_PKJCC HVAC Specs Final.pdf

MULTIPLE BUILDING HVAC REPLACEMENT 001500-1

PINE KNOT JOB CORPS CCC LIST OF DRAWINGS AND SPECIFICATIONS

SECTION 001500

PINE KNOT JOB CORPS CCC

MULTIPLE BUILDING HVAC REPLACEMENT

LIST OF DRAWINGS AND SPECIFICATIONS

PART 1 – GENERAL

1.1 DESCRIPTION

A. List of Contract Drawings:

1. Index of Sheets:

T1.0 Title Sheet G1.1 G2.1 M0.1 M1.1 M2.1 M3.1 M4.1 M5.1

Campus Map General Notes and Legends Equipment Schedule and Details Mechanical/Electrical Plan and Photos – Dispensary (Bldg75) Mechanical/Electrical Plan and Photos – Warehouse (Bldg 33) Mechanical/Electrical Plan and Photos – Humphrey Dorm (Bldg 56) Mechanical/Electrical Plan and Photos – Education (Bldg 65) Mechanical/Electrical Plan and Photos – King Hall (Bldg 57)

9 Total Number of Sheets

B. List of Contract Specifications

1. Index of Specifications

DIVISION 1 - GENERAL REQUIREMENTS

Section 001500 List of Drawings and Specifications Section 010150 General Requirements

DIVISION 23 – HEATING VENTILATING AND AIR CONDITIONING

Section 230050 Section 232300 Section 235400 Section 236200 Section 237313 Section 238216

Mechanical Materials and Methods Refrigerant Piping Furnaces Condensing Units Blower Coil Air-Handling Units Split Heat Pumps

DIVISION 26 – ELECTRICAL

MULTIPLE BUILDING HVAC REPLACEMENT 001500-2

PINE KNOT JOB CORPS CCC LIST OF DRAWINGS AND SPECIFICATIONS

Section 260100 Common Work Results for Electrical Section 260500 Conductors, Cables, and Raceways Section 262816 Enclosed Switches and Circuit Breakers

END OF SECTION 001500

PINE KNOT JOB CORPS CCC 010150 – 1

MISCELLANEOUS BUILDING HVAC REPLACEMENT GENERAL REQUIREMENTS

SECTION 010150

GENERAL REQUIREMENTS

PART 1 – SUMMARY OF WORK

1.1 DESCRIPTION

A. Work for this project requires the contractor to be responsible for supplying all labor, materials, equipment, utilities, miscellaneous items, freight and delivery and all necessary valid licenses for the work summarized as follows:

1. Replace HVAC units in various buildings at the Pine Knot Job Corps Center.

1.2 LOCATION

A. This project is located at the Pine Knot Job Corps Center located approximately one mile from Pine Knot, Kentucky. The address is 132 Job Corps Road, Pine Knot, KY 42635

B. Driving instructions can be obtained from the Center by calling 606-354-2176.

1.3 PROJECT SCHEDULING

A. Work hours for this project are between 8:00 AM-4:30 PM Monday through Friday.

1.4 POINT OF CONTACT

Center Point of Contact: Mark Kolander, ph: 606-354-4200, mark.s.kolander@usda.gov.

1.5 USE OF PREMISES

A. Confine constructions operations to immediate area of work. Do not disturb portions of Project site beyond areas in which the Work is indicated.

B. Government will occupy site and buildings during entire construction period. Cooperate with Government during construction operations to minimize conflicts and facilitate Government usage. Perform the work so as not to interfere with Government's day-to-day operations.

C. Keep driveways, parking areas, loading areas and entrances to buildings clear and available to Government, Government's employees, and emergency vehicles at all times.

Do not use these areas for parking or storage of materials. Do not close or obstruct walkways, corridors, or other occupied or used facilities without written permission from Government.

1.6 WORK RESTRICTIONS

PINE KNOT JOB CORPS CCC 010150 – 2

A. Smoking is permitted on campus only in the designated smoking area.

1.7 SCHEDULE OF ITEMS

A. Schedule of Items: The project Schedule of Items includes several sections to organize the work into Base Items.

1. Provide pricing for all items listed in the Schedule of Items.

2. Contract award will be made for all Base Items.

B. Base Items (BI):

1. Base Item No. 1- HVAC Replacement at Dispensary (Bldg 75)

a. Measurement: This item is measured as a Lump Sum quantity.

b. Payment: The contract lump sum price as shown in the Schedule of Items shall include all materials, equipment, labor and incidentals to perform all operations necessary to complete the work as shown on the drawings and specifications, including all demolition, and disposal, and electrical to install new HVAC indoor and outdoor units for 3 HVAC systems in the Dispensary Building.

2. Base Item No. 2 - HVAC Replacement at Warehouse/Fire Training (Bldg 33)

b. Payment: The contract lump sum price as shown in the Schedule of Items shall include all materials, equipment, labor and incidentals to perform all operations necessary to complete the work as shown on the drawings and specifications, including all demolition, and disposal, and electrical to install new HVAC indoor and outdoor unit for 1 HVAC system in the Warehouse/Fire Training Building.

3. Base Item No. 3 - HVAC Replacement at Humphrey Hall (Bldg 56)

b. Payment: The contract lump sum price as shown in the Schedule of Items shall include all materials, equipment, labor and incidentals to perform all operations necessary to complete the work as shown on the drawings and specifications, indoor and outdoor unit for 1 HVAC system at Humphry Hall.

4. Base Item No. 4 - HVAC Replacement at Education (Bldg 65)

b. Payment: The contract lump sum price as shown in the Schedule of Items shall include all materials, equipment, labor and incidentals to perform all operations necessary to complete the work as shown on the drawings and specifications, indoor and outdoor units for 1 HVAC system at Education Building.

PINE KNOT JOB CORPS CCC 010150 – 3

5. Base Item No. 5 - HVAC Replacement at King Hall (Bldg 57)

b. Payment: The contract lump sum price as shown in the Schedule of Items shall include all materials, equipment, labor and incidentals to perform all operations necessary to complete the work as shown on the drawings and specifications, indoor and outdoor unit for 1 HVAC system at King Hall.

