PART 6 ATTACHMENT L MCBCL Mech Design Guidance 7.17.pdf

CAMP LEJEUNE MECHANICAL DESIGN GUIDANCE 1 July 2017

Rev July 2017

Previous 8 Dec 2016

New revisions are bolded, new removals are lined through. Revisions since 10.14.08 are dated. Re-ordering of comments, grammer and typo corrections are not annotated.

The target audience of this guidance is locally administered and designed projects

(FSRM). Use as appropriate for MilCons and other projects.

GENERAL

1. Use Camp Lejeune Guide Specifications as available. These specifications have been pre-edited for use at Camp Lejeune and save time for both the designer and the reviewer. Edit as necessary. Add equipment and materials as necessary. Direct any questions, comments, and suggestions to the Mechanical Branch, Camp Lejeune

Public Works Design. We welcome your input. (7.1 2017)

2. All equipment shall be removable from the building without removing/displacing other equipment(8.8.12).

3. Isolate “steam” mechanical rooms from building. All steam equipment is more prone to leaking, thus making the room humidity saturated. Provide the steam room with an exterior door; do not provide a door(s) to adjacent spaces. Keep electrical equipment out of this room. If possible separate steam rooms from cold equipment rooms.

Minimize controls in steam mechanical rooms. Only controls necessary for equipment in the room shall be allowed. If it is convenient put controls in adjacent room. It is preferable to keep air handlers out of this room also. Do not run high pressure steam outside the steam room(ie steam entrance should be directly into steam mechanical room). Separate building for steam equipment and pumps is good.

Provide exhaust fan ventilation with 20ac/hr on cooling thermostat.

4. If possible separate fuel fired equipment and other heat producing equipment from air handlers and other equipment that has a cool surface temperature into different mechanical rooms. Fuel fired equipment and other heat producing equipment require ventilation to meet building codes and for practical reasons. Air handlers, and chilled water pumps do not require ventilation. Rooms with only chilled/hot water air handlers are not classified as mechanical rooms by the international building code and therefore do not require ventilation.(8.29.14)

5. Ventilate “hot” rooms and electrical rooms sufficient to mitigate heat gain.

6. Do not ventilate cold equipment rooms. Cold equipment rooms are those rooms with chilled water pumping, cooling air handlers, etc. These rooms should be unvented and with small dehumidifier. Drain condensate to floor drain or other disposal location. Summer dew point ranges from low to high 70’s at Camp Lejeune causing condensation on equipment and piping. Dehumidifier should be wall mounted with wheels removed and hard wired with disconnect (no pigtail with plug) to discourage theft/relocation. Dehumidifier should be hard piped to drain to avoid drainage blockage. (8.30.10)

7. Keep in mind fall hazards when locating equipment. Provide necessary fall protection.

8. During renovations; remove unused pipe, duct, and equipment. It is not necessary to disassemble building components. Abandon in place piping sub slab or buried in a wall that is not getting demolished for other reasons. (8.29.14)

9. Install ice dams on metal roofs over or near outside mechanical equipment (8.29.14)

10. Designer shall ensure that all plumbing and mechanical work includes the following requirement. "All material and equipment shall be installed in accordance with the manufacturer's recommendations for the intended purpose.

Use the more stringent methods when manufacturer's recommendations, and plans & specification requirements differ. Bring any conflicts between manufacturer's recommendations and plans & specification requirements to the government's attention." The Camp Lejeune guide specifications should include this but it may be need added to other specifications. (7.15.16)

11. Do not traverse telecom rooms with piping. This removes the risk of water damage to equipment from leaks/breaks/condensation. (7.1.17)

12. Avoid traversing telecom rooms with ducts. Ducts unrelated to the telecom room take up space, pose a risk of water damage (condensation), and cause a smoke spread risk. If it is unavoidable, the duct must have fire dampers at both ends.

(7.1.17)

HVAC: General

13. Design conditions for Camp Lejeune are: 91/77F 1%DB/MCWB and 140 grains/lb with a 84F MCDB. 26F 99% and 22F 99.6% heating conditions. Equipment selection shall meet all conditions. (8.29.14)

14. Rooftop HVAC equipment should be used with discretion. Maintenance access is more difficult, controls and water piping are exposed to more extreme conditions and roof is exposed to more abuse and wear. Ladders permanent or temporary inhibit personnel, material and equipment access, and therefore stairways shall be provided to roof top equipment.

15. Avoid use of chilled water fan coil (FCU) systems due to the high maintenance associated with them. Coil condensate drain pans are especially problematic. If

FCU’s are used, ensure adequacy of the drain system.

16. HVAC equipment should not be installed in attics or above suspended ceilings, unless absolutely necessary. When placement in an attic is dictated by necessity, provide stairs to access the attic, and maintenance access to and space around equipment;

ships ladders are undesirable. Provide drain pan float switch to shut down condensing unit or close chilled water valve to the coil. (6.26.9)

17. A/C terminal units with compressors shall be easily removed. On water source equipment that means unions on the equipment side of the service valves.

18. In refrigerated rooms/boxes: specify all evaporators on a condensing unit to defrost together, separate evaporator/condensing unit pairs should defrost non-concurrently.

19. Provide phase monitors on all 3 phase equipment. For chillers the following shall be included:

a) phase unbalance protection

b) over/under voltage protection

c) phase loss protection

d) Delay of break timer to delay automatic restarts

e) non critical fault delay

f) programmable auto/manual restart

g) load and line side monitoring

For all other equipment only phase loss, phase reversal, and phase unbalance need to be monitored. Standard internal functions of VFD are acceptable. Reset shall be automatic upon correction of the fault.

