43 15 00.00 22.pdf

P678 Dry Dock 8 Saltwater System for CVN-78 Work Order#: 1364315 Norfolk Naval Shipyard, Portsmouth, VA

SECTION 43 15 00.00 22

LOW PRESSURE COMPRESSED AIR PIPING

04/06

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

AWS Z49.1 (2012) Safety in Welding and Cutting and Allied Processes

ASME INTERNATIONAL (ASME)

ASME B1.20.1 (2013) Pipe Threads, General Purpose (Inch)

ASME B16.11 (2016) Forged Fittings, Socket-Welding and Threaded

ASME B16.3 (201 6) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.34 (2017) Valves - Flanged, Threaded and Welding End

ASME B16.39 (2014) Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300

ASME B16.5 (2017) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B16.9 (2012) Standard for Factory-Made Wrought Steel Buttwelding Fittings

ASME B31.1 (2016; Errata 2016) Power Piping

ASME B31.9 (2017) Building Services Piping

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASME BPVC SEC VIII D1 (2015) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ASTM INTERNATIONAL (ASTM)

ASTM A106/A106M (2018) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature

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Service

ASTM A53/A53M (201 8) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM D1330 (2004; R 2015) Rubber Sheet Gaskets

ASTM D4551 (2017) Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Flexible Concealed Water-Containment Membrane

ASTM G17 (2013) Standard Test Method for Penetration Resistance of Pipeline Coatings (Blunt Rod)

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-69 (2003; Notice 2012) Pipe Hangers and Supports - Selection and Application (ANSI Approved American National Standard)

MSS SP-80 (2013) Bronze Gate, Globe, Angle and Check Valves

MSS SP-84 (1990) Valves - Socket Welding and Threaded Ends

MSS SP-89 (2003) Pipe Hangers and Supports - Fabrication and Installation Practices

PIPE FABRICATION INSTITUTE (PFI)

PFI ES 22 (2016) Color Coding of Piping Materials

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-T-27730 (Rev A; Notice 2) Tape, Antiseize, Tetrafluoroethylene, with Dispenser

MIL-I-16923H Insulating Compound Electrical, Embedding, Epoxy

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS A-A-1689 (Rev B) Tape, Pressure-Sensitive Adhesive, (Plastic Film)

FS A-A-60001 (Basic) Traps, Steam

FS WW-S-2739 (Basic; Notice 1; Notice 2) Strainers, Sediment: Pipeline, Water, Air, Gas, Oil, or Steam

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1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for Contractor Quality Control approval . When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

The following shall be submitted in accordance with Section 01 33 00 .00 22

SUBMITTAL PROCEDURES:

SD-03 Product Data

Pipe ; G

Fittings ; G

Valves ; G

Hangers and supports

Quick disconnect couplings

Strainers

Lubricators

Traps

Expansion Joints ; G

Dielectric unions

Valve box

Identification labels for piping

Underground Pipe Coating; G

Coating for Underground Fittings G

SD-06 Test Reports

Non-Destructive Examination (NDE) report for welding of piping

Leak tightness tests

SD-07 Certificates

Welding Procedures And Qualifications ; G

Employer's Record Documents

Cleaning And Flushing Procedures

1.3 QUALITY ASSURANCE

Provide work specified in this section, including materials, fabrication, assembly, erection, installation, and examination, inspection and testing of compressed air systems in conformance with ASME B31.9 , as modified and

SECTION 43 15 00.00 22 Page 3 supplemented by this specification section and accompanying drawings. In ASME B31.1 , ASME BPVC SEC VIII D1 , and ASME BPVC SEC IX , the advisory provisions shall be considered mandatory, as though the word "shall" had been substituted for "should" wherever it appears; reference to the "authority having jurisdiction" and "owner" shall be interpreted to mean the Contracting Officer.

1.3.1 Employer's Record Documents

Submit to the Contracting Officer for their review and approval the following documents. This documentation and the subject qualifications shall be in compliance with ASME B31.9 .

a. List of qualified welding procedures that is proposed to be used to provide the work specified in this specification section.

b. List of qualified welders and welding operators that are proposed to be used to provide the work specified in this specification section.

c. List of qualified weld examination personnel that are proposed to be used to provide the work specified in this specification section.

1.3.2 Welding procedures and qualifications

Provide welding work specified in this section for compressed air piping systems in conformance with ASME B31.9 , as modified and supplemented by this specification section and the accompanying drawings. The welding work includes: qualification of welding procedures, welders, welding operators, and nondestructive examination personnel; maintenance of welding records, and examination methods for welds.

