ACU_Specifications_Package.pdf

United States Air Force Edwards Air Force Base

Building 1030 Benefield Anechoic Facility (BAF)

Specifications for

Aircraft Cooling Unit – New ACU at the Benefield Anechoic Facility

September 30, 2015

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Edited by the 412 Electronic Warefare Group 15 December 2016 http://www.jacobs.com/ http://www.jacobs.com/�

Edwards Air Force Base BAF ACU Benefield Anechoic Chamber 60283766.0023

TABLE OF CONTENTS Page 1

TABLE OF CONTENTS

011000 Summary

055000 Metal Fabrications

230513 Common Motor Requirements for HVAC Equipment

230519 Meters and Gages for HVAC Piping

230523.12 Ball Valves for HVAC Piping

230523.13 Butterfly Valves for HVAC Piping

230523.14 Check Valves for HVAC Piping

230529 Hangers and Supports for HVAC Piping and Equipment

230533 Heat Tracing for HVAC Piping

230548 Vibration and Seismic Controls for HVAC

230553 Identification for HVAC Piping and Equipment

230593 Testing, Adjusting and Balancing for HVAC

230719 HVAC Piping Insulation

230800 Commissioning of HVAC

230923.27 Temperature Instruments

232113 Hydronic Piping

232116 Hydronic Piping Specialties

260526 Grounding and Bonding for Electrical Systems

260529 Hangers and Supports for Electrical Systems

260553 Identification for Electrical Systems

262923 Variable Frequency Motor Controllers

SUMMARY 011000 - 1

SECTION 011000 - SUMMARY

1.1

A.

PROJECT INFORMATION

Project Identification: BAF Aircraft Cooling Unit – ACU

1. Project Location: Building 1030, Benefield Anechoic Facility (BAF), Edwards Air

Force Base, CA

B. Owner: 412th Electronic Warfare Group.

1. Owner's Representatives:

a. Ashley O’Keeffe

1) Phone : 661-277-3735

2) E-mail: ashley.okeefe.2@us.af.mil

b. Larry Oribio

1) Phone :

2) E-mail:

661-277-1791 lawerence.oribio.1@us.af.mil

1.2 Introduction

A. This is a Design-Build project. As such, the contractor is responsible for the final project design, construction, installation and performance based on the criteria in this Statement of Work (SOW) and supporting reference documentation provided to the contractor.

Contractor shall provide and install a new Aircraft Cooling Unit (ACU) including but not limited to associated chilled water, condenser water, power, controls, ductwork, piping, valves, motorized valves, dampers, and a variable frequency drive (VFD) for the new ACU blower motor. In addition, contractor shall provide and conduct`, system start-up, training, system commissioning and documented acceptance testing of the new ACU.

1. Objective

The objective of this statement of work is to define the scope of work and requirements necessary for a new ACU to be designed and installed at the BAF, Edwards Air Force Base

CA.

2. Background

The BAF is Avionics Test & Integration Facility located at Edwards Air Force Base California. The 412 Electronic Warfare Group (EWG)/Electronic Warfare Support (EWS) Division has a requirement to support avionics testing at the BAF. This includes providing cooling air during anechoic chamber test operations to one or more aircraft. The current ACU has over 20 years of operational runtime and is a single point of failure ground test support asset for anechoic chamber testing.Therefore, a requirement to install a second ACU to be utilized as a backup or primary unit has developed requiring a new ACU. The new

SUMMARY 011000 - 2

ACU system will interface with the existing supply piping/ducting, power systems, control systems and miscellaneous equipment. Engineering studies and analyses shall be performed to quantify current system capacity and capability to determine the minimum requirements for the new system.

3. Scope of Work

The Vendor shall provide engineering, design, material, labor, equipment, supervision and project management necessary to fabricate, factory test, deliver and install an aircraft cooling system as described herein. Upon fabrication completion of the unit and integration of the required components, the Vendor shall factory test the new ACU system, document and verify performance prior to delivery and perform a system acceptance test after installation of the ACU on-site. In addition, the Vendor shall provide training services to the BAF personnel responsible for the operation of the equipment. All work performed by the Vendor shall conform to this document and all applicable codes, standards, regulations, and guidance as listed herein.

4. Applicable Codes and Standards

The design, manufacture, assembly, and construction of the cooling air unit and all associated components and equipment shall meet or exceed latest copies of the following applicable codes and standards.

• All federal, state, local, county and air force codes and regulations

• American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHREA)

• ASHRAE 15 Safety Code for Mechanical Refrigeration

• Air-Conditioning and Refrigeration Institute (ARI) Standards

ANSI B9.1: Refrigerant Piping

• National Electrical Manufacturers Association (NEMA)

• NEMA ICS 6 Enclosures for Industrial Control and Systems

• American Society For Testing And Materials (ASTM)

American Society Of Mechanical Engineers (ASME)

• American Welding Society (AWS)

• American Water Works Association (AWWA)

Environmental Protection Agency and Dot Practices

Underwriters Laboratories (UL)

• UL Listing: Starters and Electrical Components

• Uniform Building Codes (UBC)

• Uniform Plumbing Codes (UPC)

SUMMARY 011000 - 3

• Power Piping Code, ANSI B31.1

• Construction Safety Orders, CAL OSHA

• Structural Welding, AWS D1.1

• Compressors & Exhausters, ASME PTC-10

• Cabinet Leakage, ANSI/ASHRAE 111-88

• Laboratory Methods of Testing Fans For Rating, AMCA 210

• Application Sound Power Level Ratings For Fans, AMCA 303

• Forced-Circulation Air-Cooling and Air-Heating Coils, ARI 410

• Filters, ASHRAE 52-76

• Ball Bearings Load Rating, AFBMA B-9

• Grade B Carbon Steel Cold Formed, ASTM A-500

• Carbon Steel Hot Rolled, ASTM A-569

• Hop Dip Process, Zinc Coat Galvanized Sheet Steel Lock Formed, ASTM A-527

• Salt Spray Test, ASTM B-117

• Humidity Exposure, ASTM D-2247

• Paint to Metal Adhesive, ASTM D-3359-B

• Industrial Adhesive Sealant, ASTM C-834-76

5. Quality Assurance

All work performed by the Vendor shall conform to this document and the references listed above. Total quality shall be achieved through performance of skilled craftsmen in the employ of approved properly equipped Vendors. Work shall be accurately cut and fit close, shall be securely interconnected and reinforced, and shall be rigidly fixed in place, true to line and level or plumbed in an approved manner. The manufacturer of the cooling air unit must have a minimum of 5 years experience in factory testing, with an in-house Electrical Testing Laboratory (ETL) certification program, in the production and manufacturing of high pressure industrial quality air handling units. The entire unit shall be certified to bear the ETL label as a completed unit and not only on individual components.