20. When connecting to existing air or hydronic system, require contractor to test existing equipment or system to establish conditions. Be specific as to what needs to be tested and when. It may be necessary to adjust flow or static (head) pressures of new equipment and measuring before ordering new equipment will reduce contract modification costs.(8.29.14)

21. In buildings where cooling is not available 12 months/year, consider the use of ductless split systems for conference rooms. Consider the use of Package Terminal

Heat Pumps or ductless split system (8.29.14) for high internal heat spaces such as server rooms.

22. Geothermal coupled heat pump systems shall be designed and installed in accordance with NAVFAC MidAtlantic Policy (8.8.12).

23. Recommended HVAC system types are (8.8.12):

a. All packaged units less than 120,000 Btu/hr shall be either heat pumps with auxiliary gas heat or heat pumps with auxiliary electric heat.

b. All packaged units greater than 120,000 Btu/hr shall be either air conditioners with gas heat or heat pumps with auxiliary gas heat.

c. All split systems less than 120,000 Btu/hr shall be either heat pumps with auxiliary electric heat or heat pumps with auxiliary gas heat.

d. All split systems greater than 120,000 Btu/hr shall be heat pumps with auxiliary gas heat.

24. VRF(Variable Refrigerant Flow): In most cases heat reclaim system is preferable to heat pump system. For systems with interior spaces and or rooms with significant internal heat gain specify that all interior units be capable of full heating capacity while other units are in the cooling mode(this requires a 3 pipe system), or schedule the minimum heating required for each indoor zone when outdoor unit is in the cooling(this allows a 2 pipe system, but sets minimum heating performance requirement). 8.29.14

25. Consider using gas fired unit heaters in boiler rooms in lieu of hot water unit heaters.

These reduces the freezing risk if the boiler trips, but there is still gas and power.

8.29.14

26. All R22 in existing equipment/systems to be demolished by the contractor will be recovered by Camp Lejeune. This should be included in the demolition specification 02 41 00 and on the drawings. The project manager will notify

Public Works Ops to instigate a work order to the base maintenance contractor prior to construction contractor starting work. (12.8.16)

27. Camp Lejeune shall be given the chance to salvage existing DDC controllers and parts before demolition. The project manager will notify Public Works Ops to instigate a work order to the base maintenance contractor prior to construction contractor starting work. (12.8.16)

HVAC: Pipes and Pumping

28. Provide primary/secondary pumping systems on multiple building chiller systems and on systems larger than 150 tons. Keep flow thru the chiller constant. Do not use variable primary flow (2.22.10). Be very careful to maintain minimum chiller flow and avoid erratic or rapid chiller flow. Minimum flow bypass valve if used and dp sensor should both be direct connected to plant controller, do not use a comm bus due to polling delays. (7.1.17). Ensure primary loop has sufficient thermal inertia. Be aware that the secondary loop has little influence on staging cycling during low load conditions. (6.20.8)

29. Do not use plastic preinsulated pipe for buried dual temperature water distribution;

use preinsulated copper pipe. HDPE is acceptable for chilled water applications.

(6.13.8)

30. Do not specify or permit mineral fiber on pipes cooler than 70F. Cellular glass, polystyrene(8.29.14), or polyisocyanurate is required on chilled water pipes and domestic cold water. (1.25.10) Allow flexible Unicellular when rigid insulation is not practical, such as small refrigerant lines sets, and tight piping.(8.29.14)

31. Use rigid insulation on all pipes subject to being stepped on or damaged.

32. Use coalescing type combination air/solid separators on all hydronic systems regardless of pipe material (steel or copper). 7.15.16

33. Do not specify or permit automatic flow control balancing valves (flow limiting valves). Specify manually TAB’d circuit setters. (1.18.13).

34. Design and specify bladder type expansion tanks (when available) with automatic air relief valve on the air separator. Bladder type expansion tanks have a full tank acceptance volume, and bladder is replaceable. Diaphragm type expansion tanks have an acceptance volume less than tank volume and the diaphragm is not replaceable. If the pre-charge air is discharged the diaphragm tank will overfill and rupture. Bladder tanks may not be available in the smaller sizes.

7.15.16

35. Paint all dual temp and chilled water steel pipe and equipment before insulation is installed. This in addition to shop primer and or mill coating. (1.28.10)

36. Do not permit grooved couplings in piping system other than the chiller connection.

(6.13.8)

37. Extruded Tee’s in copper piping are acceptable for mains 2” and larger with the branch ½ or less than the main. Joint must be brazed. (6.13.8)

38. Do not permit press type fittings in copper. (6.13.8)

39. Pump Packages: In general do not specify pump/heat exchanger packages. Most of our mechanical rooms are on the smallish side. Pump packages require maintenance space on all sides. If specifying a pump package, designer must work out general lay out of package and mechanical room to ensure maintenance access.

40. Inline or close couple pumps are preferred for circulating pumps. Provide redundant system pumps; each pump shall carry the design flow, with the second pump as an alternating backup. A single pump is adequate for equipment pumps, such as a boiler pump. Inline and close coupled pumps do not have a coupling between the motor and the pump, do not require alignment or stringent grouting requirements and therefore cause less maintenance issues.(8.29.14) For inline pumps 5 hp and larger, include rigging points for maintenance.