1.3.2.1 Butt Welded Joints

Butt welded joints shall be full penetration joints.

1.3.2.2 Specifications and Test Results

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

1.3.3 Certification

Before assigning welders or welding operators to the work, submit copies of a list of qualified welders, together with data and certification that each individual is performance qualified as specified. Do not start any welding work prior to submitting and receiving approval of welder and welding operator qualifications. The certification shall state that the type of welding and position(s) for which each individual is qualified, the code and procedure under which each individual is qualified, date of qualification(s) and the name of the firm/company and individual certifying the qualification test.

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1.4 SAFETY PRECAUTIONS

1.4.1 Welding

Safety in welding and cutting of pipe shall conform to AWS Z49.1 .

PART 2 PRODUCTS

2.1 LOW PRESSURE COMPRESSED AIR PIPING AND ACCESSORIES

Site l ow pressure compressed air piping and accessories 125 psig at 150 degrees F , shall conform to the following:

2.1.1 Steel Piping

a. Pipe : ASTM A53/A53M, seamless or electric resistance welded carbon steel, Schedule 40, black for piping 2-1/2 inches and larger .

Piping 2 inches and smaller to be ASTM A106/A106M seamless carbon steel, Schedule 80, black.

b. Fittings , size 2 -1/2 inches and larger: ASME B16.9 , carbon steel, butt welding, schedule 40, or carbon steel welding neck flanges, Class 150, ASME B16.5 , flanged fittings, carbon steel, Class 150, gaskets 1/16 inch oil resistant synthetic rubber ASTM D1330, bolts and nuts shall be Type 316 Stainless Steel . Butt welded joints shall be full penetration consumable insert or backing ring type.

c. Fittings, size 2 inches and smaller: ASME B16.3 , threaded malleable iron, Class 150, or ASME B16.11 , forged carbon steel Class 3000 socket welding or Class 3000 threaded. Joints may also be butt welded or flanged, as specified for sizes 2 -1/2 inches and larger.

d. Underground Pipe Coating : A factory applied coat of continuously extruded polytheylene coating over an adhesive undercoat shall cover pipe. Coating shall conform to FS L-C-350 Type I with 36 mil minimum thickness. Polyethylene coating shall be cut back 4 inches from end of each pipe section.

e. Pipe Joints: Heat shrinkable wrap around sleeves made of polyolefin material with high temperature mastic sealant compatible with adjacent polyethylene piping coatings. Resistant to ultraviolet rays, fungus, cathodic disbondment, and ambient temperatures up to 100 deg C ( 212 deg F ). Tubular construction or wrap around sheets must overlap adjacent coating by a minimum of 2 inches at each end. Tape coatings are not an acceptable substitution.

f. Coating for Underground Fittings : ASTM D4551, ASTM G17, MIL - I-16923H . All fittings installed below grade will have a shop applied, heat curing, thermosetting coat of fusion bonded epoxy.

The coating will be applied over the entire exterior surface of the fittings except for within 2 inches from weld end connections. The coating shall be resistant to corrosive soils, hydrocarbons, seawater and cathodic disbondment. All fittings shall be prepared and all coatings applied in accordance with manufacturers written application instructions.

g. Unions: ASME B16.39 , Class 1 ( 300 psig WOG).

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h. Flat-faced steel flanges: Where connections are made to Class 125 cast iron flanges with steel flanges, use only flat-faced Class 150 steel flanges.

2.1.2 Valves

2.1.2.1 Gate Valves

a. Bronze Gate Valves: MSS SP-80 , Class 150, 1 -1/2 inches and smaller, wedge disc, rising stem, inside screw type.

b. Steel Gate Valves: MSS SP-84 , 2 inches and smaller, ASME B16.34 , over 2 inches , butt welded ends, outside screw and yoke type with solid wedge or flexible wedge disc, Class 300. Carbon steel body, type 316 CRES disc and stem. Valve shall be of the tri-centric design. Provide a Class VI shutoff and be equipped with a gear operator. Gear operator shall be sealed to prevent water intrusion.

2.1.2.2 Butterfly Valve

High performance, wafer body style with enclosed, submersible, gear operator with handwheel (watertight with 2 inch square operating nut if used for buried service), 250 psig pressure rating with ANSI doors VI shutoff, designed to fit between ANSI Class 125/150 or 250/300 (as needed to match piping system). Valve body shall be constructed of ductile iron with the disc constructed of Type 316 stainless steel. Stem shall be stainless steel construction and the seats shall be Burr-N cartridge style seat. Valves designed to provide bi-directional dead end service.

