33_63_15_-_Hydronic_Distribution.pdf

United States Air Force Academy Repair HTHW Phase 1/4

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(PREFABRICATED CONDUIT PIPING SYSTEM)

(12145-3)

SECTION 33 63 15 – HYDRONIC DISTRIBUTION (PREFABRICATED CONDUIT PIPING SYSTEM)

GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes piping for High Temperature Hot Water (HTHW) distribution systems outside of buildings. Piping includes pipes, fittings, insulation, and specialties for the following:

1. Manufactured, preinsulated, pre-fabricated conduit piping systems.

B. Related Sections include the following:

1. Division 2 Sections for paving requirements used road surfacing.

2. Division 3 Section "Cast-in-Place Concrete" for concrete requirements and block anchors used in conduit systems.

3. Division 23 Section "Hydronic Piping" for hydronic piping systems inside buildings, tunnels, and vaults.

4. Division 31 Section "Earthwork" for excavation, backfill, and related items for structures.

1.3 DEFINITIONS

A. Thermal Conductivity and Apparent Thermal Conductivity (k-Value): As defined in ASTM C 168. In this Section, these values are the result of the formula Btu x in./hr x sq. ft. x deg F or W/m x K at the temperature differences specified. Values are expressed as Btu or W.

B. Carrier Pipe: Hydronic service pipe used to carry fluid media such as water for the purpose of hydronic heat distribution.

C. Inner Conduit: Metal casing material used to contain service piping leaks and maintain carrier pipe insulation system. Inner conduit also contains pipe support and expansion spacing.

D. Outer Jacket: Non-metallic jacket used to contain insulation layer applied to the exterior surface of the inner metal conduit system.

1.4 SUBMITTALS

A. Product Data: Include carrier piping, conduit and jacket insulation type and k-value, inner conduit, outer jacket, end seals, and major components for each conduit piping system.

B. Shop Drawings: Detail fabrication of anchors, alignment guides, supports, end seals, gland seals, and expansion loops.

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C. Calculations: Provide and submit pipe stress calculations showing stresses on piping and forces on anchors. Provide and submit anchor sizing, reinforcement and installation details.

D. Installer Certificates: Welders' certificates for welding processes and operators.

E. Field Test Reports: Indicate and interpret test results for compliance with performance requirements.

F. Warranties: Special warranties specified in this Section.

1.5 QUALITY ASSURANCE

A. ASME Compliance: Qualify welding processes and operators according to the ASME Boiler and Pressure Vessel Code: Section IX, "Welding and Brazing Qualifications."

B. ASME Compliance: Comply with ASME B31.1, "Power Piping," for materials, products, and installation.

1.6 WARRANTY

A. General Warranty: The special warranty specified in this Article shall not deprive the Owner of other rights the Owner may have under other provisions of the Contract Documents and shall be in addition to, and run concurrent with, other warranties made by the Contractor under requirements of the Contract Documents.

B. Special Warranty: Submit a written warranty, executed by Contractor, to repair dry, testable, conduit systems and replace components damaged by failure.

1. Warranty Period: Manufacturer's standard, but not less than five years from date of Substantial Completion.

PRODUCTS

1.7 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

1. Prefabricated Conduit Piping Systems:

a. Perma-Pipe, Inc. (Multi-Therm 500)

b. Thermacor Process, Inc. (Duo-Therm “505”)

2. Joint Closures & Watershed Wrap:

a. Raychem

b. Canusa

3. Mineral Wool Insulation

a. Mineral Products of Texas, Inc.

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1.8 PIPES

A. General: Applications of the following pipe materials are indicated in schedules at the end of Part 3. All pipe and fittings shall be domestic pipe and fittings manufactured in the United States.

B. Steel Carrier Pipe, 2-Inch NPS and Smaller: ASTM A 53 or A106; Type S, seamless; Grade B;

Schedule 80 and plain ends.