41. When a partial renovation of a building HVAC system re-uses existing piping, specify the contractor to clean and flush the existing piping. (1.8.10)

42. Add valves, drains, and vents at each piece of equipment to aid servicing(8.31.11).

All equipment including heat exchangers shall have P/T ports on inlet and discharge of all water connections(8.8.12). Include in-situ thermometers in mechanical rooms to aid in onsite trouble shooting.(8.29.14)

43. Require balance valves of the venturi type where the throttling valve and the measuring station are separate. i.e. the pressure is not read across the valve. 8.29.14

(7.1.17)

44. Specify that all refrigerant piping be vacuum tested to 300 microns for 24 hours after the high pressure test. The system fails the test if with the vacuum pump disconnected from the system, the pressure rises above 300 microns after 24 hours.(8.29.14)

45. Do not specify or permit gate valves. Require ball or butterfly valves. We seem to get better longevity from the ball and butterfly valves. 7.15.16

46. Provide emergency chilled water connections for portable chillers on installations with a single chiller. The connection shall be a full size TEE with lugged type butterfly valve for both the portable and insitu chillers. Cap the portable connection with blind flanges. 7.15.16

HVAC: Air Systems

47. Duct drawings shall be a minimum 3/16” scale.(8.29.14) Show TAB air flow quantities for supply, return and exhaust terminals. (7.15.16)

48. Use the latest revision of ASHRAE 62 for guidance on indoor air quality. For the purposes of outside air ventilation only, typical occupancy is considered that which happens at least once a week for buildings that follow a regular schedule or at least 15 times a year for non-schedule type buildings.

49. Buildings shall be kept at a slight positive pressure to reduce/avoid infiltration in the walls that can cause condensation. Consider the tightness of the building, also consider inaccuracies in TAB. Having outside volumes 10% in excess of exhaust volumes should be always be considered.(8.29.14)

50. Chilled water VAV with zone reheat is the preferred HVAC system for offices and should be considered wherever appropriate. VAV zone boxes without fans are preferable to units with fans. In non-fan powered zone boxes, when specifying minimum air flow the designer shall consider diffuser dumping. If a zone has a large variance of load profile from neighboring zones a fan powered box should be considered to avoid dumping of diffusers. Chilled water VAV with fan powered terminal units with reheat is the preferred HVAC system for BEQ/BOQ’s. Zone reheat shall be as specified in the scope (10.14.08).7.15.16 VAV Fan powered terminal units shall have a fan volume of 50 cfm to 50% greater than the maximum primary air flow. (1.8.10) Fan powered VAV terminal units shall be series type with the secondary fan 10-20% (50 cfm minimum) greater than maximum primary flow. (7.1.17) Minimum primary air flow shall be the greater of the minimum controllable flow or (8.29.14) the ventilation rate required. (5.12.10).

51. Particular attention should be given to humidity control by air conditioning equipment. Constant volume (8.29.14) cooling units 7.5 tons and smaller shall not have modulating water controls unless based on a constant 55 F supply temperature.

Larger units may have split face coils to give capacity step control (progressive modulating chilled water valves may be used). Modulating face and bypass dampers are okay on any size equipment.

52. Avoid HVAC systems that modulate cooling supply air temperatures unless outside air is separately conditioned.

53. Air handling unit filter access doors should be specified as hinged with non-tool captive latching devices, i.e. captive thumb screws, quarter turn latches etc. Do not specify or approve access panels that are unhinged and/or retained by sheet metal screws.

54. Require contractors to provide a listing of the HVAC filters for each piece of equipment along with their dimensions (width, height and thickness) and types

(permanent/washable, throwaway, etc)

55. Require contractor to provide 2 extra complete sets of air filters to be left in the mechanical room at BOD. Require contractor to provide and change all air filters at second season TAB if included. In all, the contractor will provide at least 5 sets of filters. 1 for startup, 1 at BOD, 2 in the box for government, 1 at 2nd season

TAB.(8.29.14)

56. Outside air intakes should be in compliance with force protection criteria, ie;

minimum of 10’ above finished grade.

57. DUCT WORK: specify and draw 45 degree expanded throat take offs with balance damper for all supply run outs to diffusers and grills. Do not permit flexible duct runs exceeding 5’(8.29.14) long. Specify that all 90 degree turns be accomplished with hard metal elbows, such as on top of diffusers, and if top take off of trunk duct. Show balance dampers on return systems with branches. Give return flows to TAB

(8.29.10).

58. Specification 23 05 93, Testing, Adjusting, and Balancing for HVAC: Change DALT requirement from 20% to 100% duct air leakage test on all projects. Specify on the drawings, duct seal class A for all ducts. (1.2.13) Specify the SMACNA leakage class (CL) on the mechanical drawings: round and oval duct= 3, rectangular duct =6, test pressure of 1” (1.2.13). Contact Camp Lejeune project management concerning scope of work for existing ducts to be re-used. (9.8.10) Consider removing all insulation on existing duct and resealing and reinsulating it.

59. The use of ceiling return air plenums is discouraged and shall not be used in new construction. (2.10.10)

60. Bull headed tees should be limited to below 900 fpm duct systems. (8.31.11)

61. Provide filters on upstream side of the wheel on both airstreams (7.15.16) of an energy recovery wheel. (8.31.11)

62. BEQ’s: Fan powered VAV boxes: secondary air shall come directly from the conditioned space via a ducted return with a filter return grille. Secondary air shall not come from the closet. Closets shall return direct back to the air handler.

(8.31.11)

63. Specify electronically commutated motors (ECM) for fan powered terminal units.

Design consideration should be provided to address the degradation of power quality and potential problems with overheating of neutral wiring conductors, connectors, and transformers(8.31.11).

64. Interior duct liner shall not take the place of exterior duct insulation. All cooling supply duct shall be insulated including duct inside conditioned space (8.8.12).