PART 2 – SUBMITTAL PROCEDURES

2.1 DEFINITIONS

A. Action Submittals: Written and graphic information that requires Government review.

B. Informational Submittals: Written information that does not require Government review.

Submittals may be rejected for not complying with requirements.

2.2 PROCEDURES

A. Contractor Responsibilities

1. Review each submittal and check for compliance with the Contract Documents.

2. Highlight, encircle, or otherwise identify deviations from the Contract Documents on submittals.

3. Include the following information on label or cover sheet for processing and recording action taken:

a. Project name.

b. Date.

c. Name and address of Contractor.

d. Name of manufacturer.

e. Unique identifier, including revision number.

f. Number and title of appropriate Specification Section.

g. Drawing number and detail references, as appropriate.

h. Date of Contractor’s approval.

i. Statement certifying that submittal has been reviewed, checked, and approved by the Contractor for compliance with the Contract Documents.

4. The Government will not review submittals that do not bear Contractor's approval and will return them without action.

5. Unless additional copies are required for final submittal, and unless the

Contracting Officer (CO) observes noncompliance with provisions of the Contract Documents, initial submittal may serve as final submittal.

6. Submittals must be submitted in electronic PDF format. Submit to CO via email or electronic file transfer site.

PINE KNOT JOB CORPS CCC 010150 – 4

7. Only final submittals with mark indicating action taken by Government are to be used for construction.

8. Submittals not required by the Contract Documents will not be reviewed and may be discarded.

B. Processing Time: Time for review shall commence on CO's receipt of submittal.

1. Initial Review: Government will review initial submittal within 10 working days.

Additional time may be needed if processing must be delayed to permit coordination with subsequent submittals. CO will advise Contractor when a submittal being processed must be delayed for coordination.

2. Resubmittals: If resubmittal is necessary, it will be processed in same timeframe as initial submittal.

2.3 ACTION SUBMITTALS

A. Prepare and submit Action Submittals required in the Technical Specifications in this contract, if applicable, and as indicated at the end of this subsection.

B. Collect information into a single submittal for each element of construction and type of product or equipment.

1. Mark up each submittal to show which products and options are applicable.

2. Include the following information, as applicable:

a. Manufacturer's written recommendations.

b. Manufacturer's product specifications.

c. Manufacturer's installation instructions.

d. Manufacturer's catalog cuts.

e. Wiring diagrams showing factory-installed wiring.

f. Compliance with recognized trade association standards.

g. Compliance with recognized testing agency standards.

C. Required Action Submittals

1. Product Data: See Technical Specification Sections.

2. Existing Conditions: Upon award, and prior to beginning work, submit plan for each building that show the following for the equipment being replaced:

a. Existing equipment make and model numbers, including performance information such as tonnage, wattage, BTU’s and electrical information such as voltage, amperage, and phase.

b. Existing electrical disconnect sizes and locations.

c. Existing circuit breaker sizes and panel locations.

d. Required electrical disconnect sizes, circuit breaker sizes, and wiring sizes for new equipment.

e. Summary of existing electrical components that will need to be replaced to accommodate new equipment.

PINE KNOT JOB CORPS CCC 010150 – 5

2.4 INFORMATIONAL SUBMITTALS

A. Prepare and submit Informational Submittals required in the Technical Specifications in this contract, if applicable, and as indicated below:

B. Required Informational Submittals:

1. Accident Prevention Plan.

2. Construction Schedule.

2.5 CLOSEOUT SUBMITTALS

A. Prepare and submit Closeout Submittals, as follows:

1. See Technical Specification Sections.

PART 3 – TEMPORARY FACILITIES AND CONTROLS

3.1 USE OF UTILITIES

A. Utilities: Use of Government existing facilities will be permitted without metering and without payment of use charges, as long as facilities are cleaned and maintained in an acceptable condition. At Substantial Completion, restore these facilities to condition existing before initial use. The following are available for use by the contractor: water, and electrical power services. The following are not available: telephone service. The contractor is expected to provide whatever phone service he deems necessary for the duration of the project.

3.2 SANITARY FACILITIES

A. Sanitary facilities are available for use by the Contractor in each of the buildings in this contract. Facilities must be cleaned and maintained daily.

3.3 STAGING AND STORAGE

A. Coordinate on-site staging and storage requirements with the Center Point of Contact or the Contracting Officer Representative (COR).

3.4 CONSTRUCTION WASTE DISPOSAL FACILITIES

A. Provide waste-collection containers in sizes adequate to handle waste from construction operations. Containerize and clearly label hazardous, dangerous, or unsanitary waste materials separately from other waste.

3.5 SAFETY AND ENVIRONMENTAL PROTECTION

A. Environmental Protection: Contractor shall provide protection, operate temporary facilities, and conduct construction in ways and by methods that comply with

PINE KNOT JOB CORPS CCC 010150 – 6

environmental regulations and that minimize possible air, waterway, and subsoil contamination or pollution or other undesirable effects.

B. Barricades, Warning Signs, and Lights: Comply with the national or state Manual on Uniform Traffic Control Devices (MUTCD) for erecting structurally adequate barricades, paint with appropriate colors, graphics, and warning signs/lights to inform personnel, students, and the public of possible hazards.

C. Fire Protection.

1. Store combustible materials in containers in fire-safe locations.

2. Maintain unobstructed access to fire extinguishers, fire hydrants, fire-protection facilities, stairways, and other access routes for firefighting. Prohibit smoking in hazardous fire-exposure areas.

3. Supervise welding operations, combustion-type temporary heating units, and similar sources of fire ignition.

PART 4 – EXECUTION REQUIREMENTS

4.1 EXAMINATION

A. Before beginning work, examine areas and document existing conditions. Proceed with installation only after unsatisfactory conditions have been corrected. Proceeding with the Work indicates acceptance of surfaces and conditions.

B. Field verify all new and existing dimensions affecting the work of this contract before ordering products.

C. Immediately on discovery of the need for clarification of the Contract Documents, submit a request for information to CO. Include a detailed description of problem encountered, together with recommendations for changing the Contract Documents.