The Vendor is responsible for purchasing all new equipment and components. The overall per-formance of the new ACU System, as well as the performance of individual components shall

National Fire Codes, NFPA 90A - Insulation

• California Mechanical Code, latest edition

• California Electric Code, latest edition

• Boiler and Pressure Vessel Code, ASME Section VIII

SUMMARY 011000 - 4

be guaranteed for a minimum of two year, parts and labor, after acceptance of the unit at the

Owner's facility.

6. Deliverables

a. Within four weeks after this contract has been awarded, shop drawings of all interconnecting ducting, piping and housings shall be provided. These drawings shall specify material, wall thicknesses, fabrication notes, component selectin data, sequence of operations, wiring and control diagrams, and design operating pressure. In addition, the Vendor shall provide a drawing list for review.

b. The Vendor shall coordinate with the contractor for the concrete pad the unit shall be installed on. The pad shall be minimum 12” high above grade to match existing.

c. At time of delivery of unit to the installation site, the Vendor shall supply three copies of final configuration drawings, final electrical drawings, manufacture's information on components of the Avionics Cooling Unit (ACU), and general information for repair and maintenance of the unit. It is important that the copies are clear and legible. The drawings shall be sufficiently complete to permit in-house repair and maintenance. The final drawings will be reviewed and must be approved by the 412 EWG/EWS prior to project completion.

7. General Design Requirements

The aircraft cooling unit shall be a custom designed, fabricated and tested unit capable of providing, at the unit outlet interface, 20° F air at 12.5 psig with variable flow rates from 500 lbm/min to 100 lbm/min. The air discharge of the unit shall match the facilities' 16-inch flanged pressure duct. The unit shall be capable of continuous operation of up to 15 hours with minimal interruption to flow for coil defrosting.

a. Blower

The unit blower shall be designed so as to overcome the constrictions and pressure drop associat-ed with the cooling unit itself and still provide the outlet interface pressure and flow rates stated above. Multi-stage centrifugal type blower must be of the manufacturer's standard design and all performance and testing associated with the blower shall be in accordance with ASME PTC-10.

The blower housing shall be constructed of cast iron sections held securely between cast iron inlet and outlet heads with steel tie rods. Two piece fabricated construction with rope packing or welded steel construction is not acceptable. No contact shall be made between the shaft rotor and the housings, other than through bearings. Where the blower shaft passes through both the inlet and outlet heads, non-contact labyrinth seals with babbit inserts shall be provided to prevent air leakage. The inlet and outlet connections shall be ASA 125 drilled and tapped flange pattern, and shall be an integral part of the heads.

All bearings shall be mounted in cast iron outboard bearing housings designed to isolate the bearings from blower temperatures. The housings shall have a bronze labyrinth type insert in the

SUMMARY 011000 - 5

area inboard of the bearing, to serve as a backup bearing and protect the bearing from external contamination. The blower shaft shall be of sufficient diameter to operate below critical speed, and shall be made of high grade steel. The shaft speed shall not exceed 3600 RPM.

Blower shall each be provided with two (2) grease lubricated anti-friction bearings. It shall be possible to replace the bearings without disconnecting any piping or disassembling the compressor casing. Both inlet and outlet bearings shall be sized for a minimum expected life of 10 years as defined by AFBMA B-10 standards. Grease lubricated units shall incorporate a grease slinger mounted inboard of the bearing to insure a constant flow of lubricant to the bearing.

The compressor shall be connected to the driver with a suitable flexible coupling. The couplings shall be covered by a base mounted metal coupling guard. Each compressor, motor and driver shall be mounted on one full length steel base, set on suitable rubber vibration isolation pads.

The motor driver shall be premium efficiency inverter duty type for VFD use, in accord with NEMA and IEEE standards. The enclosure shall be Open Drip Proof (ODP), suitable for use in the location shown on the plans. All bearings shall be anti-friction ball bearing type. The motor horsepower rating shall be in excess of the maximum load that will be imposed under the design requirements; overload capacity of the motor may not be utilized. Each motor shall have a 1.15 service factor at job site conditions. Electrical characteristics shall be 460 volt, 3 phase and 60 hertz. The blower motor shall be of the energy efficiency type with an efficiency rating of not less than 95 percent.

Each blower shall be provided with an air volume modulation system to operate at predetermined CFM set points, maintaining specified static pressure and flow rate, be fully automatic with bypass piping rated at operating pressure, and controlled via 4 - 20 mA signal or 0-10 VDC.

Surge protection shall also be provided.

b. Coils

The cooling coils shall be of the nominal sizes specified on the attached sketch and shall be capable of cooling the air to 20° F, measured at the unit outlet. All coils shall have a drain connection at the bottom header and an air vent connection on the upper header. Coil tubes shall be constructed of copper; fins shall be aluminum with a minimum thickness of 0.008-inch, and the coil casings shall be constructed of 16 gage galvanized steel. Coils of the "hair pin" design are unacceptable.

Cooling coils downstream of the blower shall be housed in a welded steel housing designed and fabricated for a minimum working pressure of 15 psig. All welding shall be performed by AWS D1.1 certified welders and pressure tested to 15 psig. The coils shall be situated such that the headers and return bends are fully contained within the housing. Removable end panels shall be provided in the housing so that the coils can slide out for service and inspection. The access doors shall be bolted and provided with gasket material suitable for the specified operating pressure. All connections shall be 125# ANSI flanges made of cast iron or steel.