65. Exterior duct shall be externally insulated with 1.5” thick foam rubber insulation with robust weather jacket. Insulation shall be 100% adhered to the duct. The weather jacket shall be either a sheet metal overlay or factory adhered multilayer (mylar and aluminum) covering. (1.18.13)

66. Size cooling coils downstream of Enthalpy recovery wheels for degradation of wheel performance. For BEQ’s, the EAT of the coil shall be schedule as though the coil has lost one half of its scheduled performance. This will aid in system recovery after outages, and in during periods of high shower use. For non-BEQ’s, EAT of the coil shall be scheduled as though the enthalpy wheel has lost 15% of its scheduled performance. The economic analysis and energy study shall use the scheduled wheel effectiveness. Water flow and chiller sizing shall be based on the reduced wheel performance.(8.29.14)

67. Specify duct access doors at fire dampers and special duct mounted equipment requiring regular access such as duct mounted coils. Duct access doors are not desired at control dampers, manual dampers, and turning vanes. 8.29.14

68. On 5 ton unitary and smaller require the secondary drain pan to be pre-formed plastic with float or dampness type switch. Require a float switch in the secondary drain connection of the unit. Both switches to shut off unit upon activation. (7.15.16)

69. On unitary air conditioning equipment and small fan coil units, consider filter return grilles in lieu of unit mounted air filters for ease of access, meeting face velocity limits. Meeting the higher MERV ratings may not be practical on unitary equipment regardless of location. (12.8.16).

HVAC: Chillers and outdoor equipment

70. Provide aluminum fins on copper tubes or aluminum micro channel coils (8.8.12).

Require coils on all outdoor equipment larger than 10 tons, and on DX, chilled water, and hot water coils with greater than 50% outside air regardless of capacity (8.31.11) to pass ASTM B117 90 3000 hour salt spray resistance test as installed. For equipment within 1000 feet of the ocean, intracoastal waterway, New River, Wallace

Creek require 6000 hour resistance.(8.29.14) The heat transfer rating of phenolic-coated coils should be as installed (i.e. after coating). Although UFC does not exempt small equipment from coating standards. It is more cost effective to replace small equipment with a shorter life span than to special order what is normally standard equipment. (7.1.17)

71. Air cooled equipment is (8.29.14) preferred to water cooled equipment for individual equipment smaller than 150 tons. Camp Lejeune weather is mild and humid which only gives slight efficiency advantage to water cooled equipment. Larger plants such as multiple 400 ton chillers should be water cooled. The efficiency advantage overcomes the additional maintenance of cooling towers. This is not in reference to ground source or ground coupled systems. This statement is for open or closed type evaporative cooling towers. 7.15.16

72. Do not use steam absorption chillers. Helical screw compressors are desirable.

Reciprocating and scroll compressors are acceptable. Where applicable on large installations centrifugal equipment is acceptable, (greater than 150 tons). Oiless centrifugal is acceptable (1.25.10). Specify high lift compressors for air cooled oiless centrifugal chillers (8.29.14).

73. Provide adequate thermal mass in chilled water systems to ensure proper control and longevity of chillers. Chiller manufacturers recommend 2 to 7 minute water loop return times; use a minimum of 5 minutes to size inertia tanks and/or increase pipe sizing/length.

74. Do not permit 400 series refrigerants except 407C and 410A. 400 series refrigerants are zeotropes and cause maintenance problems. Use of 407C is discouraged, as it is a short term stop gap measure that the manufacturers can drop into basically a R22 machine. Designer shall research the availability of 410A and/or 134A equipment. If sufficient competition is available with 410A and/or 134A, prohibit the use of 407C and R22. 5.22.09.(7.15.16).

75. Do not permit/specify engine driven refrigeration equipment.

76. On chillers and large condensing units; provide core filter dryer on suction line as available as standard option.

77. On chillers and large condensing units; provide liquid and suction line service valves as available as standard option.

78. Do not permit welding on chillers. Water connections shall be by grooved coupling or flanges. Provide 16-20 mesh strainer on water inlet.

79. Require 5 year warranty on compressor parts. Require 5 year warranty on labor if available.

80. Use multiple chillers on loads above 160 tons. (7.15.16)

GAS PIPING

81. The design for LP gas tanks shall be as follows:

a) construction contractor to provide:

i. 6” thick concrete slab, 6’x8’ for 500 gallon tank, 6’x16’ for 1000 gallon tank

(6.10.9)

ii. Underground gas line to stub up through oversized sleeve in slab, 3”from edge

iii. 1st stage regulator

iv. Protective bollards, 7’long, 4” schedule 40 galvanized steel, concrete filled, 3’ bury with concrete encased, paint bright yellow/black with 4” stripes.

v. Make tank hook up

vi. Purchase at construction contractor’s expense, LP gas for startup, and construction period.

b) Camp Lejeune will arrange rental, including placement, but not hook up, of the tank. Camp Lejeune will contract for tank fill up after BOD of project.

c) Designer shall specify size of the tank (typical sizes are 123, 500, & 1000 gallon), size and location of the concrete pad, and placement/number of protective bollards. Bollards shall be placed to protect from the grass cutters (each open corner), and nearby traffic (may require intermediate bollard spacing). Design shall comply with all applicable codes. As a reminder, 500 gallon tank shall be minimum of 10’ from the building, 1000 gallon tank shall be minimum of 25’ from the building. The long axis of the tank shall be parallel with the building.

d) AROICC will notify Camp Lejeune metering & LP tank inspector (currently Rich

Barnes @ 451-4785) of the need/timing of tank placement, and tank fill after

BOD.

82. On LP systems, first stage regulator is located at the LP tank and should be set for 10 psig. The second stage regulator should be located on the exterior of the building wall in a protected location. Provide a building shut off valve on all systems.

(1.19.2010).