4.2 INSTALLATION

A. Locate the Work and components of the Work accurately, in correct alignment and elevation to fit with existing construction.

B. Make vertical work plumb and make horizontal work level.

C. Install per manufacturer's written instructions and recommendations.

4.3 PROGRESS CLEANING

A. Clean Project site and work areas daily, including common areas. Dispose of materials lawfully.

PINE KNOT JOB CORPS CCC 010150 – 7

1. Comply with NFPA 241 requirements for removal of combustible waste materials and debris.

2. Do not hold materials more than 7 days during normal weather or 3 days if the temperature is expected to rise above 80 deg F (27 deg C).

B. Burying or burning waste materials on-site will not be permitted. Washing waste materials down sewers or into waterways will not be permitted.

4.4 PROTECTION OF INSTALLED CONSTRUCTION

A. Provide protection and maintain conditions that ensure installed Work does not get damaged or deteriorated prior to Substantial Completion.

4.5 CORRECTION OF THE WORK

A. Repair or remove and replace defective construction. Restore damaged substrates and finishes.

1. Repairing includes replacing defective parts, refinishing damaged surfaces, touching up with matching materials, and properly adjusting operating equipment.

PART 5 – WASTE MANAGEMENT AND RECYCLING

5.1 DESCRIPTION

A. This Section consists of administrative and procedural requirements for recycling and disposal of nonhazardous waste.

5.2 GENERAL

A. Provide handling, containers, storage, signage, transportation, and other items as required to implement waste disposal.

B. Identify anticipated types of waste generated and determine whether it will be recycled or disposed.

5.3 RECYCLING WASTE

A. Remove, recover, and reclaim refrigerant from air conditioning equipment being removed in accordance with Section 608 of the Clean Air Act of 1990 as amended, including final regulations.

B. Provide marked containers or bins for controlling recyclable waste.

C. Separate recyclable waste from other waste materials, trash, and debris.

PINE KNOT JOB CORPS CCC 010150 – 8

D. Remove recyclable waste from the property and transport to recycling receiver or processor.

E. The contractor is encouraged to also recycle other waste materials where possible.

Revenues, savings, rebates, tax credits, and other incentives received for recycling waste materials shall accrue to the Contractor.

PART 6 – CLOSEOUT PROCEDURES

6.1 SUBSTANTIAL COMPLETION

A. Definition of Substantial Completion: The Date certified by the CO when construction is sufficiently complete, in accordance with the Contract Documents, so the Government can occupy or utilize the Work or designated portion thereof for the use for which it is intended, as expressed in the Contract Documents.

B. Preliminary Procedures: Before requesting inspection for determining date of Substantial Completion, complete the following. List items below that are incomplete in request.

1. Prepare a list of items to be completed and corrected (punch list), the value of items on the list, and reasons why the Work is not complete.

2. Advise the CO of pending insurance changeover requirements.

3. Submit specific warranties, workmanship bonds, final certifications, and similar documents.

4. Obtain and submit releases permitting Government unrestricted use of the Work and access to services and utilities.

5. Deliver tools, spare parts, extra materials, and similar items to location designated by Government. Label with manufacturer's name and model number where applicable.

6. Complete startup testing of systems.

7. Submit changeover information related to Government occupancy, use, operation, and maintenance.

8. Complete final cleaning requirements, including touchup painting.

9. Touch up and otherwise repair and restore marred exposed finishes to eliminate visual defects.

C. Inspection: Submit a written request for inspection for Substantial Completion. On receipt of request, CO will either proceed with inspection or notify Contractor of unfulfilled requirements. CO will prepare the Certificate of Substantial Completion after inspection or will notify Contractor of items, either on Contractor's list or additional items identified by CO, that must be completed or corrected before certificate will be issued.

1. Reinspection: Request reinspection when the Work identified in previous inspections as incomplete is completed or corrected.

PINE KNOT JOB CORPS CCC 010150 – 9

2. Results of completed inspection will form the basis of requirements for Final Completion.

6.2 FINAL COMPLETION

A. Preliminary Procedures: Before requesting final inspection for determining date of Final Completion, complete the following:

1. Submit certified copy of CO’s Substantial Completion inspection list of items to be completed or corrected (punch list), endorsed and dated by CO. The certified copy of the list shall state that each item has been completed or otherwise resolved for acceptance.

2. Submit evidence of final, continuing insurance coverage complying with insurance requirements.

3. Instruct Government personnel in operation, adjustment, and maintenance of products, equipment, and systems.

B. Inspection: Submit a written request for final inspection for acceptance. On receipt of request, CO will either proceed with inspection or notify Contractor of unfulfilled requirements. CO will prepare a final Certificate for Payment after inspection or will notify Contractor of construction that must be completed or corrected before certificate will be issued.

1. Reinspection: Request reinspection when the Work identified in previous inspections as incomplete is completed or corrected.

6.3 LIST OF INCOMPLETE ITEMS (PUNCH LIST)

A. Preparation: Submit two copies of list. Include name and identification of each space and area affected by construction operations for incomplete items and items needing correction including, if necessary, areas disturbed by Contractor that are outside the limits of construction.

6.4 PROJECT RECORD DOCUMENTS

A. General: Do not use Project Record Documents for construction purposes. Protect Project Record Documents from deterioration and loss. Provide access to Project Record Documents for CO's reference during normal working hours.

B. Provide Draft of Project Record Drawings at Substantial Completion. CO will return reviewed copy. Provide Final Project Record Drawings at Final Completion.

C. Record Drawings: Maintain and submit one set of blue- or black-line white prints of Contract Drawings and Shop Drawings.

1. Mark Record Prints to show the actual installation where installation varies from that shown originally. Require individual or entity who obtained record data, PINE KNOT JOB CORPS CCC 010150 – 10 whether individual or entity is Installer, subcontractor, or similar entity, to prepare the marked-up Record Prints.

a. Give particular attention to information on concealed elements that cannot be readily identified and recorded later.

b. Record data as soon as possible after obtaining it. Record and check the markup before enclosing concealed installations.