2.1.2.3 Ball Valves

Full port design, copper alloy body, except sizes 2.5 inches and larger shall be ANSI Class 150 steel-bodied. Valves shall have two-position lever handles.

2.1.3 Hangers and Supports

Provide pipe hangers and supports conforming to MSS SP-58 , MSS SP-69 , MSS SP-89 , and ASME B31.1 , except as specified or indicated otherwise.

Clips shall fit closely around piping but shall have sufficient clearance to permit longitudinal movement of piping during normal expansion and contraction. Provide supports at valves, fittings, branch lines, outlets, changes in direction, and accessories.

2.1.4 Quick Disconnect Couplings

All stainless steel and suitable for a working pressure of not less than 1 50 psig . Female side of coupling (fixed end) shall have male thread connection with automatic shutoff. Provide male side of coupling with hose stem and ball check to bleed pressure from hose and prevent hose whipping.

2.1.5 Strainers

FS WW-S-2739 . Bronze or malleable iron body, Class 125, Style Y, Type II, simplex type, with 20-mesh Monel or stainless steel screen.

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2.1.6 Traps

FS A-A-60001 to drain water and other liquids from system. Type of traps, as indicated, and rated working pressure not less than system operating pressure.

2.1.7 Lubricators

Brass body, 150 psig minimum rating with metal bowl.

2.1.8 Dielectric Unions

Steel female pipe thread end and copper solder-joint ends, conforming to dimensional, strength and pressure requirements of ASME B16.39 , Class 1.

Steel parts shall be galvanized or plated. Union shall have a water-impervious insulation barrier capable of limiting galvanic current to one percent of the short-circuit current in a corresponding bimetallic joint. When dry, it shall also be able to withstand a 600-volt breakdown test.

2.1.9 Tetrafluoroethylene Tape

MIL-T-27730 for screw-jointed pipe.

2.1.10 Expansion Joints

Expansion joint bellows shall be inconel and corrugated type bellows, reinforced with rings, internal sleeves, and external protective covers or externally pressurized joints, rated for 150 psig and 850 degrees F .

Provide limit stops to limit total movement in both directions. Cold set joints to compensate for temperature at time of installation. Joints shall withstand 10,000 cycles over a 20 year period. Joints shall be for minimum working pressure of ASME Class 150 set for minimum 5 inches axial compression. Provide single or double bellows expansion joint as indicated on the drawings. Provide flanged or buttwelding end connections as indicated.

2.2 VALVE BOX

Provide cast iron, 2-piece slide type with words "Air" cast or otherwise marked on the cover. Size shall be large enough for removal of valve without removing box. Cast-iron box shall have a heavy coat of bituminous paint. Paint shall be tan in color. Provide valve box for areas as follows:

a. Roads & traffic areas: Heavy Duty, cast iron cover

b. Other areas: Standard duty, heavy steel plate or concrete cover

2.3 IDENTIFICATION LABELS FOR PIPING

Labels for pipes 3/4 inch o.d. and larger shall bear printed legends to identify contents of pipes and arrows to show direction of flow. Except that of pipes smaller than 3/4 inch o.d., labels shall have color coded backgrounds to signify levels of hazard in accordance with PFI ES 22 .

Legends and type and size or characters shall also conform to PFI ES 22 .

Labels shall be made of plastic sheet in conformance with FS A-A-1689 with pressure-sensitive adhesive suitable for the intended applications or they may be premolded of plastic to fit over specific pipe outside diameters

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3/4 inch and larger. For pipes smaller than 3/4 inch o.d., furnish brass identification tags 1 1/2 inches in diameter with legends in depressed black-filled characters.

2.4 BURIED UTILITY WARNING AND IDENTIFICATION TAPE

Polyethylene plastic tape manufactured specifically for warning and identification of buried utility lines. Tape shall be of the type provided in rolls, 6 inches minimum width, color codes for compressed air (gray) with warning and identification imprinted in bold black letters continuously and repeatedly over entire tape length. Warning and identification shall be "CAUTION BURIED COMPRESSED AIR LINE BELOW" or similar wording. Code and letter coloring shall be permanent, unaffected by moisture and other substances contained in trench backfill material.