83. Size interior gas piping with a 15% safety buffer. I.E. Size the piping for 15% more demand than anticipated. (1.28.10)

84. Common interior gas pressures are 7”, 2 psi, and 5 psi. Use 7” if 2” or smaller piping can serve the load, otherwise use 2psi with regulators at each appliance.

(1.28.10)

85. Require sediment traps before each appliance and each medium pressure regulator.

(8.29.14)

CONTROLS

86. Avoid use of economizers (dry bulb or enthalpy). High humidity and poor control reliability prohibit success with economizers except in extremely high internal load buildings.

87. Direct Digital Control (DDC) systems are the preferred HVAC control systems for new and replacement control systems.

88. Where DDC is not practical, such as with small unitary equipment, use standalone programmable thermostats. (8.29.14)

89. CO2 sensors and outside air modulation should be considered in facilities with highly varying occupancies.

90. Specify that pneumatic control devices be able to withstand 30 psi without damage.

91. Control valve actuators shall be spring return normally open on preheat coils and other coils subject to freezing, spring return closed on hot water converters, and spring return closed on outside air dampers. (10.22.08)

92. Specify individual scheduling for air handlers. Specify a gradual (progressive) startup and a gradual (progressive) shut down of air handlers. A sudden startup or shut down of the entire building is too fast for chiller controls to react and sometimes causes safety trips.

93. Do not specify or provide air filter status alarms. Filters are changed on a schedule and filter alarms cause nuisance reporting. (1.2.13)

94. For Combined heating/cooling systems such as VAV with zone reheat; provide single common heating-cooling global set point that is reset based on ambient conditions.

For most applications, allow occupants to adjust the zone set point +/-3F from the global set point. Global set point shall be 70F at less than 50F ambient; and 76F at greater than 80F ambient. Between 50F and 80F, the global set point shall reset linearly or in no fewer than 3 steps. The single set point prevents the zone temperature from swinging between heating and cooling set points in low load conditions. (8.29.14) Use a +/- 1F differential from the common set point to make effective cooling and heating setpoints. UFC requires two set points, heating of

68F and cooling of 78F. Note that this is not practical as the system will cool to the heating set point at minimum cooling capacities. The Federal mandated heating and cooling set points were rescinded many years ago. UFC 3-410-01 para 3-4.3 allows indoor conditions as approved by the authority having jurisdiction (AHJ). CMC has a policy of allowing individual installations to govern the set point. (7.1.17)

95. Set points for Unitary air conditioning/heat pumps (unless agreed otherwise):

70F htg/76F cooling Occupied; cooling set back 85F, gas heating set back 60F, heat pump set back 65F. (12.8.16) UFC requires heating set point of 68F and cooling set point of 78F. This creates excessive maintenance work tickets for failed HVAC systems because occupants are unhappy with indoor environment.

UFC requires unoccupied heating set back of 55F. Recovery from 55F is impractical with heat pumps and it drives the equipment into using electric resistance heat. UFC 3-410-01 para 3-4.3 allows indoor conditions as approved by the authority having jurisdiction (AHJ). CMC has a policy of allowing individual installations to govern the set point. (7.1.17)

96. Specify on the drawings occupied/unoccupied schedules. Use Monday thru

Friday 6am to 6pm as a default if a more precise schedule cannot be identified.

(12.8.16)

97. Do not specify VFD’s with external bypass. Do specify VFD’s with 5% bus reactors.(7.15.16)

98. The project drawings for DDC shall include: system architecture including each type terminal device and any allowable gateways etc; detailed control sequences with P&ID, I&O Point Table, any exterior conduit runs (min 1”), conduit home run (min 1”) from the BACnet Building Controller to the telephone equipment room. The points table may include 2 different sets of points; local view and

EMCS view. Coordinate control power requirements with electrical sheets.

Show circuits dedicated to controls for all control cabinets. (7.15.16).

99. Energy Monitoring Requirements are met by: suppler billing for gas, dedicated

Itron metering system for electric and water. and connection to the DDC for water. (7.15.16/7.1.17)

PLUMBING

100. Lubrication oil lines should not be installed below building floor slabs. It is preferred that lubrication oil lines be installed overhead. If this is not possible or desirable by the customer, lines within service bays should be installed in trenches with removable tops. (6.26.9)

101. Install shop air compressors in accessible locations with appropriate space for periodic service. Shop air compressors are serviced by the building occupants and

(6.26.09) should not be installed within mechanical rooms since occupant access is prohibited by base maintenance. Shop air compressors should be provided with sufficient cooling ventilation. Install air compressors associated with building HVAC controls within mechanical rooms.

102. Air compressor receivers over 5 cubic feet (37.4 gal) are unfired pressure vessels that must undergo hydrostatic and operational tests witnessed by the base boiler inspector. (5.19.8)

103. Air Compressors should be mounted on vibration pads/mounts. Specify/show flexible connectors on the piping. (10.22.08)

104. Where practical provide hose bibs near all HVAC coils for wash down/cleaning purposes.

105. Provide floor drains in all mechanical rooms.

106. Provide trap primers on all floor drains except locations that are expected to get regular use throughout the year. Trap primer shall be pressure type installed on a cold water line and shall not be installed on a flush valve.(2.27.9)

107. Provide sectional shut off valves for domestic hot & cold water for each bathroom

(group).

108. Do not permit lever type control handles on pressure balance shower valves in

BEQ’s. This type of handle invites the user to pull for volume control, thereby breaking the handle.