2. Mark record sets with erasable, red-colored pencil. Use other colors to distinguish between changes for different categories of the Work at the same location.

3. Note Construction Change Directive numbers, Change Order numbers, alternate numbers, and similar identification where applicable.

4. Identify and date each Record Drawing; include the designation "PROJECT RECORD DRAWING" in a prominent location. Organize into manageable sets;

bind each set with durable paper cover sheets. Include identification on cover sheets.

6.5 FINAL CLEANING

A. General: Provide final cleaning. Conduct cleaning and waste-removal operations to comply with local laws and ordinances and Federal and local environmental and antipollution regulations.

B. Cleaning Agents: Use cleaning materials and agents recommended by manufacturer or fabricator of the surface to be cleaned. Do not use cleaning agents that are potentially hazardous to health or property or that might damage finished surfaces.

C. Complete the following cleaning operations before requesting inspection for certification of Substantial Completion for entire Project or for a portion of Project:

1. Clean Project site, yard, and grounds, in areas disturbed by construction activities, including landscape development areas, of rubbish, waste material, litter, and other foreign substances.

2. Remove tools, construction equipment, machinery, and surplus material from Project site.

3. Touch up and otherwise repair and restore marred, exposed finishes and surfaces.

Replace finishes and surfaces that cannot be satisfactorily repaired or restored or that already show evidence of repair or restoration.

D. Remove waste materials from Project site and dispose of lawfully.

PINE KNOT JOB CORPS CCC 010150 – 11

END OF SECTION 010150

PINE KNOT JOB CORPS CCC 010150 – 12

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MULTIPLE BUILDING HVAC REPLACEMENT 230050 - 1

PINE KNOT JOB CORPS CCC MECHANICAL MATERIALS AND METHODS

SECTION 230050

MECHANICAL MATERIALS AND METHODS

PART 1 - GENERAL

1.1 SUMMARY

This section includes general mechanical removal and installation requirements.

1.2 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specifications.

1.3 COORDINATION

A. Coordinate shutdown of heating, cooling and ventilation systems with Contracting Officer.

PART 2 – PRODUCTS (NOT USED)

PART 3 -EXECUTION

3.1 MECHANICAL REMOVAL

A. Disconnect, demolish, and remove HVAC systems, equipment, and components indi-cated to be removed.

1. Equipment to Be Removed: Disconnect and temporarily cap connections. Re-move equipment. Dispose of equipment of off Government land.

B. If during construction duct, insulation, or equipment to remain is damaged in appear-ance or is unserviceable, remove damaged or unserviceable portions and replace with new products of equal capacity and quality.

C. Remove, relocate, and extend existing installations to accommodate new construction.

D. Remove exposed abandoned ducts, including abandoned ducts above accessible ceiling finishes, in attic, and in crawl space. For inaccessible ducts, cut pipe flush with walls and floors, cap duct, and patch surfaces.

E. Repair adjacent construction and finishes damaged during demolition and extension work.

F. Extend existing installations using materials and methods as specified.

MULTIPLE BUILDING HVAC REPLACEMENT 230050 - 2

PINE KNOT JOB CORPS CCC MECHANICAL MATERIALS AND METHODS

G. Removed equipment, etc. become the property of the Contractor unless otherwise noted.

3.2 HVAC SYSTEMS - COMMON REQUIREMENTS

A. Install equipment in accordance with manufacturer’s installation instructions.

B. Install equipment to allow maximum possible headroom.

C. Install equipment level and plumb, parallel and perpendicular to other building systems and components in exposed interior spaces, unless otherwise indicated.

D. Drawings are diagrammatic and show general design, arrangement, and extent of sys-tems. Do not scale drawings for roughing-in measurement. Field verify locations, and make changes to configurations to suit actual conditions.

END OF SECTION 230050

MULTIPLE BUILDING HVAC REPLACEMENT 232300 - 1

PINE KNOT JOB CORPS CCC REFRIGERANT PIPING

SECTION 232300

REFRIGERANT PIPING

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes refrigerant piping used for air-conditioning applications.

1.2 SUBMITTALS

A. As specified in, “Submittal Procedures” Paragraph of Division 1 Section “General Requirements”.

B. Product Data: For each type of refrigerant pipe, hangers, and supports.

1.3 CLOSEOUT SUBMITTALS

A. As specified in, “Submittal Procedures” Paragraph of Division 1 Section “General Requirements”.

1. Field quality-control reports.

1.4 QUALITY ASSURANCE

A. Comply with ASHRAE 15, "Safety Code for Refrigeration Systems."

B. Comply with ASME B31.5, "Refrigeration Piping and Heat Transfer Components."

PART 2 – PRODUCTS

2.1 COPPER TUBE AND FITTINGS

A. Copper Tube: ASTM B 280, Type ACR.

1. Wrought-Copper Fittings: ASME B16.22.

2. Wrought-Copper Unions: ASME B16.22.

B. Brazing Filler Metals: AWS A5.8.

C. Flexible Connectors:

1. Body: Tin-bronze bellows with woven, flexible, tinned-bronze-wire-reinforced protective jacket.

2. End Connections: Socket ends.

3. Offset Performance: Capable of minimum 3/4-inch (20-mm) misalignment in minimum 7-inch- (180-mm-) long assembly.

MULTIPLE BUILDING HVAC REPLACEMENT 232300 - 2

4. Pressure Rating: Factory test at minimum 500 psig (3450 kPa).

5. Maximum Operating Temperature: 250 deg F (121 deg C).

2.2 REFRIGERANT LINE SETS

A. Refrigerant line set consisting of copper tubes and insulation for use with R-410A refrigerant, tested in accordance with ASTME243,

1. Copper tubes: ASTM B280, annealed, refrigerant grade, ACR type with flared ends and provided with forged brass flare nuts protected with plastic inserts.

precharged and capped, minimum 1/2” insulated copper liquid and suction tubing.

