrinkling or cracking; and no loss of adhesion; and the specimen shall show no signs of rust creepage beyond 0.125 inch on either side of the scratch mark. The film thickness of the factory painting system applied on the equipment shall not be less than the film thickness used on the test specimen. If manufacturer's standard factory painting and plating system are being proposed for use in lieu of the shop painting and plating systems, certifications that the manufacturer's standard factory painting system conforms to the heat resistance requirement shall be submitted in addition to other certifications.

C. Field Painting: Field painting is not permitted.

3.2. FUNCTIONAL TEST:

A. General: The contractor shall submit his proposed testing program at least one week prior to the scheduled test to assure agreement as to personnel and instrumentation required and scope of testing program. Testing, adjusting and balancing of HVAC (Heating, Ventilating and

Air Conditioning) systems shall be in accordance with the applicable provisions of AABC-02, NEBB-01 or SMANCA-07. All tests shall be conducted in the presence of the Contracting

Officer or his authorized representative (Construction Inspector) who shall be given 2 days notice before any test is to be conducted. The contractor provide his notice in writing two days before testing. Water and electricity required for the tests will be furnished by the government.

Any material, equipment, instruments, and personnel required for the tests shall be provided by

15011-7

ZNRE 19-1069

the contractor. Test instruments proposed to be used shall be brought to the job site at least 3 days prior to the scheduled tests to allow for inspection and approval.

B. Tests for Pressurized Piping: Except as otherwise specified below, piping shall be tested hydrostatically and proved tight at a pressure not less than l-l/2 times the maximum operating pressure of the system for a period of time sufficient to inspect every joint in the system and in no case less than 2 hours. No loss of pressure will be permitted. Leaks detected shall be repaired by tightening, rewelding joints, or replacing pipe or fittings. Calking of joints will not be permitted. Concealed and insulated piping shall be tested in place before covering or concealing. Tests shall be conducted in the presence of the Contracting Officer or his representative who shall be given a notice of 2 days before any test is to be conducted. Any material, equipment, or instruments required for conducting tests shall be provided by the

Contractor.

1) Water Piping: The piping system shall be tested hydrostatically, before insulation is applied where possible, and shall be proved tight under test pressure 7.5 Kg/cm2 (107 psig).

2) Refrigerant Piping: The system shall be tested for tightness after installation and before insulation is applied. Controls and other equipment that may be damaged by the test pressure employed shall be temporarily removed or made inoperative before the tests are made and the openings shall be plugged or capped. Threaded, soldered, or brazed joints that leak shall be corrected by having the joints remade. Welded joints that leak shall be repaired by cutting out the faulty weld affected section and rewelding the joint or renewing the section of pipe.

a) Test Pressures: Refrigerant system test pressures for tightness shall not be less than recommended by the manufacturer or approved by the Contracting Officer.

b) Charging the System for Test: The low and high pressure sides of the system shall be charged with a dry, inert gas, such as nitrogen (N2) or anhydrous carbon dioxide (CO2) using a small amount of the refrigerant gas to act as a tracer. A pressure limiting or reducing valve with pressure gage shall be used on the high pressure gas tank to limit the pressure in the system to the specified test pressure for the respective refrigerant.

c) Leakage Test: With the system charged to the desired pressure, the gas supply shall be tightly shut off and system held for 30 minutes, during which time there shall be no loss of pressure. If a pressure drop, not attributable to temperature changes, occurs during this period the entire system shall be checked with a halide torch or an electronic leak detector. When leaks are found they shall be repaired and another 30 minute period at the test pressure shall be made. Testing and repair shall continue until there is no loss of pressure. The loss of refrigerant during the first season of operation shall be guaranteed not to exceed l0 percent of the system, and all refrigerant required shall be furnished if the loss is the result of defective equipment or installation.

d) Evacuation, Dehydration, and Charging: After the system is found to be without leaks, evacuate the system using a reliable gage and a vacuum pump capable of pulling a vacuum of at least 1 mm Hg absolute. Evacuate the system in strict accordance with the triple evacuation and blotter method or in strict accordance with equipment manufacturer's printed instructions. System leak testing, evacuation, dehydration, and charging with refrigerant shall comply with the requirements contained in High Pressure Gas Control Law, HASS 010 or manufacturer's standards.

15011-8

ZNRE 19-1069

C. Tests for Nonpressurized Piping. Waste and other nonpressurized piping to be tested by the contractor shall be as follows:

1) Drainage and Vent Piping. Water test shall be applied to the drainage and venting system either in its entirety or in sections. If the entire system is tested, all openings in the pipes shall be tightly closed except the highest opening, and the system shall be filled with water to the point of overflow. If the system is tested in sections, each opening except the highest opening of the section under test shall be tightly plugged, and each section shall be filled with water and tested with at least a 3,050-mm (l0-foot) head of water. In testing successive sections, each section shall be tested so that each joint or pipe in the building, except the uppermost l0 feet of the system, has been subjected to a test of at least a 3,050-mm (l0-foot) head of water. The water shall be kept in the system, or in the portion under test, for at least l5 minutes before the inspection starts; the system shall then be tight at all joints.