2.5 FRESH WATER

Fresh water for cleaning, flushing, and testing shall be clean and potable.

PART 3 EXECUTION

3.1 INSTALLATION

Install materials and equipment as indicated and in accordance with the manufacturer's recommendations.

3.1.1 Excavation and Backfilling

Section 31 23 00.00 20 EXCAVATION AND FILL .

3.1.2 Piping

Unless specifically stated to the contrary, fabrication, assembly, welding, and brazing shall conform to ASME B31.1 for all piping of the air system. Piping shall follow the general arrangement shown. Cut piping accurately to measurements established for the work. Work piping into place without springing or forcing, except where cold-springing is specified. Piping and equipment within buildings shall be entirely out of the way of lighting fixtures and doors, windows, and other openings.

Locate overhead piping in buildings in the most inconspicuous positions.

Do not bury or conceal piping until it has been inspected, tested, and approved. Where pipe passes through building structure, pipe joints shall not be concealed, but shall be located where they may be readily inspected and building structure shall not be weakened. Avoid interference with other piping, conduit, or equipment. Except where specifically shown otherwise, vertical piping shall run plumb and straight and parallel to walls. Piping connected to equipment shall be installed to provide flexibility for vibration. Adequately support and anchor piping so that strain from weight of piping is not imposed on the equipment. Provide five (5) copies of the Non-Destructive Examination (NDE) report for welding of piping .

3.1.2.1 Fittings

Use long radius ells where appropriate to reduce pressure drops. Mitering of pipe to form elbows, notching straight runs to form full sized tees, or any similar construction shall not be used. Make branch connections with welding tees, except factory made forged welding branch outlets or nozzles having integral reinforcements conforming to ASME B31.1 may be used.

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3.1.2.2 Clearances for Welding

Provide clearances from walls, ceilings, and floors to permit the installation of joints. The clearances shall be at least 6 inches for pipe sizes 4 inches and less, 10 inches for pipe sizes over 4 inches , and sufficient in corners. However, the specified clearances shall not waive requirements for welders to be qualified for the positions to be welded.

3.1.2.3 Cleaning and Flushing Procedures

Before jointing and erection of piping, thoroughly clean interiors of pipe sections and components. In steel pipe, loosen scale and other foreign matter by rapping sharply and expel by wire brush and swab. Blow out both steel pipe and components with compressed air at 100 psig or more.

Maintain cleanliness by closure of pipe openings with caps or plugs.

Before making final terminal connections, blow out complete system with compressed air at 100 psig or more.

3.1.2.4 Changes in Pipe Size

Use reducing fittings for changes in pipe size. The use of bushings will not be permitted. In horizontal lines, 2 1/2 inches and larger, reducing fittings shall be of the eccentric type to maintain the bottom of the lines in the same plane.

3.1.2.5 Drainage and Flexibility

Compressed air piping shall be free of unnecessary pockets and pitched approximately 3 inches per 100 feet in the direction of flow to low points. Where pipes must be sloped so that condensate flows in opposite direction to air flow, slope 6 inches per 100 feet or greater. Provide flexibility by use of fittings, loops, and offsets in piping. Install branches at top of a main to prevent carryover of condensate and foreign matter.

3.1.3 Threaded Joints

Where possible use pipe with factory cut threads, otherwise cut pipe ends square, remove fins and burrs, and cut taper pipe threads in accordance with ASME B1.20.1 . Threads shall be smooth, clean, and full cut. Apply thread tape to male threads only. Work piping into place without springing or forcing. Backing off to permit alignment of threaded joints will not be permitted. Engage threads so that not more than three threads remain exposed.

3.1.4 Welding Procedures

Perform welding in accordance with qualified procedures using qualified welders and welding operators. Do not perform welding when the quality of the completed weld could be impaired by the prevailing working or weather conditions. The Contracting Officer will determine when weather or working conditions are unsuitable for welding. Welding of hangers, supports, and plates to structural members shall be in accordance with

AWS D1.1/D1.1M .

3.1.4.1 Cleaning for Welding

Surfaces to be welded be free from loose scale, slag, rust, paint, oil, SECTION 43 15 00.00 22 Page 9 and other foreign material. Joint surfaces shall be smooth and free from defects which might affect proper welding. Clean each layer of weld metal thoroughly by wire brushing, grinding, or chipping prior to inspection or deposition of additional weld metal.

3.1.4.2 Welding of Valves

Welding of Valves: Disassemble valves subject to damage from heat during welding and reassemble after installation. Open valves two or three turns off the seat when not subject to heat damage during welding; do not backseat valve.