109. Avoid frost proof hose bibs. Use standard hose bibbs. Frost proof hose bibbs will break when they freeze, whereas standard hose bibbs are less likely to be damaged by freezing.(8.29.14)

110. Provide strainers on RPZ back flow preventers.

111. Double Check and RPZ type back flow preventers (BFP) shall be tested/certified by the installing contractor prior to BOD. Add the following paragraph to any specification section that includes a BFP(10.22.08). “3.X Back Flow Preventer

Certification: After installation all double check and reduce pressure zone type back flow preventers shall be inspected, tested and certified by a certified tester. Submit tester certification and Test Data Certification Sheet.”

112. Extruded Tee’s in copper piping are acceptable for mains 2” and larger with the branch ½ or less than the main. Joint must be brazed. (6.13.8)

113. Do not permit grooved connections in domestic water copper piping.

114. Do not permit press type fittings in copper. (6.13.8)

115. Combination waste & vent is discouraged and may be used only for floor drains and floor sinks when other venting methods are not possible. Venting lavatories and sinks other than floor sinks is not permitted with combination waste & vent(8.8.12).

Make use of circuit venting where appropriate.

116. Drain lines serving commercial dishwashers should be high silicone cast iron.

Drains serving low temperature mild acid such as carbonated beverage machine drains should be PVC. Indicate on the drawings drain line material.

117. Domestic water piping shall be type L copper for above ground and type K copper for below grade. Do not permit press fittings. For O&M projects cross linked

Polyethylene (PEX) is permitted when largest pipe can be served by 1” PEX.

(5.19.8)

118. Domestic waste and vent drawings shall include a plan view of the plumbing fixtures and the waste piping serving those fixtures for each floor level, and an isometric view riser diagram. Vent piping does not need to be shown on the plan view; but do show the connection points to the waste piping. Waste piping shall be represented as a single continuous line. Vent piping shall be represented as a single dashed line. Indicate pipe sizing on the isometric riser diagram. (8.8.12)

119. Domestic hot and cold water drawings shall include a plan view of the plumbing fixtures and the water piping serving those fixtures for each floor level, and a riser diagram. The riser diagram may be an isometric view. The cold water shall be represented as a single line with a single dash. The hot water shall be represented as a single line with a double dash. (8.8.12)

120. Do not combine waste/vent drawings with hot/cold water drawings. Waste/vent plans, hot/cold plans, and riser diagrams may be included (8.29.14)on the same sheet if project size and space permits. (8.8.12)

121. Do not install whole building tempering valve for BEQ domestic hot water system heated by geothermal heat pumps that do not output 140F in a single pass. These heat pumps have trouble consistently heating storage tanks to 140F year-round and therefore tempering valve performance is affected (8.29.14). Store the hot water at

130-140 degrees, and deliver at the storage temperature. (1.18.13)

122. Provide pre-heat tank on solar hot water systems. Tank shall be sized for 1 day’s worth of peak heat production (60F to 180F) for BEQs and 3 day’s worth of peak heat production for other buildings, but not more than 1 day’s use of hot water. (8.29.14).

Mess Halls may have limited or no preheat storage as the day time demand is likely to exceed the collector capacity and the system will act only in the preheat manner (7.15.16).

123. Provide a testable double check back flow preventer on the building domestic water service unless otherwise noted in the scope of work. Locate in the mechanical room. (7.15.16).

FUEL FIRED DOMESTIC WATER HEATERS, WATER BOILERS and SMALL

STEAM BOILERS (8.30.10)

124. Boilers 399,000 btu/hr and smaller are heating appliances. Boilers 400,000 btu/hr and larger are utility boilers and have increased surveillance, inspection, and maintenance requirements. Utility boilers are serviced, inspected, and operated by

Utilities Department. Heating appliances are serviced and maintained by the Base

Maintenance Contractor. Use multiple condensing boilers under 400,000 btu/hr input for applications where the total load is less than 2,200,000 btu/hr for heating, and 1,440,000 btu/hr for domestic water.(8.29.14) Size the boilers for N+1 of 75% of the peak load, and all boilers no less than 100% of the peak demand. Where N equals the number of boilers to produce 75% peak demand (8.8.12). Except for very small buildings provide at least two boilers. Combined boiler capacity greater than building load is not necessary or desired. (12.8.16).

125. Dining Facilities: Provide separate steam boilers for the process loads

(dishwashers, steam kettles etc). Size each boiler for 110% of the process load in an

N+1 configuration. Boilers shall be 150psig maximum allowable working pressure, wet back fire tube. Operate boiler at 50psig with a minimum pressure of 25psig

(accounting for dead band during burner cycling). Burner shall be modulating type or two firing rate (hi/low fire) type. Provide steam pressure reducing station in a 1/3-2/3 configuration to reduce pressure to operating pressure of the equipment. (8.8.12)

126. Specify emergency gas shutoff. This is a remotely operated shut off valve. The labeled red mushroom valve shall be located next to the exit door.

127. Specify Gas pressure gage.

128. Specify lockable disconnect.

129. All boiler controls shall meet CSD-1. Show on the drawings the emergency shutdown switch required by CSD-1 CE 110 (a). The preferred method is a single illuminated 50mm dia mushroom switch with one set of normally open contacts on the inside of the exit door. On single boiler installations this switch shall trip a shunt trip breaker for the boiler. On multiple boiler installations this switch shall trip a shunt trip breaker that energizes a normally open contactor. (i.e. when shunt trip breaker trips, it no longer holds the contactor closed). Contactor shall have one set of contacts for each boiler circuit. The idea is to require a manual reset of the shut trip breaker after an emergency activation. Provide appropriate signage (1.2.13)

130. Specify service valves on inlet and outlet connections.

131. Boilers and tankless domestic water heaters shall have a minimum 30” piping and maintenance clearance on all sides. At least every other side shall have 30” clear floor space for personnel access (8.8.12). Do not stack boilers. All boilers shall sit on housekeeping pad on floor. Pumps may be stacked. (8.29.14)

132. Tank type domestic water heaters shall have 15” clearance to the sides and rear, and minimum 30” piping and maintenance clearance to the front (8.8.12).