C. Steel Carrier Pipe, 2-1/2- to 10-Inch NPS: ASTM A 53 or A106; Type S; Grade B; Schedule 40 and plain ends.

1.9 PIPE FITTINGS

A. General: Applications of the following fitting materials are indicated in schedules at the end of Part 3. All pipe and fittings shall be domestic pipe and fittings manufactured in the United States.

B. Steel Welding Fittings: ASTM A 234 (Buttweld), seamless.

1.10 CONDUIT PIPING SYSTEMS

A. Description: Factory-fabricated and -assembled, airtight and watertight, drainable, pressure-tested piping system including steel inner conduit with outer insulation and jacket, carrier pipe supports, and insulated carrier piping. Fabricate so insulation can be dried in place by forcing dry air through conduit. Factory-fabricated system shall be designed to maintain steel conduit temperature below 250°F rating of polyurethane foam insulation and outer jacket system.

B. Design Criteria:

1. Maximum Temperature: 425 °F.

2. Maximum Pressure: 450 psig.

3. Minimum Temperature: 50 °F.

4. Average Soil Temperature: 50 °F.

5. Burial Depth: 48 - 52 inches.

6. Soil Conductivity Factor: 12 BTU-in/sq ft-hr-°F

C. Piping System Material Options: Carrier pipe materials are specified above, carrier pipe insulation materials are specified below, and their system applications and joining methods are specified in Piping System Schedule at the end of Part 3.

D. Clearance between Carrier Pipe Insulation and Conduit: 1 inch.

E. Inner Conduit: Steel, welded smooth wall, minimum 10 gauge thick. Oversized casing shall be provided to allow for carrier pipe expansion. Changes in casing size shall be accomplished by eccentric and/or concentric fittings and shall provide for continuous drainage.

F. Conduit Insulation: Conduit insulation shall be a spray applied polyurethane foam having a nominal 2 pound per cubic foot density for all straight lengths and fittings. The insulation thickness shall be minimum 1 inch. Fabricator shall provide quality assurance certification of procedures for verifying insulation application process by either a visual, and an infrared or X-ray examination of the entire component length to assure that no insulation voids exist.

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Urethane foam shall meet ASTM C591 and have the minimum characteristics of 0.14 K-factor, density of 2 pcf and a closed cell content of greater than 90 percent.

G. Outer Jacket: Outer jacket shall consist of one of the following:

1. Extruded, black high-density polyethylene, minimum 0.125” thick for jacket sizes less than 12” in diameter, 0.15” thick for jacket sizes 12” to 24” in diameter and 0.175 inch thick for jacket sizes greater than 24” in diameter. The casing shall incorporate electric fusion, butt fusion, or extrusion welding at all fittings, joint closures, or other points of connection. This shall create a casing that is seamless throughout the entire system with the exception of anchors whose watershed rings are sealed with a watershed wrap prohibiting the ingress of water. Jacket accessories shall include the following:

a. Joint Closure Kits: Mineral wool insulation for carrier pipe, conduit sleeve for conduit, half-shell, pourable or split insulation for conduit, with a high-density polyethylene pressure testable joint closure for outer jacket. All joint closures shall occur at straight sections of pipe.

b. Conduit Insulation End Seals: Manufacturers standard high temperature mastic, factory applied to all ends of a pipe length and field applied to field cut sections of pipe. End seals shall completely seal the exposed ends of the insulation to seal watertight around casing and carrier pipe. End seals shall be certified as having passed a 20 foot head pressure test.

c. Jacket/Conduit Insulation End Sleeves: Corrosion coated 8 inch long cup shaped steel sleeve with 4” wide high temperature shrink sleeve to protect the HDPE jacket/foam insulation from being deformed by link-seals where the conduit system penetrates valve vault and building walls.

H. Conduit Piping Supports: All piping within the inner casing (steel conduit) shall be supported at not more than 10 foot intervals. Supports shall be designed to allow continuous airflow and drainage of the conduit in place. The straight supports shall be designed to occupy not more than 10 percent of the annular air space. Supports shall be of the type where insulation thermally isolates the carrier pipe from the outer conduit. The surface of the insulation shall be protected at the support by a sleeve not less than 12 inches long, fitted with traverse and, where required, rotational arresters.