SUMMARY 011000 - 6

The pre cooling coils shall be chilled water type, 5/8-inch tube. The DX coils shall be provided with electric resistance coils imbedded in cooling coils for defrost protection.

Controls shall be provided to monitor frost conditions and sequence the inlet shutoff valves, electric heaters, and stand-by coil. All coils shall be tested and certified in accordance with ARI Standard 410, Forced Circulation Air-Cooling and Air-Heating Coils.

c. Refrigeration

The compressor and refrigerant type selected for service shall be of the heavy duty, and for medium temperature application, open drive reciprocating type, and shall be mounted on spring vibrating isolators with isolators mounted in line with the crankshaft on suction and discharge refrigeration lines. There shall be two steps of unloading with hot gas bypass to provide stable evaporator capacity and discharge temperature. Each circuit to include UL listed receiver. The associated shell and tube condenser shall carry the ASME code stamp and incorporate removable heads and cleanable tubes.

Vendor may propose refrigerant type, compressor type and overall direct expansion cooling system that may differ from the above paragraph as a new design may warrant or require.

d. Electrical Components & Controls

The blower motor shall be provided with a variable frequency drive. The starter shall be rated for 460 V, 3 phase voltage and the blower motor horsepower.

Auxiliary components requiring starters shall be equipped with magnetic starters wired to the corresponding equipment in accordance to NEC electrical requirements, and the control transformer wired and fused. Single point wiring shall include factory wired fused disconnect switch or circuit breaker.

All control panels, actuators, sensors, transducers, transmitters, and controls shall be factory mounted, wired, and tested. These control panels shall include auxiliary terminal blocks for future remote control and monitoring capabilities via 4-20 mA and 0-10 VDC compatible signals.

The Vendor shall also supply a remote control and status panel to control and display the pressue, temperature and flow of the unit. The panel shal be installed inside the BAF and connected via Ethernet to the existing equipment control system.

e. Equipment Housing

The new cooling air unit shall be located outside; due to the harsh environment of the Mojave de-sert the unit must be enclosed in a protective housing. The housing shall incorporate forced venti-lation with active cooling to maintain an interior design temperature of no greater than 100° F

Controls shall be of the PLC type and approved by the 412 EWG prior to system design completion and integration. Due to the higher pressure and flow requirements of this aircraft avionics cooling unit not normally associated with building air-conditioning systems, monitoring and control response times are extremely critical. Detailed control schematics and sequence of operations shall be included in the design as part of a deliverable for review and approval.

Instrumentation such as but not limited to CT’s, PT’s and transducers for monitoring shall be provided to indicate the discharge temperature, pressure, air flow rate (pounds per minute), blower amperage and voltage from the unit.

SUMMARY 011000 - 7

while in operation. . The entire unit and housing shall be mounted on a welded steel frame with integral lifting lugs. The steel frame shall be treated as a lifting fixture capable of handling a minimum of 1.5 times the unit weight. All frame welds shall be completed by AWS certified welders and inspected as such. A coat of zinc epoxy primer and two coats of alkyd enamel finish paint shall be applied to the steel frame prior to installation of the protective housing.

The entire floor shall be of double bottom construction with a minimum of 3-inch of glass fiber insulation, with integral vapor barrier. The floor shall be constructed of a minimum of 16 gage G-90 galvanized steel and the sub-floor constructed of a minimum of 20 gage G-90 galvanized steel. The floor shall be reinforced with a minimum of 4-inch channels located not to exceed 24-inch on center. The flooring shall be secured to the structural members below with cad plated neoprene washered self-tapping screws not to exceed 10-inch on center or with concealed 1-inch welds spaced a minimum of 4-inch on center. All floor seams and edges shall be sealed with a continuous bead of polyurethane industrial sealant or acrylic latex conforming to ASTM C834-76.

The unit housing structure and or panels shall be constructed so as to withstand a wind load of no less than 85 mph. The housing must provide for the removal of equipment without effecting the structural integrity of the equipment. The interior of the housing shall be insulated with 1-inch x 1.5# glass fiber (or equivalent) and incorporate an integral vapor barrier. Insulation shall be installed so as not to be disturbed by the removal of individual panels. Double wall access doors shall be provided for the regular service and maintenance of all equipment requiring such and shall meet all OSHA requirements. Seams shall be sealed with continuous beads of a polyurethane industrial sealant conforming to ASTM C834-76. The housing walls and floors shall be designed to deflect no more than 1/200 of span while the unit is in operation. The cabinet construction shall result in an ASHRAE/ANSI Standard 111-88 Leakage Class of less than nine

(9) or 1% or less at operating conditions.

The finish coating on the housing shall be a high gloss alkyd enamel paint applied over baked epoxy primer. Seal all fixed joints with flexible weather tight sealer. Coating shall exhibit no visible effects after 100 hours exposure to 100% relative humidity at 100 F per ASTM D-2247, and less than 1 millimeter undercutting and no blistering after 100 hours exposure in 5% salt spray test per ASTM B-117.

A minimum of 4 marine lights shall be mounted and wired throughout the unit to provide lighting for the operation and maintenance of the system. All lights shall be wired to separate switches and wired to external 115 V disconnect switch, separate from 480 V power source. In addition, 4 electrical outlet receptacles shall be provided.

Stainless steel drain pans shall be provided for all coils. The pans shall be pitched to a common drain connection which shall include a fixed pivot float drain trap with cast iron body. Valve, valve seat, lever, and float are to be stainless steel. Traps shall be designed to operate at 15 psig.

8. Testing & Training

The blower assembly shall be balanced to not exceed 1.25 mils in the vertical plane, when measured at the blower bearing housing, and shall be run continuously for a minimum of three hours to verify that bearing temperatures are within the manufacturer's specifications. Air flow shall be tested and measured in accordance with the guidelines established by the Air Movement and Control Associat-

SUMMARY 011000 - 8

ion (AMCA). The cabinet shall be tested for leaks, and the refrigeration system shall be tested and operating to determine performance based on factory ambient temperatures. All test documentation will be compiled into a single transmittal and shall bear the signature of a Professional Registered Engineer representing the Vendor.