133. Provide condensate neutralization kit for each all boiler/water heaters. Tank shall hold at least ¼ cubic foot of limestone and be rechargeable without disconnecting piping or brackets (8.8.12). Condensate for groups of small boilers (up to

1,200,000 btu/hr input(12.8.16)) may be collected in a header and pass thru a single neutralization tank. (7.15.16)

134. Exhaust vents shall be vertical discharge for environmental reasons, even with sidewall penetrations. i.e. no rain caps. (1.2.13)

135. For Fuel Gas fired water and steam boilers provide a gas shutoff valve within 30 feet of the mechanical room exit door and on the same or adjacent wall to the exit door. i.e. valve shall be easily accessible in direct route from door with no more than one 90 degree turn. This valve shall be quick operating type valve such as a ¼ turn ball valve. (1.18.13)

136. Steam Boilers shall have sample points for blowdown, condensate, and make up water. Sample points shall have sample coolers for blowdown and condensate water. Provide intermittent or continuous blowdown conductivity monitors with automated blow down valves. Provide meter with flow totalizer on makeup water. Refer to the following for specifics: UFC 3-240-13FN 25 May

2005, ASME Research Report CRTD-Vol. 81: Consensus on Operating Practices for the Sampling and Monitoring of Feedwater and Boiler Water Chemistry in

Modern Industrial Boilers. (7.15.16)

STEAM: Camp Lejeune is in the process of closing down the existing central steam distribution systems. New and renovated facilities are to use other sources of heating unless otherwise noted by the project manager (8.8.12).

137. Meters are required for steam, water(8.30.10) and electrical service to MWR facilities and all other reimbursable customers. (7.1.17)

138. Avoid (5.19.8) steam pits within mechanical rooms. Steam lines should be counter flowed from an exterior manhole.

139. Steam condensate receiver pumps should be steam pressure powered. Do not use electric duplex condensate pumps.

140. Minimize use of steampits. Those required must be raised 18 inches (450 mm) above finish grade and equipped with a full grated top. Steampits are required for the connection and valving of building service lines. Drip legs can be direct buried with steam trap above ground in a “doghouse” if the steam pit is not required for other reasons. Steampits are required at low points and end of mains in order to gravity drain condensate for cold start up of distribution system.

141. Do not use FRP pipe for buried steam condensate lines. Use schedule 80 black steel pipe in condensate systems.

142. Steam tunnels and trenches are preferred by base utilities over direct buried preinsulated steam and condensate systems. Trench tops may double as a sidewalk where appropriate.

143. Direct buried steam and condensate piping shall be drainable, dryable, testable.

Do not include thermal performance testing or sensors (i.e. Delete from guide specification). Edit the testing specification as follows: Socket welded pipe does not need to be tested. As an alternative to radiographic testing, the butt welds may be ultrasonically tested. The report shall be similar to that of the radiographic exam, i.e., examiner shall sign and date report, defects and location shall be noted, weld shall be graded acceptable or unacceptable, etc. Welded connections shall not be covered until the government selects 10% of the connections to be tested. (5.26.09)

144. Use externally pressurized bellows expansion joints when inline expansion in steam lines is required and where loops cannot be utilized. Slip tube expansion joints are acceptable but not preferred over externally pressurized bellows joints.

145. Provide check valves and test valves at all steam condensate drip stations.

146. Base operating steam pressures are as follows:

Steam Plant Steam Pressure

Plant 1700 150 psi (1034 kPa)

Plant AS4151 50 psi (345 kPa)(8.29.14) Decom 2016

Plant G650 50 psi (345 kPa) decommissioned 2015

Plant M625 50 psi (345 kPa)(8.29.14)Decom 2016

Plant RR15 50 psi (345 kPa)

Plant PP2615 50 psi (345 kPa)(decommissioned 8.30.10)

Plant M230 50 psi (345 kPa)(decommissioned)

Plant BB9 100 psi (690 kPa) decommissioned 2016

Plant NH100 100 psi (690 kPa)

147. Specify steam control valve actuators that can withstand heat conducted from steam lines and equipment. Do not specify, or approve, hydraulic powered actuators in steam applications.

148. Install blow down valves on all strainers.

149. It is preferred to distribute hot water throughout building or building complex for heating in lieu of direct steam heat.

150. Specify flange gaskets to be metal spiral wound ASME B16.20.

151. All steam pressure powered pumps (PPP) shall have a direct acting pressure regulator on the motive steam. Provide pressure gages on the motive steam line and the condensate collection system. Regulator to be set for 20 psi higher than the condensate back pressure. Regulator shall be 20’ from PPP, or the line between the regulator and the pump shall be oversized. (12.31.07) If the steam distribution pressure exceeds pump body pressure rating, a safety relief valve must be installed in the steam supply. (8.30.10)

152. Ensure that all steam heated equipment with modulating steam control valves have vacuum breakers, air vents, and gravity drain to a condensate receiver. Show sufficient details to ensure contractor pipes accordingly. The mechanical room plan shall also allow for this. If a pumping trap is required, show it on the drawing.