3.1.5 Valves

ASME B31.1 . Install valves at the locations indicated and elsewhere as required for the proper functioning of the system.

3.1.5.1 Gate Valves , Ball Valves and Butterfly Valves

Install valves in positions accessible for operation and repair. Install valve with stem horizontal or above.

3.1.6 Hangers and Supports

Selection, fabrication and installation of piping hangers and supports shall conform to MSS SP-58 , MSS SP-69 , and MSS SP-89 .

3.1.7 Strainers

Provide strainers with meshes suitable for the services where indicated, or where dirt might interfere with the proper operation of valve parts, orifices, or moving parts of equipment.

3.1.8 Cleaning of System

Clean the various system components before final closing as the installations are completed. Remove foreign matter from equipment and surrounding areas. Preliminary or final tests will not be permitted until the cleaning is approved by the Contracting Officer.

3.1.9 Unions and Flanges

Provide unions and flanges where necessary to permit easy disconnection of piping and apparatus, and as indicated. Provide a union for each connection having a screwed-end valve. Provide unions or flanges as indicated. Provide unions on piping under 2 inches in diameter, and provide flanges on piping 2 inches and over in diameter. Install dielectric unions or flanges between ferrous and non-ferrous piping, equipment, and fittings; except that bronze valves and fittings may be used without dielectric couplings for ferrous-to-ferrous or non-ferrous to non-ferrous connections.

3.1.10 Identification of Piping

Identify piping in accordance with PFI ES 22 . Use commercially manufactured piping identification labels. Space identification marking on runs not farther apart than 50 feet .

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3.1.11 Warning and Identification Tape

Coordinate installation of utility warning and identification tape with backfill operation. Provide tape above buried lines at a depth of 8 to 12 inches below finish grade.

3.2 FIELD QUALITY CONTROL

3.2.1 Examinations

3.2.1.1 Welding Examinations

The Contractor shall perform visual examinations to detect surface and internal discontinuities in completed welds. NDE on piping welds covered by ASME B31.9 is visual inspection only. Verify piping welds meet the acceptance criteria. Submit a NDE report meeting the requirements specified in ASME B31.9 . Visually examine all welds. When examination indicates defects in a weld joint, the weld shall be repaired by a qualified welder. Remove and replace defects as specified in ASME B31.1 , unless otherwise specified. Repair defects discovered between weld passes before additional weld material is deposited. Whenever a defect is removed, and repair by welding is not required, blend the affected area into the surrounding surface, eliminating sharp notches, crevices, or corners. After defect removal is complete and before re - welding, examine the area by the same methods which first revealed the defect to ensure that the defect has been eliminated. After re - welding, re - examine the repaired area by the same test methods originally used for that area. Any indication of a defect shall be regarded as a defect unless reevaluation by surface conditioning and reexamination shows that no unacceptable defects are present. The use of any foreign material to mask, fill in, seal, or disguise welding defects will not be permitted.

3.2.2 Testing

3.2.2.1 General Requirements, Testing

Perform testing after cleaning. Contractor shall provide everything required for tests. Tests shall be subject to the approval of the Contracting Officer. Calibrate the test pressure gages with a dead weight tester within 15 days before use and certify by initial and date on a sticker applied to dial face.

3.2.2.2 Hydrostatic Tests and Leak Tightness Tests

a. Preliminary Preparation

Remove or isolate from the system the components which would be damaged by water during hydrostatic tests and reinstall after successful completion of tests.

b. Performance of Hydrostatic Tests

Hydrostatically test piping systems in accordance with ASME B31.1 . Vent or flush air from the piping system. Pressurize system for 10 minutes with water at one and one-half times design working pressure, then reduce to design working pressure and check for leaks and weeps.

c. Compressed Air Leak Test

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After satisfactory completion of hydrostatic pressure test, blow systems dry with clean, oil-free compressed air, and test with clean, dry air at design working pressure. Brush joints with soapy water solution to check for leaks. Install a calibrated test pressure gage in piping system to observe any loss in pressure. Maintain required test pressure for a sufficient length of time to enable an inspection of joints and connections.

3.2.2.3 Operational Tests

Test equipment as in service to determine compliance with contract requirements and warranty. During the tests, test equipment under every condition of operation. Test safety controls to demonstrate performance of their required function. Completely test system for compliance with specifications.

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1.3.3 Certification