The Vendor shall provide training for the personnel responsible for the maintenance and operation of the cooling air system. This training should take place at the Vendor's facilities so that a clear understanding of the system is achieved prior to delivery to the job site.

9. Unit Installation

Delivery of the cooling air unit shall be the responsibility of the fabricating Vendor. Prior to delivery of the unit, the Vendor shall provide the owner with detailed drawings of the unit footprint, mounting details, interface/plumbing details, and a rigging/lift procedure. All installation data must be approved by the Owner prior to delivery of the unit. The vendor shall supply the above information 4 weeks after being awarded the work. The contractor shall have inlet and outlet ducting, water supply and return lines, and electrical power, routed to with 15 feet of the proposed unit location. Final connection of these facilities will be the responsibility of the contractor, including all work associated with the lifting, setting, and final anchoring of the cooling air unit.

The Vendor will provide supervision for the lifting, setting, and final anchoring activities. If the unit cannot be shipped as a single package (due to size restrictions) the Vendor shall also be responsible to provide personnel to supervise the final integration and/or assembly of the unit at the installation site. Upon delivery, the unit shall be inspected to insure the physical condition is satisfactory; however, this shall not be considered as the performance acceptance of the unit.

10. Start-Up

Upon completion of the unit installation and connection of all facilities, the Vendor shall provide the personnel and supervision necessary to perform the activation and initial start-up of the unit.

The system shall be run at operating conditions for a minimum of two hours, shut down, restarted and run again for verification of the unit's integrity. A breakdown of the personnel, by functional title, required to perform the start-up, and their qualifications shall be provided prior to traveling to the job site.

11. Acceptance

The COE project engineer and COE Quality representative will be responsible for the final acceptance of the installation. They will ensure that the Vendor complied with the requirements of this SOW, and the intent of the proposed sketch and expected quality. All shipping crates are to be removed from the site by the Vendor.

12. Shop drawings shall be developed, submitted and approved prior to the start of any fabrication or construction.

a. Product data for all new equipment including, but not limited to, ACU, Instrumentation and controls, and variable frequency drives.

SUMMARY 011000 - 9

b. Detailed shop drawings of:

i. ACU

ii. Instrumentation diagram

iii. Conduit and wiring layout

c. As-built documentation of new and existing equipment, controls, conduit and wiring.

d. O&M manuals for new equipment.

13. Contract Milestones: The project shall be completed with 160 calendar days from NTP. Submit proposed project schedule showing completion within 160 calendar days with allowances for review and approval of submittals, new equipment procurement, installation, and close-out items.

14. The ACU manufacturer shall provide the controls. The manufacturer shall incorporate the con-trols with the existing ACU control system. Minimum three full days of traing shall be provided.

The manufacturer shall visit the site minimum of three times after the acceptance of the system for final tuning and training.

15. Existing ACU information is provided in the end of this section, however the contractor shall visit the project site and field verify as-built condition. The new unit shall match the existing unit in construction.

METAL FABRICATIONS 055000 - 1

SECTION 055000 - METAL FABRICATIONS

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Miscellaneous steel framing and supports.

1.2 ACTION SUBMITTALS

A. Product Data: For the following:

1. Paint products.

B. Shop Drawings: Show fabrication and installation details. Include plans, elevations, sections, and details of metal fabrications and their connections. Show anchorage and accessory items.

C. Calculations: Anchorage calculations for floor and wall mounted equipment prepared by a licensed engineer in the State of California.

1.6 QUALITY ASSURANCE

A. Welding Qualifications: Qualify procedures and personnel according to AWS D1.1, "Structural Welding Code - Steel."

PART 2 - PRODUCTS

2.1 PERFORMANCE REQUIREMENTS

A. Thermal Movements: Allow for thermal movements from ambient and surface temperature changes acting on exterior metal fabrications by preventing buckling, opening of joints, overstressing of components, failure of connections, and other detrimental effects.

2.2 METALS

A. Metal Surfaces, General: Provide materials with smooth, flat surfaces unless otherwise indicated. For metal fabrications exposed to view in the completed Work, provide materials without seam marks, roller marks, rolled trade names, or blemishes.

B. Steel Plates, Shapes, and Bars: ASTM A 36.

C. Stainless-Steel Bars and Shapes: ASTM A 276, Type 304.

METAL FABRICATIONS 055000 - 2

D. Rolled-Steel Floor Plate: ASTM A 786, rolled from plate complying with ASTM A 36 or ASTM A 283, Grade C or D.

E. Rolled-Stainless-Steel Floor Plate: ASTM A 793.

F. Steel Tubing: ASTM A 500, cold-formed steel tubing.

G. Steel Pipe: ASTM A 53, Standard Weight (Schedule 40) unless otherwise indicated.

H. Cast Iron: Either gray iron, ASTM A 48, or malleable iron, ASTM A 47, unless otherwise indicated.

I. Aluminum Extrusions: ASTM B 221, Alloy 6063-T6.

J. Aluminum Castings: ASTM B 26, Alloy 443.0-F.

2.3 FASTENERS

A. General: Unless otherwise indicated, provide Type 304 stainless-steel fasteners for exterior use and zinc-plated fasteners with coating complying with ASTM B 633 or ASTM F 1941, Class Fe/Zn 5, at exterior walls. Select fasteners for type, grade, and class required.

1. Provide stainless-steel fasteners for fastening aluminum.

2. Provide stainless-steel fasteners for fastening stainless steel.

B. Cast-in-Place Anchors in Concrete: Either threaded type or wedge type unless otherwise indicated; galvanized ferrous castings, either ASTM A 47 malleable iron or ASTM A 27 cast steel. Provide bolts, washers, and shims as needed, all hot-dip galvanized per ASTM F 2329.

C. Post-Installed Anchors: Torque-controlled expansion anchors or chemical anchors.

1. Material for Interior Locations: Carbon-steel components zinc plated to comply with ASTM B 633 or ASTM F 1941, Class Fe/Zn 5, unless otherwise indicated.