(12.31.07)

153. Valves for 100psi and greater steam shall be steel bodied valves. (1.28.10)

154. Camp Lejeune has introduced flooded vertical heat exchangers that use line pressure steam and a control valve on the condensate discharge in lieu of a steam control valve thereby omitting the need for a steam pressure regulator, steam pressure safety valve, steam control valve and a condensate pump. Contact the Public Works project manager to coordinate the use of the traditional steam system or the flooded vertical heat exchanger on each project. Contact the mechanical branch manager to get the standard detail and about application. (1.28.10)

SWIMMING POOLS (5.10.09)

155. Swimming pool chemistry and filters are monitored by PW Utilities and pools shall be equipped as followings.

156. Pool shall have pool controller that automatically monitors and feeds sodium hypochlorite and sulfuric acid, and backwashes the filter.

a) Controller shall read ORP or free chlorine, and PH.

b) Controller shall transmit free chlorine, and PH values to the corresponding water plant via radio.

c) Pool water temperature shall also be sensed and transmitted on indoor pools.

d) Controller shall transmit a master alarm to the corresponding water plant via radio in the event of high or low ORP or PH levels, no sensor water flow, and elapsed chemical feed alarm.

e) Chemical feed system shall be interlocked to shut off in the event of no pool circulation water flow.

f) The preferred pool controller is Bec System 7.

g) Electronics shall have a 60 minute battery backup.

157. Filter backwash shall have manual over-ride such that the filters can be backwashed in the event of controller failure.

158. Normal pool water waste shall be to the sanitary sewer, with a bypass to the storm sewer. This can be used to empty pool after dechlorination. A dechlorinator shall be installed. (7.2.09)

159. A normally energized duplex receptacle needs to be installed near the chemical feed pumps to manually feed chemicals in the event of pool controller failure. If chemical feed is controlled by energizing/de-energizing the receptacle supplying the feed pumps, each pump shall have a separate, independent, and labeled receptacle.

(7.2.09)

160. Minimum chemical storage for an indoor Olympic size pool shall be 300 gallons of sodium hypochlorite, and 150 gallons of sulfuric acid. Chemical storage shall be proportional to pool size. Outdoor pools require increased storage capacity. All chemical storage tanks shall have secondary containment. Chemical rooms shall be mechanically vented, dedicated to chemical storage and large enough to increase the storage by 50%. Chemical rooms shall be located with easy access by delivery tanker truck. Entrances to chemical room shall be labeled with Hazmat Placard. (7.2.09)

161. Do not use brass saddles at chemical injection points. Use PVC.

162. Do not locate normally serviced equipment such as pumps, backflow preventers, lint traps, etc in pits. Equipment that requires regular operation, service, or maintenance shall not be located in confined spaces. (7.2.09)

163. The contractor shall modify the front end software at the water plant to receive and display the new pool.

a) Wallace creek recreation center shall transmit to the building 20 water plant.

b) The wounded warrior pool shall transmit to the building 670 water plant.

164. Swimming pools shall comply with 15A NCAC 18.A2500, (North Carolina Rules for Public Swimming Pools), with the following exception: Do not provide an integral vacuum system as called for in 15A NCAC 18A.2518(g). The pool chemistry is maintained by the PW Utilities. The cleaning is done by the pool operators. We do not want pool operators to have access to the pump room, which would be necessary if an integral vacuum system were installed.

165. Filter rooms should have a pedestrian door and an 8’x8’ roll up door for forklift and pallet access. Provide differential pressure gage across each filter to be easily read while standing in front of filter. (7.2.09)

ENERGY

166. For partial renovation and/or repair projects, energy modelling may not be practical or in the design scope of work. To comply with the intended goal of 20% better than ASHRAE, specify equipment and individual assembly performance to be

20% better than the ASHRAE prescriptive requirement. Examples: replacing just the air conditioning in a building, or reroofing a building. In these cases the building cannot be made to comply with the 20% goal, but an air conditioner 20% better, or roof insulation 20% better than ASHRAE meets the intent. (8.29.14)

167. Building thermal envelope assemblies shall at a minimum meet the prescriptive requirements of ASHRAE 90.1 with the following exceptions. (2.10.10)

168. Metal and wood studs walls shall be 6” with R19 insulation. (2.10.10)

169. Mass walls shall have a minimum of R10 rigid insulation between wythes of masonry or on the exterior of the massive layer. Insulation in the cells of CMU does not fulfill this requirement. (2.10.10)

170. Windows shall meet ATFP requirements, laminated, meet ASHRAE 90.1 prescriptive requirements. No tilting sashes are permitted. (2.10.10)

171. Water meters are required on all new buildings. Preferred location is in mechanical room and shall report thru the DDC to the EMCS. (8.30.10)

172. Return duct to ERV’s shall be insulated when passing thru unconditioned spaces.

(8.8.12)

173. Equipment energy efficiencies shall meet the Federal Energy Management

Program (FEMP) designated efficiency, DOE Energy Star criteria, and ASHRAE

90.1 2010. Refer to FEMP, Energy Star, ASHRAE documentation for greater detail.

Specify efficiencies as necessary to meet the project’s goals. Unless otherwise noted, the minimum efficiencies are listed below (7.15.16).

a. Hot water gas fired boilers under 300 MBH: 90% AFUE

b. Hot water gas fired boilers over 300 MBH: 94% Thermal Efficiency

c. Gas fired steam boiler, 300 MBH-10,000 MBH: 80% Thermal Efficiency

d. Domestic hot water gas fired heater with storage, <= 75 MBH input: <=55 gal, EF=>.67; <55 gal, EF=>.77

e. Domestic hot water gas fired heater with storage, over 75 MBH input: TE>=.94, or EF>=.93

f. Domestic hot water gas fired instantaneous, >40 and <200 MBH input: TE>.9

g. Air-source heat pump, 3 phase, packaged unit, <65,000 Btu/hr: 14 SEER; 11

EER; 8.0 HSPF

h.…