I. Anchors: Anchors shall consist of an anchor plate and water shed ring fabricated of ASTM A36 steel plate. Anchors plates shall be a minimum 1/2” thick steel plates, welded on both sides to the carrier pipe and conduit. Anchors shall be equipped with drain and vent openings inside conduit. Anchors shall incorporate a 3” wide steel water shed ring seal welded to the anchor plate and sized to allow the jacket to slide underneath. Water shed ring shall be sealed to the HDPE jacket using a heat shrink wrap. Anchor plates shall be corrosion coated with a high temperature mastic material after the watershed rings have been sealed with heat shrink wrap.

J. Fittings: Factory-fabricated fittings and tees.

K. Expansion Loops: Size casing to contain piping expansion.

L. Pressure Test of Inner (Steel) Conduit: Factory test to 15 psig (105 kPa) for four hours using soap solution. Furnish test certificates.

M. Conduit accessories include the following:

1. Guides: Steel plate welded to pipe sleeves and to casing, complete with vent and drainage openings inside casing.

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2. End Seals: Steel plate welded to carrier pipes and to casing, complete with drain and vent openings on vertical centerline. Terminate minimum 6 inches inside wall penetration; unless otherwise indicated.

3. Gland Seals: Packed stuffing box and gland follower mounted on steel plate, welded to end of casing, permitting axial movement of carrier piping, with drain and vent connections on vertical centerline. Terminate minimum 6 inches inside wall penetration;

unless otherwise indicated.

4. Leak Plates: Steel-plate flange, 4 inches (100 mm) larger than casing and welded to casing only.

5. Drain and Vent Connections: Provide threaded drain port on conduit system drain port with valved galvanized outlet pipe and fittings and threaded end cap same size as drain port. Provide galvanized vent piping extended from conduit system vent port to underside of top of the valve vault. Inside building entrances, extend vent piping minimum of 12 inches above conduit. Vent piping shall terminate with goose neck configuration with outlet turned down and as indicated.

1.11 FACTORY-APPLIED PIPE INSULATION

A. General: Applications of the following insulation materials are indicated in schedules at end of Part 3.

B. Terms used in this Article are defined in ASTM C 168.

C. Carrier Pipe Insulation: ASTM C 547, Type I, Felted mineral wool bonded together with a high temperature binder. Mineral wool insulation shall incorporate a water repellant additive.

Insulation shall have passed the Federal Agency Committee on Underground Heat Distribution Systems 96 hour boiling test.

1. Apparent Thermal Conductivity (k-Value): 0.26 at 75 deg F (0.037 at 24 deg C) mean temperature.

2. Density: Maximum 10-lb/cu. ft. (160-kg/cu. m) average.

3. Maximum Temperature Use: 1,200°F.

4. Thickness: 2” (50mm) thick for 2” piping, 3-1/2” (89mm) for 8” piping.

D. Conduit Pipe Insulation: ASTM C 591, preformed, rigid, cellular, polyurethane plastic.

Insulation for conduit system may be foamed in place.

1. Thermal Conductivity (k-Value): 0.14 at 75 deg F (0.020 at 24 deg C).

2. Service Temperature: Minus 250 to 250 deg F (Minus 156 to 121 deg C).

3. Moisture Absorption: ASTM D 2842, maximum 0.054 percent by volume.

4. Water-Vapor Transmission: ASTM E 96, 1.26 perm inches (1.83 ng/Pa x s x m).

5. Thickness: 1 inch (25mm).

1.12 FIELD-APPLIED PIPE INSULATION

A. General: Applications of the following insulation materials are indicated in schedules at end of Part 3.

B. Terms used in this Article are defined in ASTM C 168.

C. Carrier Pipe Insulation: ASTM C 547, Type I, Felted mineral wool bonded together with a high temperature binder. Mineral wool insulation shall incorporate a water repellant additive.