2. Material for Exterior Locations and Where Stainless Steel Is Indicated: Alloy Group 1 stainless-steel bolts, ASTM F 593, and nuts, ASTM F 594.

2.4 MISCELLANEOUS MATERIALS

A. Low-Emitting Materials: Paints and coatings shall comply with the testing and product requirements of the California Department of Public Health's (formerly, the California Department of Health Services') "Standard Method for the Testing and Evaluation of Volatile Organic Chemical Emissions from Indoor Sources Using Environmental Chambers."

B. Universal Shop Primer: Fast-curing, lead- and chromate-free, universal modified-alkyd primer complying with MPI#79 and compatible with topcoat.

1. Use primer containing pigments that make it easily distinguishable from zinc-rich primer.

C. Galvanizing Repair Paint: High-zinc-dust-content paint complying with SSPC-Paint 20 and compatible with paints specified to be used over it.

METAL FABRICATIONS 055000 - 3

D. Nonshrink, Nonmetallic Grout: Factory-packaged, nonstaining, noncorrosive, nongaseous grout complying with ASTM C 1107. Provide grout specifically recommended by manufacturer for interior and exterior applications.

E. Concrete: Normal-weight, air-entrained, concrete with a minimum 28-day compressive strength of 3000 psi.

2.5 FABRICATION, GENERAL

A. Shop Assembly: Preassemble items in the shop to greatest extent possible. Use connections that maintain structural value of joined pieces.

B. Cut, drill, and punch metals cleanly and accurately. Remove burrs and ease edges. Remove sharp or rough areas on exposed surfaces.

C. Weld corners and seams continuously to comply with the following:

1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.

2. Obtain fusion without undercut or overlap.

3. Remove welding flux immediately.

4. At exposed connections, finish exposed welds and surfaces smooth and blended.

D. Form exposed connections with hairline joints, flush and smooth, using concealed fasteners or welds where possible. Locate joints where least conspicuous.

E. Fabricate seams and other connections that are exposed to weather in a manner to exclude water. Provide weep holes where water may accumulate.

2.6 MISCELLANEOUS FRAMING AND SUPPORTS

A. General: Provide steel framing and supports not specified in other Sections as needed to complete the Work.

B. Fabricate units from steel shapes, plates, and bars of welded construction unless otherwise indicated. Fabricate to sizes, shapes, and profiles indicated and as necessary to receive adjacent construction.

2.7 METAL BOLLARDS

A. Fabricate metal bollards from 6-inch diameter Schedule 40 steel pipe.

2.8 STEEL AND IRON FINISHES

A. Galvanizing: Hot-dip galvanize all exterior items to comply with ASTM A 153 for steel and iron hardware and with ASTM A 123 for other steel and iron products.

METAL FABRICATIONS 055000 - 4

B. Shop prime interior iron and steel items.

1. Shop prime with universal shop primer.

C. Preparation for Shop Priming: Prepare surfaces to comply with SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning."

D. Shop Priming: Apply shop primer to comply with SSPC-PA 1, "Paint Application Specification No. 1: Shop, Field, and Maintenance Painting of Steel," for shop painting.

PART 3 - EXECUTION

3.1 INSTALLATION, GENERAL

A. Cutting, Fitting, and Placement: Perform cutting, drilling, and fitting required for installing metal fabrications. Set metal fabrications accurately in location, alignment, and elevation; with edges and surfaces level, plumb, true, and free of rack; and measured from established lines and levels.

B. Fit exposed connections accurately together to form hairline joints. Weld connections that are not to be left as exposed joints but cannot be shop welded because of shipping size limitations.

Do not weld, cut, or abrade surfaces of exterior units that have been hot-dip galvanized after fabrication and are for bolted or screwed field connections.

C. Field Welding: Comply with the following requirements:

1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.

2. Obtain fusion without undercut or overlap.

3. Remove welding flux immediately.

4. At exposed connections, finish exposed welds and surfaces smooth and blended so no roughness shows after finishing and contour of welded surface matches that of adjacent surface.

D. Fastening to In-Place Construction: Provide anchorage devices and fasteners where metal fabrications are required to be fastened to in-place construction.

E. Provide temporary bracing or anchors in formwork for items that are to be built into concrete, masonry, or similar construction.

3.2 INSTALLING METAL BOLLARDS

A. Fill solidly with concrete and allow concrete to cure seven days before installing.

B. Anchor bollards in place with concrete footings. 4-feet above ground, 4’ below ground encased in minimum 8-inch concrete. Place concrete and vibrate or tamp for consolidation. Support and brace bollards in position until concrete has cured.

METAL FABRICATIONS 055000 - 5

C. Fill bollards with concrete, mounding top surface to shed water.

3.3 ADJUSTING AND CLEANING

A. Touchup Painting: Immediately after erection, clean field welds, bolted connections, and abraded areas. Paint uncoated and abraded areas with the same material as used for shop painting to comply with SSPC-PA 1 for touching up shop-painted surfaces.

B. Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas and repair galvanizing to comply with ASTM A 780.

END OF SECTION 055000

COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT 230513 - 1

SECTION 230513 - COMMON MOTOR REQUIREMENTS

1.1 MATERIALS

A. Polyphase Motors: Design B, medium induction motors.

1. Efficiency: Energy efficient.

2. Service Factor: 1.15.

3. Multispeed Motors: Variable torque.

4. Rotor: Random-wound, squirrel cage.

5. Bearings: Regreasable, shielded, antifriction ball bearings suitable for radial and thrust loading.

6. Temperature Rise: Match insulation rating.

7. Insulation: Class F.

8. Code Letter Designation:

a. Motors 15 HP and Larger: NEMA starting Code F or Code G.

b. Motors Smaller than 15 HP: Manufacturer's standard starting characteristic.

9. Enclosure Material: Cast iron for motor frame sizes 324T and larger; rolled steel for motor frame sizes smaller than 324T.

B. Polyphase Motors with Additional Requirements:

1. Motors used with reduced-voltage and multispeed controllers.

2. Energy- and premium-efficient and Inverter-duty motors used with variable frequency controllers.

3. Severe-duty motors.

C. Single-Phase Motors:

1. Motors Larger than 1/20 HP: Permanent-split capacitor; split phase; capacitor start, inductor run; or capacitor start, capacitor run to suit starting torque and requirements of specific motor application.