2. Insulation: Flexible, closed-cell, CFC-free, elastomeric material.

a. Thermal Conductivity: 0.27 BTU-inch/hour per Sq Ft/oF.

b. Water Vapor Transmission: 0.08 Perm-inch.

2.3 PIPE SUPPORTS AND HANGERS

A. Hangers: Pre-galvanized or hot dipped galvanized steel hangers with fiberglass or other pipe insulation pad or cushion for support of bearing surface of pipe.

B. Rooftop Pipe Supports: 6-inch square polycarbonate base with pre-formed pipe cradle, aluminum pipe strap, and stainless steel screws suitable for refrigerant pipe support. Unipier Rooftop Pipe Support System by Unistrut or equal.

C. Insulated pipe supports: Load-bearing rigid foam insert with elastomeric foam collars, with minimum compressive strength of 72 psi encased in sheet metal shield. Provide pipe support with the same insulation thickness as the pipe insulation.

D. Protection Shields (MSS Type 40): Galvanized protection shields to prevent crushing insulation.

2.4 INSULATION

A. Insulation: Closed-cell, sponge- or expanded-rubber materials complying with ASTM C 534, Type I, minimum insulation thickness of 1 inch.

1. Protective Finish: White, water-based latex enamel paint.

PART 3 – EXECUTION

3.1 PIPING INSTALLATION

A. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems.

MULTIPLE BUILDING HVAC REPLACEMENT 232300 - 3

B. Install refrigerant piping according to ASHRAE 15.

C. Install piping in concealed locations unless otherwise indicated and except in equipment rooms and service areas.

D. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise.

E. Install piping above accessible ceilings to allow sufficient space for ceiling panel removal.

F. Install piping adjacent to machines to allow service and maintenance.

G. Install piping free of sags and bends.

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

I. Select system components with pressure rating equal to or greater than system operating pressure.

J. Install piping as short and direct as possible, with a minimum number of joints, elbows, and fittings.

K. Arrange piping to allow inspection and service of refrigeration equipment. Install valves and specialties in accessible locations to allow for service and inspection.

L. Slope refrigerant piping as follows:

1. Install horizontal hot-gas discharge piping with a uniform slope downward away from compressor.

2. Install horizontal suction lines with a uniform slope downward to compressor.

3. Liquid lines may be installed level.

M. When brazing or soldering, remove solenoid-valve coils and sight glasses; also remove valve stems, seats, and packing, and accessible internal parts of refrigerant specialties. Do not apply heat near expansion-valve bulb.

N. Install pipe sleeves at penetrations in exterior walls, roofs and floor assemblies. Install sleeves through floors, walls, or ceilings, sized to permit installation of full-thickness insulation. Route refrigerant lines through sleeve and seal weather tight.

O. Install piping with adequate clearance between pipe and adjacent walls and hangers or between pipes for insulation installation.

3.2 PIPE JOINT CONSTRUCTION

MULTIPLE BUILDING HVAC REPLACEMENT 232300 - 4

A. Soldered Joints: Construct joints according to ASTM B 828 or CDA's "Copper Tube Handbook."

B. Brazed Joints: Construct joints according to AWS's "Brazing Handbook," Chapter "Pipe and Tube."

1. Use Type BcuP, copper-phosphorus alloy for joining copper socket fittings with copper pipe.

2. Use Type BAg, cadmium-free silver alloy for joining copper with bronze or steel.

3.3 HANGERS AND SUPPORTS

A. Install the following pipe attachments:

1. Adjustable steel clevis hangers for individual horizontal runs less than 20 feet long.

2. Roller hangers and spring hangers for individual horizontal runs 20 feet or longer.

3. Pipe Roller: MSS SP-58, Type 44 for multiple horizontal piping 20 feet or longer, supported on a trapeze.

B. Install hangers for copper tubing with the following maximum spacing and minimum rod sizes:

1. NPS 1/2 (DN 15): Maximum span, 60 inches (1500 mm); minimum rod size, 1/4 inch (6.4 mm).

2. NPS 5/8 (DN 18): Maximum span, 60 inches (1500 mm); minimum rod size, 1/4 inch (6.4 mm).

3. NPS 1 (DN 25): Maximum span, 72 inches (1800 mm); minimum rod size, 1/4 inch (6.4 mm).

C. Install insulated pipe supports and protection shields under all insulated lines at unistrut clamps, clevis hangers, or other locations where insulation may be compressed. Do not install pipe strap in contact with copper pipe.

3.4 INSULATION INSTALLATION

A. Install insulation in accordance with manufacturer’s recommendations and as specified in Section 23 “HVAC Insulation.”

3.5 FIELD QUALITY CONTROL

A. Notify Contracting Officer at least 48 hours before inspection and testing. Perform tests and inspections in the presence of the Contracting Officer. Prepare report for each test, signed by Installer, General Contractor, and Contracting Officer.

B. Purging, Leak Testing, and Charging:

MULTIPLE BUILDING HVAC REPLACEMENT 232300 - 5

1. Perform purging, leak testing, and charging in the presence of the Contracting Officer.

2. Perform purging, leak testing, and charging in accordance with manufacturer’s literature.

END OF SECTION 232300

MULTIPLE BUILDING HVAC REPLACEMENT 232300 - 6

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MULTIPLE BUILDING HVAC REPLACEMENT 235400 - 1

PINE KNOT JOB CORPS CCC FURNACES

SECTION 235400

FURNACES

PART 1 – GENERAL

1.1 SUMMARY

A. This Section includes gas-fired condensing furnaces and accessories.

1.2 SUBMITTALS

A. As specified in, “Submittal Procedures” Paragraph of Division 1 Section “General Requirements”.

1. Product Data: Include rated capacities, operating characteristics, furnished spe-cialties and accessories for each of the following:

a. Furnace.

b. Cooling coil.

c. Thermostat.

d. Venting.