D. Tests for Air Moving System: The fan shall be balanced to produce the indicated air quantities at the conditions shown. Control devices shall be set to control at the points indicated or directed. Bearings shall be lubricated, and the speed and direction of rotation of each fan shall be checked. The running current of each motor shall be checked.

E. Tests for Equipment: All equipment shall be tested to demonstrate its capacity & characteristics in accordance with standards and/or manufacturer's instructions.

3.3. OPERATIONAL TEST:

A. After installation work has been completed, and as designated by the Contracting Officer and/or Construction Inspector, general operating tests on the entire system shall be conducted by a competent and experienced engineer in accordance with manufacturer's instructions and specifications. Tests shall demonstrate specified capacity and rating of the units. The general operating test shall cover a period of 4 hours, except the test for air conditioning system, hot water boiler generator and shall demonstrate that the whole system is functioning in accordance with the designated design condition. The contractor shall furnish all testing equipment and personnel required for the tests. The Government will furnish the necessary electricity and water. The contractor shall furnish three copies of records and testing data. Setting and function of all automatic controls shall be marked at each respective control. The test report shall include the following information with conclusion as to the adequacy of the system, and signature of Construction Inspector witness.The test for the air conditioning system [and hot water boiler generator system] shall demonstrate change cooling and heating (each test 2 times).

1) Time, date, and duration of test.

2) General

a) Pump suction and discharge pressures.

b) Fans:

1. Specified air quantity and static pressures.

2. Installed motor rating.

3) Plumbing

a) Water pressures at the most remote and the highest fixtures.

b) Operation of each fixture and fixture trim.

15011-9

ZNRE 19-1069

c) Operation of each valve, hydrant, and faucet.

d) Temperature of each domestic hot water supply.

e) Operation of each floor and roof drain by flooding with water.

4) Ducting

a) Air outlets and inlets to be measured: Size, velocity in mps (fpm) and air quantity in cmh (cfm).

b) Main air ducts to be measured: Size, velocity in mps (fpm) and air quantity in cmh (cfm).

c) Outlets & Inlets.

1. Specified size and air quantity.

2. Installed size.

3. Measured air velocity.

4. Computed air quantity.

5) Air conditioner: Air conditioner capacity including size and type of unit, air quantity, all fan and compressor motors rpm and horsepower. Contractor shall provide report for follow item. Each data shall be sampled in summer and winter, from 0800 to 1600, every one hour, total 7 calendar days for each season.

a) System inlet and outlet wetbulb and drybulb degrees C and F.

b) Condensing temperature degrees C and F.

c) Individual room temperature [wetbulb and drybulb] degrees C and F.

d) Outside air temperature [wetbulb and drybulb] degrees C and F.

6) Automatic Controls: Tabulated list indicating type of control, location, setting, and function.

7) Air conditioning system: The load test of cooling & heating for 4 days (2times).

8) Hot water boiler system: The operation test of heating & domestic for 4 days (2 times).

3.4. OPERATING AND MAINTENANCE INSTRUCTIONS:

A. Seven complete sets of instructions containing the manufacturer's operating and maintenance instructions for each piece of equipment shall be furnished to the Contracting

Officer. Each set shall be permanently bound and shall have a hard cover. One complete set shall be furnished at the time the test procedure is submitted, and the remaining sets shall be furnished before the contract is completed. The following identification shall be inscribed on the covers: The words "OPERATING AND MAINTENANCE INSTRUCTIONS," the name and location of the building, the name of the contractor and the contract number. The instruction sheets shall be approximately 215 x 280-mm (8-l/2 by 11 inches), with large sheets of drawings folded in. The instructions shall include, but shall not be limited to, the following:

1) System layout showing piping, valves, ducting, dampers and controls.

2) Approved wiring and control diagrams, with data to explain the detailed operation and control of each component.

15011-10

ZNRE 19-1069

3) A control sequence describing start up, operation and shutdown.

4) Operating and maintenance instructions for each piece of equipment, including lubrication instructions.

5) Manufacturer's bulletins, cuts and descriptive data.

6) Parts lists and recommended spare parts.

B. The operation and maintenance instructions shall be bound in book form within the

Japanese and English language. Heating, Ventilating and Air Conditioning (HVAC) field training or on the job training (OJT) of the summer and winter season shall be provided to designated operating staff members who concerned shops and maintenance engineers after the system is functionally completed but prior to final acceptance tests. The field training shall cover all of the items contained in the bound Operating and Maintenance Instructions. Framed instructions in laminated plastic, including wiring, pump, and timer control diagram, equipment, control tags, system layout, and condensed operating instructions shall be posted where directed.

3.5. JOB SITE CLEANING:

A. Cloths, cotton waste and other debris that might constitute a fire hazard shall be placed in closed metal containers and removed at the end of each day. Upon completion of the work, staging, scaffolding, and containers shall be removed from the site or destroyed in an approved manner. Paint and other deposits on adjacent surfaces shall be removed and the entire job left clean and acceptable. Paint and thinner wastes shall be properly disposed in accordance with all applicable Japanese laws.

3.6. DEFECTIVE WORK:

A. If inspection or test shows defects, such defective work or material shall be replaced at

Contractor's expense and inspection and tests shall be repeated. Repairs to piping shall be made with new material. No calking of screwed joints or holes will be acceptable.

-- End of Section --