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Insulation shall have passed the Federal Agency Committee on Underground Heat Distribution Systems 96 hour boiling test.

1. Apparent Thermal Conductivity (k-Value): 0.26 at 75 deg F (0.037 at 24 deg C) mean temperature.

2. Density: Maximum 10-lb/cu. ft. (160-kg/cu. m) average.

3. Maximum Temperature Use: 1,200°F.

4. Thickness: 3 inches (75 mm).

5. Securing Wire: 0.062-inch- (1.6-mm-) diameter, soft-annealed, stainless-steel wire.

6. Bands: ASTM A 666, Type 304, stainless steel, 3/4 inch (19 mm) wide, 0.020 inch (0.5

mm) thick.

D. Conduit Pipe Insulation: ASTM C 591, preformed, rigid, cellular, polyurethane plastic.

Insulation for conduit system may be foamed in place.

1. Thermal Conductivity (k-Value): 0.14 at 75 deg F (0.020 at 24 deg C).

2. Service Temperature: Minus 250 to 250 deg F (Minus 156 to 121 deg C).

3. Moisture Absorption: ASTM D 2842, maximum 0.054 percent by volume.

4. Water-Vapor Transmission: ASTM E 96, 1.26 perm inches (1.83 ng/Pa x s x m).

5. Thickness: 1 inch (25 mm).

1.13 JOINING MATERIALS

A. General: Applications of the following piping joining materials are indicated in schedules at the end of Part 3.

B. Welding Materials: Comply with the ASME Boiler and Pressure Vessel Code: Section II, Part C, for materials appropriate for pipe being welded.

C. Transition Couplings: Coupling or other manufactured fitting same size as, with pressure rating at least equal to, and with ends compatible with piping to be joined.

EXECUTION

1.14 TRENCHING AND BACKFILLING

A. Refer to Division 31 Section "Earthwork" for excavating, trenching, and backfilling for underground piping.

1.15 JOINT CONSTRUCTION

A. Follow pre-fabricated piping system manufacturer's written instructions.

1.16 PIPING INSTALLATION

A. General Locations and Arrangements: Drawings indicate general location and arrangement of piping systems. Indicated locations and arrangements were used to size pipe and other design considerations. Install piping as indicated, unless deviations to layout are approved on Coordination Drawings.

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B. Install components with pressure rating equal to or greater than system operating pressure.

C. Install piping free of sags and bends.

D. Install fittings for changes in direction and branch connections.

E. Install couplings according to manufacturer's written instructions.

F. Refer to Division 23 Section "Basic Mechanical Materials and Methods" for sleeves and mechanical sleeve seals through exterior building walls.

G. Install pipe anchors to prevent stresses from exceeding those permitted by ASME B31.1 to prevent transfer of loading and stresses to connected equipment.

1. Fabricate and install anchors by welding steel shapes, plates, and bars to piping and to structure. Comply with ASME B31.1 and AWS D1.1.

1.17 PRE-FABRICATED DIRECT-BURY CONDUIT SYSTEM INSTALLATION

A. Final Elevations: The conduit system shall slope continuously and drain toward drip locations at valve vaults, tunnels or mechanical rooms in buildings. The Contractor shall construct the system at the elevation shown on the drawings and shall replace existing grades to match the existing unless otherwise noted.

B. Coordination with Existing Utilities: Before beginning work in a given area, all utility information shall be field verified by surface markings made by the affected utility representative. The actual routing may be offset or changed if approved by the Owner/Engineer in order to reduce conflicts, interruptions, expedite the work, or for any other reason to the mutual benefit of the Contractor and the Owner.

C. Pipe Expansion: Expansion shall be accommodated by expansion loops, elbows, and Z-bends as indicated. Pre-fabricated direct-buried piping shall be constructed in accordance with the manufacturer's requirements.

D. Pipe Anchors: Pipe anchors shall be as indicated on the drawings and in accordance with the pre-fabricated pipe manufacturer's requirements.