2. Sample warranty.

1.3 CLOSEOUT SUBMITTALS

A. As specified in, “Submittal Procedures” Paragraph of Division 1 Section “General Re-quirements”.

1. Operation and maintenance data for each product.

2. Spare Parts: Provide one spare filter for each piece of equipment with filters.

3. Field quality test reports.

4. Special Warranty: Submit manufacturer's standard form in which manufacturer agrees to repair components listed below that fail within specified warranty pe-riod:

a. Furnace Heat Exchanger: Limited lifetime.

b. Parts: Five years from date of Substantial Completion.

1.4 QUALITY ASSURANCE

A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to the CO, and marked for in-tended use.

B. ANSI/UL Compliance: ANSI Z21.47/UL1995, “Unitary Air Conditioning Standard for Safety Requirements.”

MULTIPLE BUILDING HVAC REPLACEMENT 235400 - 2

PART 2 – PRODUCTS

2.1 GAS-FIRED FURNACES, CONDENSING (F-1 THROUGH F-3)

A. Basis of Design: Subject to compliance with requirements, provide S9X models by Trane. or equal product.

B. General: EnergyStar certified, factory assembled, piped, and tested; complying with ANSI Z21.47/CSA 2.3, "Gas-Fired Central Furnaces," and with NFPA 54.

C. Cabinet: Cold rolled steel with baked enamel finish.

1. Fully insulated cabinet with foil faced insulation on sides and back of heating compartment and sealed mat face insulation in blower compartment.

2. Lift-out panels to expose burners and all other items requiring access for mainte-nance.

D. Configuration: horizontal.

E. Fan: Forward-curved centrifugal blower, factory balanced, resilient mounted, direct drive.

F. Blower motor: ECM type equipped with ball bearings and is resiliently mounted.

G. Heat Exchanger:

1. Primary: Aluminized steel, multi-pass crimped clamshell type.

2. Secondary: Stainless steel.

H. Burner: Aluminized steel inshot type.

1. Gas Valve: main shutoff valve, pressure regulator, safety pilot with electronic flame sensor, limit control, transformer, and combination ignition/fan timer con-trol board.

2. Ignition: Electric pilot ignition, with hot-surface igniter or electric spark igni-tion.

I. Gas-Burner Safety Controls:

1. Electronic Flame Sensor: Prevents gas valve from opening until pilot flame is proven; stops gas flow on ignition failure.

2. Flame Rollout Switch: Installed on burner box; prevents burner operation.

3. Limit Control: Fixed stop at maximum permissible setting; de-energizes burner on excessive bonnet temperature; automatic reset.

J. Furnace Controls: Solid-state board integrates ignition, heat, cooling, and fan speeds;

adjustable fan-on and fan-off timing; terminals for connection to accessories.

MULTIPLE BUILDING HVAC REPLACEMENT 235400 - 3

K. Drain Pan: Stainless steel or composite material that won’t corrode or rust. Provide blocked drain sensor.

L. Diagnostic 7-segment LED.

M. Accessories:

1. Combustion air drain kit.

2. Neutralizer kit.

3. Filter rack.

4. Filters: MERV 13, pleated 2-inch deep, throw-away filters.

2.2 COIL SECTION

A. Refrigerant Coil: Copper tubes mechanically expanded into aluminum fins. Comply with ARI 210/240, "Unitary Air-Conditioning and Air-Source Heat Pump Equip-ment." Match size with furnace and condensing unit. Include condensate drain pan with accessible drain outlet.

1. Refrigerant Coil Enclosure: Steel, insulated enclosure matching furnace with access panel and flanges for integral mounting at furnace cabinet and corrosion resistant drain pan with dual drain connections.

2.3 THERMOSTATS

A. Available Manufacturers: Trane XR202 equal.

B. Programmable, low voltage, thermostat, wall plate, and terminal block for control of furnaces and condensing units.

C. Features:

1. Choice of 7 day or 5/1/1 day programmable or non-programmable.

2. Heating Stages: One stage.

3. Cooling Stages: One stage.

4. Automatic Changeover between heating and cooling.

5. Battery Back-up.

D. Warranty: 5-year limited warranty.

2.4 VENTING

A. Concentric Termination Kit: PVC fitting for combining-air intake and vent for through the roof installation. Include neoprene rubber roof flashing.

B. CPVC Plastic Vent Materials:

1. CPVC Plastic Pipe: Schedule 40, complying with ASTM F 441/F 441M.

2. CPVC Plastic Fittings: Schedule 40, complying with ASTM F 438, socket type.

MULTIPLE BUILDING HVAC REPLACEMENT 235400 - 4

3. CPVC Solvent Cement: ASTM F 493.

a. Use CPVC solvent cement that has a VOC content of 490 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

b. Use adhesive primer that has a VOC content of 550 g/L or less when cal-culated according to 40 CFR 59, Subpart D (EPA Method 24).

C. PVC Plastic Vent Materials:

1. PVC Plastic Pipe: Schedule 40, complying with ASTM D 1785.

2. PVC Plastic Fittings: Schedule 40, complying with ASTM D 2466, socket type.

3. PVC Solvent Cement: ASTM D 2564.

a. Use PVC solvent cement that has a VOC content of 510 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

b. Use adhesive primer that has a VOC content of 550 g/L or less when cal-culated according to 40 CFR 59, Subpart D (EPA Method 24).

PART 3 – EXECUTION

3.1 INSTALLATION

A. Install gas-fired furnaces and associated fuel and vent features and systems according to NFPA 54.

B. Base-Mounted Units: Secure units to substrate.

C. Complete installation and startup checks and start units according to manufacturer's written instructions.

D. Verify proper operation of capacity control device.

E. Adjust airflow and initial temperature set points.

F. Set controls, burner, and other adjustments for optimum heating performance and effi-ciency. Adjust heat-distribution features, including shutters, dampers, and relays, to provide optimum heating performance and system efficiency.

G. After completing installation, clean furnaces internally according to manufacturer's written instructions.

H. Install new filters in each furnace within 14 days after Substantial Completion.

I. Connect thermostat to existing wiring. Program thermostat in accordance with requirements from Contracting Officer.

J. Before start-up, verify that systems have been tested and operational and performance tests have been made.

MULTIPLE BUILDING HVAC REPLACEMENT 235400 - 5

3.2 CONNECTIONS

A. Connect new furnace to existing gas connection.

B. Vent and Outside-Air Connection, Condensing, Gas-Fired Furnaces: Connect plastic piping vent material to furnace connections and extend outdoors. Terminate vent out-doors with a cap and in an arrangement that will protect against entry of birds, insects, and dirt.