2. Multispeed Motors: Variable-torque, permanent-split-capacitor type.

3. Bearings: Prelubricated, antifriction ball bearings or sleeve bearings suitable for radial and thrust loading.

4. Motors 1/20 HP and Smaller: Shaded-pole type.

5. Internal thermal protection.

END OF SECTION 230513

METERS AND GAGES FOR HVAC PIPING 230519 - 1

SECTION 230519 - METERS AND GAGES FOR HVAC PIPING

1.1 PRODUCTS

A. Bimetallic-Actuated Thermometers:

1. Case: Liquid-filled and sealed type(s); stainless steel; 3-inch diameter.

2. Dial: Nonreflective aluminum with etched scale in deg F.

3. Connector Type(s): Union joint, adjustable angle.

4. Window: Plain glass.

B. Filled-System Thermometers:

1. Direct-Mounted, Metal-Case, Vapor-Actuated Thermometers:

a. Case: Sealed type, cast aluminum or drawn steel; 4-1/2-inch diameter.

b. Movement: Mechanical, dampening type,.

c. Dial: Nonreflective aluminum with etched scale in deg F.

d. Window: Glass.

e. Ring: Stainless steel.

f. Connector Type(s): Union joint, adjustable, 180 degrees in vertical plane, 360 degrees in horizontal plane, with locking device.

C. Liquid-In-Glass Thermometers:

1. Metal-Case, Compact-Style, Liquid-in-Glass Thermometers:

a. Case: Cast aluminum; 6-inch size.

b. Case Form: Straight.

c. Tube: Glass with magnifying lens and blue or red organic liquid.

d. Tube Background: Nonreflective aluminum with etched scale in deg F.

D. Thermowells:

1. Material for Use with Copper Tubing: CNR or CUNI.

2. Material for Use with Steel Piping: CRES.

3. Type: Stepped shank unless straight or tapered shank is indicated.

4. Heat-Transfer Medium: Mixture of graphite and glycerin.

E. Pressure Gages:

1. Direct-Mounted, Metal-Case, Dial-Type Pressure Gages:

a. Case: Liquid-filled type(s); cast aluminum or drawn steel; 4-1/2-inch diameter.

b. Pressure-Element Assembly: Bourdon tube unless otherwise indicated.

c. Pressure Connection: Brass, with NPS 1/4, ASME B1.20.1 pipe threads and bottom-outlet type unless back-outlet type is indicated.

d. Dial: Nonreflective aluminum with etched scale in psi.

e. Window: Glass.

METERS AND GAGES FOR HVAC PIPING 230519 - 2

f. Ring: Stainless steel.

g. Accuracy: Grade A, plus or minus 1 percent of middle half of Grade A, plus or minus 1 percent of middle half of scale range.

F. Gage Attachments:

1. Snubbers: Brass; with NPS 1/4, and piston-type surge-dampening device. Include extension for use on insulated piping.

2. Siphons: Loop-shaped section of stainless-steel pipe with NPS 1/4 pipe threads.

3. Valves: Brass or stainless-steel needle, with NPS 1/4 or NPS 1/2, pipe threads.

G. Test Plugs: Test-station fitting made for insertion into piping tee fitting.

H. Test-Plug Kits: Furnish one test-plug kit(s) containing one thermometer(s), one pressure gage and adapter, and carrying case.

I. Sight Flow Indicators:

1. Construction: Bronze or stainless-steel body, with sight glass and ball, flapper, or paddle wheel indicator.

2. Minimum Pressure Rating: 125 psig.

3. Minimum Temperature Rating: 200 deg F.

J. Flowmeters:

1. Turbine Flowmeters:

a. Sensor: Impeller turbine; for inserting into pipe fitting or for installing in piping and measuring flow directly in gallons per minute.

1) Minimum Pressure Rating: 150 psig.

2) Minimum Temperature Rating: 180 deg F.

b. Display: Shows rate of flow, with register to indicate total volume in gallons.

END OF SECTION 230519

BALL VALVES FOR HVAC PIPING 230523.12 - 1

SECTION 230523.12 - BALL VALVES FOR HVAC PIPING

1.1 COOLING TOWER-WATER VALVES

A. Pipe NPS 2 and Smaller:

1. Ball Valves: One piece, full port, brass or with stainless-steel trim.

B. Pipe NPS 2-1/2 and Larger:

1. Iron Ball Valves: Class 125.

2. Steel Ball Valves: Class 150.

END OF SECTION 230523.12

BUTTERFLY VALVES FOR HVAC PIPING 230523.13 - 1

SECTION 230523.13 - BUTTERFLY VALVES FOR HVAC PIPING

1.1 COOLING TOWER-WATER AND CHILLED WATER VALVES

A. Pipe NPS 2-1/2to NPS 12:

1. Iron, Single-Flange Butterfly Valves, NPS 2-1/2 to NPS 12: 200 CWP, EPDM seat, stainless-steel disc.

2. Iron, Single-Flange Butterfly Valves, NPS 14 to NPS 24: 150 CWP, EPDM seat, stainless-steel disc.

3. High-Performance Butterfly Valves: Class 150, single flange.

END OF SECTION 230523.13

CHECK VALVES FOR HVAC PIPING 230523.14 - 1

SECTION 230523.14 - CHECK VALVES FOR HVAC PIPING

1.1 COOLING TOWER-WATER VALVES

A. Pipe NPS 2 and Smaller:

1. Bronze Swing Check Valves: Class 150, bronze disc.

B. Pipe NPS 2-1/2 and Larger:

1. Iron Swing Check Valves: Class 125, metal seats.

2. Iron Swing Check Valves with Closure Control, NPS 2-1/2 to NPS 12: Class 125, lever and spring.

END OF SECTION 230523.14

HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT 230529 - 1

SECTION 230529 - HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT

1.1 PERFORMANCE REQUIREMENTS

A. Pipe hangers and equipment supports designed by Contractor.

B. Seismic-restraint hangers and supports designed by Contractor and approval obtained from authorities having jurisdiction.