1.18 IDENTIFICATION INSTALLATION

A. Install continuous plastic underground detectable warning tapes during back-filling of trenches for underground distribution piping. Locate 6 to 8 inches below finished grade, directly over piping. Refer to Division 23 Section “Basic Mechanical Materials and Methods” for detectable warning-tape materials and devices and their installation.

1.19 FIELD QUALITY CONTROL

A. Prepare hydronic carrier piping for testing according to ASME B31.1 and as follows:

1. Leave joints, including welds, uninsulated and exposed for examination during test.

2. Isolate equipment. Do not subject equipment to test pressure.

3. Install relief valve set at pressure not more than one-third higher than test pressure.

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B. Test hydronic carrier piping as follows:

1. General: Tests shall be conducted before, during, and after the installation of the system.

All instruments, equipment, facilities, and labor required to properly conduct the tests shall be provided by the Contractor. Test pressure gauges for a specific test shall be approved by the Engineer and shall have dials indicating not less than one and one-half (1-1/2) times nor more than three (3) times the test pressure.

2. Cleaning of Piping: Prior to the hydrostatic and operating tests, the interior of the piping shall be flushed with clean water until the piping is free of all foreign materials. Flushing and cleaning out of system pipe, equipment, and components shall not be considered completed until witnessed and accepted by the Owner's Representative. After flushing the system is completed, the system shall be drained and filled with clean water.

Temporary bypasses or temporary strainers shall be provided around equipment and control valves to prevent clogging.

3. Field Tests: The following field tests shall be conducted when applicable to the system involved. If any failures occur, the Contractor shall make such adjustments or replacements as the Owner's Representative may direct, and the tests shall be repeated until satisfactory tests are completed.

a. Hydrostatic Tests of Service Piping: Service piping shall be tested hydrostatically before insulation is applied at field joints, and shall be proved tight at a pressure of 600 psig. Hydrostatic test pressure shall not exceed 650 psig. Hydrostatic test pressures shall be held for a minimum of four (4) hours. If the hydrostatic test pressure cannot be held, the Contractor shall make such adjustments or replacements and the tests repeated until satisfactory results are achieved. Use ambient temperature water. When there is a risk of freezing, air or compatible liquid may be used.

b. Equipment Tests: All valves and any other operable item of equipment shall be operated to verify proper operation and compliance with the specifications. Isolate equipment not rated for pipe test pressure.

c. Operational Tests: After installation of the prefabricated conduit system, or testable portion thereof, operational tests shall be conducted. Operational tests shall consist of operating the system at the pressure and temperature expected for the system when in normal service, and shall demonstrate satisfactory operating effectiveness. The test on each system, or portion thereof, shall last a minimum of 24 hours.

4. Use ambient temperature water.

5. Use vents installed at high points to release trapped air while filling system. Use drains installed at low points for complete removal of liquid.

6. After hydrostatic test pressure has been applied for 10 minutes, examine piping, joints, and connections for leakage. Eliminate leaks by tightening, repairing, or replacing components as appropriate, and repeat hydrostatic test until there are no leaks.

7. Prepare a written report of testing.

C. Test conduit as follows:

1. The conduit shall be air tested at 15 PSIG. Test pressure shall be held for two hours.

Repair any conduit leaks and retest prior to making joint closures.

1.20 COMMISSIONING

A. Open valves to fully open position.

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1.21 PIPING SYSTEM SCHEDULE

A. High Temperature Hot Water (HTHW) Supply, Carrier Pipe Materials and Joining Method:

Include the following:

1. Pipe: Steel pipe.

2. Fittings: Steel welding.

3. Joining Method: Welding.

4. Carrier Pipe Insulation Material and Thickness: Mineral wool of thickness indicated in schedules on the drawings.

B. High Temperature Hot Water Return, Carrier Pipe Materials and Joining Method: Include the following:

1. Pipe: Steel pipe.

2. Fittings: Steel welding.

3. Joining Method: Welding.

4. Carrier Pipe Insulation Material and Thickness: Mineral wool of thickness indicated in schedules on the drawings.

END OF SECTION 33 63 15