1. Ream ends of pipes and tubes and remove burrs. Bevel plain ends of steel pipe.

2. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly.

3. Plastic Piping Solvent-Cement Joints: Clean and dry joining surfaces. Join pipe and fittings according to the following:

a. Comply with ASTM F 402 for safe-handling practice of cleaners, primers, and solvent cements.

b. CPVC Piping: Join according to ASTM D 2846/D 2846M Appendix.

c. PVC Pressure Piping: Join schedule number ASTM D 1785, PVC pipe and PVC socket fittings according to ASTM D 2672. Join other-than-schedule-number PVC pipe and socket fittings according to

ASTM D 2855.

d. Requirements for Low-Emitting Materials:

1) Use CPVC solvent cement that has a VOC content of 490 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

2) Use PVC solvent cement that has a VOC content of 510 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

3) Use adhesive primer that has a VOC content of 550 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

4. Slope pipe vent back to furnace or to outside terminal.

C. Connect furnace to existing ductwork with flexible connector.

3.3 FIELD QUALITY CONTROL

A. Notify Contracting Officer at least 48 hours before inspection and testing. Perform tests and inspections in the presence of the Contracting Officer. Prepare report for each test, signed by Installer, General Contractor, and Contracting Officer.

B. Operational Test: After electrical circuitry has been energized, start units to confirm proper operation, product capability, and compliance with requirements.

C. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.

MULTIPLE BUILDING HVAC REPLACEMENT 235400 - 6

END OF SECTION 235400

MULTIPLE BUILDING HVAC REPLACEMENT 236200 - 1

PINE KNOT JOB CORPS CCC CONDENSING UNITS

SECTION 236200

CONDENSING UNITS

PART 1 – GENERAL

1.1 SUMMARY

A. This Section includes air cooled condensing units.

1.2 SUBMITTALS

A. As specified in, “Submittal Procedures” Paragraph of Division 1 Section “General Requirements”.

1. Submit manufacturer's literature for each unit. Include performance data in terms of capacities, sound power characteristics, motor requirements, and elec-trical characteristics.

2. Sample warranty.

1.3 CLOSEOUT SUBMITTALS

A. As specified in, “Submittal Procedures” Paragraph of Division 1 Section “General Requirements”.

1. Operation and Maintenance Data.

2. Field quality test reports.

3. Warranty: Submit manufacturer's standard form in which manufacturer agrees to repair components listed below that fail within specified warranty period:

a. Compressors: 5 year limited, 1 year on parts.

b. Coil; 5 year limited, 1 year on parts.

1.4 QUALITY ASSURANCE

A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to the CO, and marked for in-tended use.

B. ANSI/UL Compliance: ANSI Z21.47/UL1995, “Unitary Air Conditioning Standard for Safety Requirements.”

C. AHRI Compliance: Rated in accordance with AHRI Standard 210.

PART 2 – PRODUCTS

2.1 CONDENSING UNITS CU-1 THROUGH CU-3

MULTIPLE BUILDING HVAC REPLACEMENT 236200 - 2

A. Basis of Design: Subject to compliance with requirements, provide model 4TTR by Trane. or equal product.

B. Description: EnergyStar, factory assembled and tested, consisting of compressor, con-densing coil, fan, motors, refrigerant reservoir, and operating controls.

C. Cabinet: Heavy gage steel with pre-painted finish and removable panels. Compressor and control box compartment insulated with fiberglass insulation. Weatherproof.

D. Outdoor Fans: Direct drive propeller type.

1. Motors: Variable-speed, totally enclosed, and permanently lubricated sleeve bearings. Protected by internal thermal overload.

2. Fan blades: Statically and dynamically balanced; corrosion resistant.

3. Fan guard: Corrosion-resistant PVC coated steel.

E. Compressor: scroll type with oil system, operating oil charge, and motor. Compres-sor mounted on rubber vibration isolators and covered with a sound absorbing blanket.

Provide with protection from over-temperature and over-current.

F. Condenser Coil: Constructed of aluminum fins mechanically bonded to copper tubes.

Coils leak tested at 550 psig air pressure.

G. Refrigerant: Non-chlorine, ozone friendly, R-410A.

H. Refrigeration Components:

1. High capacity drier for field installation.

2. Include liquid-line and vapor-line shutoff valves.

3. Full refrigerant charge.

I. Safeties:

1. High pressure switch with manual reset.

2. Low pressure switch.

J. Accessories: Provide the following:

1. Low ambient kit to allow operation with outdoor temperatures to 30 degree F.

2.2 REFRIGERANT PIPING

A. Refrigerant Piping: Refer to Division 23 Section, “Refrigerant Piping” for refrigerant piping and line sets.

PART 3 – EXECUTION

MULTIPLE BUILDING HVAC REPLACEMENT 236200 - 3

3.1 INSTALLATION

A. Install units level and plumb, firmly anchored in locations indicated; maintain manu-facturer's recommended clearances.

B. Install condensing units on existing exterior concrete pads.

3.2 CONNECTIONS

A. Connect refrigerant piping or pre-charged line sets to refrigerant coil in furnace and to air-cooled, compressor-condenser unit. Comply with requirements in Division 23 Section "Refrigerant Piping.”

B. Connect supply and return condenser connections with shutoff-duty valve and union or flange on the supply connection and with throttling-duty valve and union on the re-turn connection.

C. Before start-up, verify that systems have been tested and operational and performance tests have been made.

3.3 FIELD QUALITY CONTROL

A. Notify Contracting Officer at least 48 hours before inspection and testing. Perform tests and inspections in the presence of the Contracting Officer. Prepare report for each test, signed by Installer, General Contractor, and Contracting Officer.

B. Operational Test: After electrical circuitry has been energized, start units to confirm proper operation, product capability, and compliance with requirements.

C. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.

D. Verify proper airflow over coils.

E. Perform tests and inspections and prepare test reports.

END OF SECTION 236200

MULTIPLE BUILDING HVAC REPLACEMENT 237313 - 1

PINE KNOT JOB CORPS CCC BLOWER COIL AIR-HANDLING UNITS

SECTION 237313

BLOWER COIL AIR-HANDLING UNITS

PART 1 – GENERAL

1.1 SUMMARY

A. Section Includes:

1. Constant-air-volume, single-zone air-handling units.

2. Electric heating coils.

3. Thermostats.

1.2 SUBMITTALS

A. As specified in, “Submittal Procedures” Paragraph of Division 1 Section “General Requirements”.

1. Product Data: For each air-handling unit indicated.

a. Unit dimensions and weight.

b. Cabinet material, metal thickness, finishes, insulation, and accessories.

c. Fans:

1) Certified fan-performance curves with system operating conditions indicated.

2) Certified fan-sound power ratings.

3) Fan construction and accessories.

4) Motor ratings, electrical characteristics, and motor accessories.

2. Certified coil-performance ratings with system operating conditions indicated.

3. Filters with performance characteristics.

B. Closeout Submittals: As specified in, “Submittal Procedures” Paragraph of Division 1 Section “General Requirements”.

1. Operation and maintenance data for each product.

2. Spare Parts: Provide one spare filter for each piece of equipment with filters.

3. Field quality test reports.

1.3 QUALITY ASSURANCE

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

B. NFPA Compliance: Comply with NFPA 90A for design, fabrication, and installation of air-handling units and components.

MULTIPLE BUILDING HVAC REPLACEMENT 237313 - 2

C. AHRI Certification: Air-handling units and their components shall be factory tested and certified according to AHRI 430, "Central-Station Air-Handling Units," and shall be listed and labeled by AHRI.

D. Comply with NFPA 70.

PART 2 – PRODUCTS

2.1 MANUFACTURERS

A. Basis-of-Design Product: Subject to compliance with requirements, provide product indicated on Drawings or comparable product by one of the following:

1. Carrier Corporation; a member of the United Technologies Corporation Family.

2. Trane; American Standard Inc.

3. YORK International Corporation.

2.2 UNIT CASINGS

A. Casings:

1. Heavy-gauge galvanized steel with coil access panels located on both sides.

Forming: Form walls, roofs, and floors with at least two breaks at each joint.

2. Sealing: Seal all joints with water-resistant sealant.

B. Casing Insulation: 1-inch, 1-1/2 pcf density fiberglass foil-faced insulation.

C. Condensate Drain Pans:

1. Noncorrosive, double-sloped, removable drain pan.

2. Drain Connection: Primary and auxiliary drain connections, located at lowest point of pan. Minimum 3/4" connection.

2.3 FAN, DRIVE, AND MOTOR SECTION

A. Fan and Drive Assemblies: Statically and dynamically balanced and designed for con-tinuous operation at maximum-rated fan speed and motor horsepower.

B. Fan: Dynamically balanced, double width double inlet forward-curved, centrifugal blower type directly mounted to motor shaft.

C. Motor:

1. Direct drive, multiple voltage ECM motor. Open type with permanently sealed ball bearings and internal overload protection.

2. Factory-programmed and run-tested brushless DC/electronically commutated motors.

2.4 COILS

MULTIPLE BUILDING HVAC REPLACEMENT 237313 - 3

A. Electrical Heating Coils, Controls, and Accessories: Comply with UL 1995.

1. Open Heating Elements: Resistance wire of 80 percent nickel and 20 percent chromium supported and insulated, fastened to supporting brackets, and mount-ed in galvanized-steel frame.

2. Stages: One.

3. Single point power connection.

4. Overtemperature Protection: Disk-type, automatic and manual reset-type ther-mal safety.

5. Control Panel: Unit mounted with disconnecting means and overcurrent protec-tion.

a. Magnetic contactor.

b. Step controller.

c. Time-delay relay.

d. Airflow proving switch.

2.5 THERMOSTATS

A. Available Manufacturers: Trane XR202 equal.

B. Programmable, low voltage, thermostat, wall plate, and terminal block for control of furnaces and condensing units.

C. Features:

1. Choice of 7 day or 5/1/1 day programmable or non-programmable.

2. Heating Stages: One stage.

3. Cooling Stages: One stage.

4. Automatic Changeover between heating and cooling.

5. Battery Back-up.

D. Warranty: 5-year limited warranty.

PART 3 – EXECUTION

3.1 INSTALLATION

A. Equipment Mounting: Install air-handling unit without vibration isolation devices.

B. Arrange installation of units to provide access space around air-handling units for ser-vice and maintenance.

C. Do not operate fan system until filters (temporary or permanent) are in place. Replace temporary filters used during construction and testing, with new, clean filters.

MULTIPLE BUILDING HVAC REPLACEMENT 237313 - 4

D. Install filter-gage, static-pressure taps upstream and downstream of filters. Mount fil-ter gages on outside of filter housing or filter plenum in accessible position. Provide filter gages on filter banks, installed with separate static-pressure taps upstream and downstream of filters.

E. Install piping adjacent to air-handling unit to allow service and maintenance.

F. Connect piping to air-handling units mounted on vibration isolators with flexible con-nectors.

G. Refrigerant Piping: Comply with applicable requirements in Division 23 Section "Re-frigerant Piping." Install shutoff valve and union or flange at each supply and return connection.

H. Connect air-handling units to existing ducts with flexible connections.

I. Connect thermostat to existing wiring. Program thermostat in accordance with requirements from Contracting Officer.

END OF SECTION 237313

MULTIPLE BUILDING HVAC REPLACEMENT 238126 - 1

PINE KNOT JOB CORPS CCC SPLIT-SYSTEM HEAT PUMPS

SECTION 238126

SPLIT-SYSTEM HEAT PUMPS

PART 1 – GENERAL

1.1 SUMMARY

A. This Section includes split system heat pump units consisting…