1.2 SUBMITTALS

A. Shop Drawings: Signed and sealed by a professional engineer.

1.3 QUALITY ASSURANCE

A. AWS D1.1/D1.1M, "Structural Welding Code - Steel."

B. ASME Boiler and Pressure Vessel Code.

1.4 COMPONENTS

A. Metal Pipe Hangers and Supports: Carbon steel or stainless steel.

B. Trapeze pipe hangers.

C. Fiberglass pipe hangers.

D. Metal Framing Systems: MFMA manufacturer.

E. Fiberglass strut systems.

F. Thermal-hanger shield inserts.

G. Fastener Systems: Powder-actuated fasteners and mechanical-expansion anchors.

H. Equipment supports.

END OF SECTION 230529

HEAT TRACING FOR HVAC PIPING 230533 - 1

SECTION 230533 - HEAT TRACING FOR HVAC PIPING

1.1 SUMMARY

A. Section includes heat tracing for HVAC piping with the following electric heating cables:

1. Self-regulating, parallel resistance.

1.2 ACTION SUBMITTALS

A. Product Data: For each type of product.

B. Shop Drawings: For electric heating cable.

1.3 INFORMATIONAL SUBMITTALS

A. Field quality-control reports.

B. Sample Warranty: For special warranty.

1.4 CLOSEOUT SUBMITTALS

A. Operation and maintenance data.

1.5 WARRANTY

A. Special Warranty: Manufacturer agrees to repair or replace electric heating cable that fails in materials or workmanship within specified warranty period.

1. Warranty Period: Three years from date of Substantial Completion.

PART 2 - PRODUCTS

2.1 SELF-REGULATING, PARALLEL-RESISTANCE HEATING CABLES

A. Comply with IEEE 515.1.

B. Heating Element: Pair of parallel No. 16 or No. 18 AWG, tinned nickel-coated, stranded copper bus wires embedded in crosslinked conductive polymer core, which varies heat output in response to temperature along its length. Terminate with waterproof, factory-assembled, nonheating leads with connectors at one end, and seal the opposite end watertight. Cable shall be capable of crossing over itself once without overheating.

HEAT TRACING FOR HVAC PIPING 230533 - 2

C. Electrical Insulating Jacket: Flame-retardant polyolefin.

D. Cable Cover: Tinned-copper or Stainless-steel braid and polyolefin outer jacket with ultraviolet inhibitor.

E. Maximum Operating Temperature (Power On): 150 deg F (65 deg C).

F. Maximum Exposure Temperature (Power Off): 185 deg F (85 deg C).

G. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.

H. Capacities and Characteristics:

1. Maximum Heat Output: 8 W/ft. (26 W/m).

2. Electrical Characteristics for Single-Circuit Connection:

a. Volts: 120.

b. Phase: 1.

c. Hertz: 60.

2.2 CONTROLS

A. Remote bulb unit with adjustable temperature range from 30 to 50 deg F (minus 1 to plus 10 deg C).

B. Snap action; open-on-rise, single-pole switch with minimum current rating adequate for connected cable.

C. Remote bulb on capillary, resistance temperature device, or thermistor for directly sensing pipe-wall temperature.

D. Corrosion-resistant, waterproof control enclosure.

2.3 ACCESSORIES

A. Cable Installation Accessories: Fiberglass tape, heat-conductive putty, cable ties, silicone end seals and splice kits, and installation clips all furnished by manufacturer, or as recommended in writing by manufacturer.

B. Warning Labels: Refer to Section 230553 "Identification for HVAC Piping and Equipment."

C. Warning Tape: Continuously printed "Electrical Tracing"; vinyl, at least 3 mils (0.08 mm) thick, and with pressure-sensitive, permanent, waterproof, self-adhesive back.

1. Width for Markers on Pipes with OD, Including Insulation, Less Than 6 Inches (150 mm): 3/4 inch (19 mm) minimum.

2. Width for Markers on Pipes with OD, Including Insulation, 6 Inches (150 mm) or Larger:

1-1/2 inches (38 mm) minimum.

HEAT TRACING FOR HVAC PIPING 230533 - 3

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install electric heating cable across expansion joints according to manufacturer's written instructions; use slack cable to allow movement without damage to cable.

B. Install electric heating cables after piping has been tested and before insulation is installed.

C. Install electric heating cables according to IEEE 515.1.

D. Install insulation over piping with electric cables according to Section 230719 "HVAC Piping Insulation."

E. Install warning tape on piping insulation where piping is equipped with electric heating cables.

F. Set field-adjustable switches and circuit-breaker trip ranges.

G. Ground equipment according to Section 260526 "Grounding and Bonding for Electrical Systems."

H. Connect wiring according to Section 260519 "Low-Voltage Electrical Power Conductors and Cables."

3.2 FIELD QUALITY CONTROL

A. Perform the following tests and inspections

1. Perform tests after cable installation but before application of coverings such as insulation, wall or ceiling construction, or concrete.

2. Test cables for electrical continuity and insulation integrity before energizing.

3. Test cables to verify rating and power input. Energize and measure voltage and current simultaneously.

B. Repeat tests for continuity, insulation resistance, and input power after applying thermal insulation on pipe-mounted cables.

C. Cables will be considered defective if they do not pass tests and inspections.

D. Prepare test and inspection reports.

E. Remove and replace damaged heat-tracing cables.

END OF SECTION 230533

VIBRATION AND SEISMIC CONTROLS FOR HVAC 230548 - 1

SECTION 230548 - VIBRATION AND SEISMIC CONTROLS FOR HVAC

1.1 PERFORMANCE REQUIREMENTS

A. Wind-Restraint Loading:

1. Basic Wind Speed: 70 mph.

2. Minimum 10 lb/sq. ft. multiplied by maximum area of HVAC component projected on vertical plane normal to wind direction, and 45 degrees either side of normal.

B. Seismic-Restraint Loadings as required by current CBC .

1. Assigned Seismic Use Group or Building Category as Defined in the IBC: III.

a. Component Importance Factor: 1.5.

b. Component Response Modification Factor: 1.5.

c. Component Amplification Factor: 2.5.

1.2 COMPONENTS

A. Vibration Isolators:

1. Elastomeric Isolation Pads: Single or multiple layers of sufficient durometer stiffness for uniform loading over pad area. Material to be oil and water resistant with elastomeric properties.

a. Surface Pattern: Ribbed pattern.

b. Infused nonwoven cotton or synthetic fibers.

c. Load-bearing metal plates adhered to pads.

2. Double-Deflection, Elastomeric Isolation Mounts: Molded, oil-resistant rubber, neoprene, or other elastomeric material.

3. Restrained Elastomeric Isolation Mounts: All-directional isolator with seismic restraints;

molded, oil-resistant elastomeric material with cast-ductile-iron or welded-steel housing.

4. Open-Spring Isolators: Freestanding, laterally stable.

5. Housed-Spring Isolators: Freestanding, laterally stable, open-spring isolators in two-part telescoping housing.

6. Restrained-Spring Isolators: Freestanding, laterally stable, open-spring isolators with vertical-limit stop restraint.

7. Housed-Restrained-Spring Isolators: Freestanding, steel, open-spring isolators with vertical-limit stop restraint in two-part telescoping housing.

8. Pipe-Riser Resilient Support: All-directional, acoustical pipe anchor.

9. Resilient pipe guides.

10. Air-Spring Isolators: Freestanding, single or multiple, compressed-air bellows.

11. Restrained-Air-Spring Isolators: Freestanding, single or multiple, compressed-air bellows with vertical-limit stop restraint.

12. Elastomeric hangers.

VIBRATION AND SEISMIC CONTROLS FOR HVAC 230548 - 2

13. Spring Hangers: Combination coil-spring and elastomeric-insert hangers with spring and insert in compression and with vertical-limit stop.

B. Seismic Restraint Devices:

1. Snubbers: Welded structural-steel shapes and replaceable resilient isolation washers and bushings.

2. Restraint Channel Bracings: MFMA-4, shop- or field-fabricated bracing assemblies.

3. Restraint Cables: ASTM A 603 galvanized-steel cables.

4. Hanger-Rod Stiffener: Steel tube or steel slotted-support-system sleeve with internally bolted connections to hanger rod.

5. Resilient Isolation Washers and Bushings: One-piece, molded, oil- and water-resistant neoprene, with a flat washer face.

6. Anchor Bolts: Mechanical type, seismic rated.

C. Vibration Isolation Equipment Bases:

1. Steel Base: Factory-fabricated, welded, structural-steel bases and rails.

2. Inertia Base: Factory-fabricated, welded, structural-steel bases and rails ready for field-applied, cast-in-place concrete.

1.3 FIELD QUALITY CONTROL

A. Testing: By Contractor-engaged agency.

END OF SECTION 230548

IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT 230553 - 1

SECTION 230553 - IDENTIFICATION FOR PIPING AND EQUIPMENT

1.1 QUALITY ASSURANCE

A. Quality Standard for Piping Identification: ASME A13.1.

1.2 PRODUCTS

A. Equipment Labels: Metal.

B. Warning Signs and Labels: 1/16 inch thick with fasteners.

C. Pipe Labels: Pretensioned.

D. Stencils: Brass.

E. Valve Tags: Brass, 0.032-inch or stainless steel, 0.025-inch minimum thickness.

F. Warning Tags: 3 by 5-1/4 inches minimum fasteners.

END OF SECTION 230553

TESTING, ADJUSTING, AND BALANCING FOR HVAC 230593 - 1

SECTION 230593 - TESTING, ADJUSTING, AND BALANCING FOR HVAC

1.1 SUMMARY

A. TAB for the following:

1. Balancing Hydronic Piping Systems:

a. Constant-flow hydronic systems.

2. TAB Equipment:

a. Cooling Tower.

b. Motors.

3. Control system verification.

1.2 QUALITY ASSURANCE

A. TAB Agent Qualifications: AABC, NEBB or TABB certified.

1.3 EXECUTION

A. Tolerances: Plus or minus 10 percent of design values.

B. Inspections: Random checks by Architect to verify final TAB report.

C. Additional Tests: Random tests within 90 days of completing TAB to verify balance conditions and seasonal tests.

END OF SECTION 230593

HVAC PIPING INSULATION 230719 - 1

SECTION 230719 - PIPING INSULATION

1.1 QUALITY ASSURANCE

A. Surface-Burning Characteristics: Flame-spread index of 25, and smoke-developed index of 50 for insulation installed indoors; according to ASTM E 84.

B. Mockup of each type of pipe insulation and finish.

1.2 FIELD QUALITY CONTROL

A. Field Inspections: By Contractor-engaged agency.

1.3 OUTDOOR, ABOVEGROUND PIPING INSULATION SCHEDULE

A. Condenser (Cooling Tower) Water: Cellular glass or mineral-fiber, preformed pipe insulation, Type I.

1.4 OUTDOOR, FIELD-APPLIED JACKET SCHEDULE

A. Piping, Concealed: Stainless steel.

B. Piping, Exposed: Stainless steel.

END OF SECTION 230719

COMMISSIONING OF HVAC 230800 - 1

SECTION 230800 - COMMISSIONING OF HVAC

1.1 SUMMARY

A. Requirements for commissioning HVAC&R systems, assemblies, and equipment.

B. Allowances for labor, instrumentation, tools, and equipment costs for technicians for performance of commissioning testing.

C. Unit prices for adjusting allowances.

D. Contractor's Responsibilities:

1. Perform commissioning tests at the direction of the CxA.

2. Attend construction phase controls coordination meeting.

3. Attend testing, adjusting, and balancing review and coordination meeting.

4. Participate in HVAC&R systems, assemblies, equipment, and component maintenance orientation and inspection.

5. Provide information to CxA for final commissioning documentation.

6. Provide measuring instruments and logging devices to record test data, and provide data acquisition equipment to record data.

E. CxA's Responsibilities:

1. Provide Project-specific construction checklists and…