QQQA RCAG Specifications.pdf

Federal Aviation Administration

QQQA RCAG

BARSTOW, CALIFORNIA

AIR CONDITIONING REPLACEMENT PROJECT

PERFORMANCE WORK STATEMENT (PWS)

FY24 JCN 20013605

Prepared by:

Sharon Wu, ME, AJW-2W15F

April 17, 2024

QQQA HVAC Replacement

TABLE OF CONTENTS

DIVISION 1

1-1.0 SCOPE OF WORK

1-2.0 PROJECT LOCATION

1-3.0 WARRANTY

1-4.0 SUBMITTALS

1-5.0 PERFORMANCE TIME

1-6.0 WORK SCHEDULE

1-7.0 AVAILABILITY OF UTILITIES

1-8.0 PERFORMANCE OF WORK BY CONTRACTOR

1-9.0 PRECONSTRUCTION CONFERENCE

1-10.0 SECURITY REQUIREMENTS

1-11.0 SITE VISIT

1-12.0 GOVERNMENT FURNISHED MATERIALS (GFM)

1-12.1 CONTRACTOR FURNISHED MATERIALS

1-13.0 LIST OF PROJECT CONSTRUCTION DRAWINGS (ATTACHMENTS)

1-14.0 WASTE MANAGEMENT

1-15.0 WORK SITE AREA

1-16.0 INSPECTION

1-17.0 GENERAL NOTES

DIVISION 2

2-1.0 SCOPE

2-2.0 CODES AND STANDARDS

2-3.0 APPLICABLE DOCUMENTS

2-4.0 AIR DISTRIBUTION

2-4.1 Sheet Metal Ductwork 2-4.2 Duct Liner 2-4.3 Turning Vanes 2-4.7 Duct Support

2-4.8 Air Distribution Devices

2-5.0 AIR CONDITIONING EQUIPMENT

2-5.0.1 Split System Air Conditioner

2-6.0 PIPING

2-6.1 Pipe Hangers and Supports 2-6.8 Insulation

2-7.0 FILTERS

2-8.0 CONTROLS

2-8.1 Relays

2-9.0 ELECTRICAL

2-9.1 Conduit Fittings 2-9.2 Wire 2-9.3 Grounding 2-9.6 Safety Switches

2-10.0 FIRE PROTECTION

2-11.0 DEMOLITION

2-14.0 IDENTIFICATION

2-15.0 CLEANING

2-17.0 REFRIGERATION STARTUP REPORT

2-18.0 INSTRUCTION MANUALS

2-19.0 SPARE PARTS

DIVISION 1

GENERAL REQUIREMENTS

1-1.0 SCOPE OF WORK

Furnish all labor, equipment and materials to accomplish the following:

Demolition:

1. Remove two each – four ton split system condensing units and air handling units, including associated electrical, controls, refrigerant piping, condensate piping, supply air plenum, and stand.

Installation:

1. Provide two each – four ton split system condensing units and air handling units, including associated electrical, controls, refrigerant piping, condensate piping, supply air plenum, and stand.

2. Provide the following:

a. 5 sets of spare filters (Farr 30/30 or equal) per air conditioning unit installed

b. 1 spare sets of fuses for each fused disconnect

Only one air conditioning split system may be replaced at a time; one split system air conditioner must remain fully operational at all times to maintain space temperature set point.

The air conditioning systems specified herein and shown on the drawings must be complete, functional, and operational in all respects.

BACKGROUND: This site currently has two 4-ton split unit R-22 HVAC systems. One unit is the original unit from 1985 and a second unit was later installed to replace an original unit. Both units use outdated R-22 refrigerants and must be replaced with R-410 or accepted equivalent. There is an existing concrete pad for each condenser. Site is in the sandy hills southeast of Barstow, CA and requires a 4x4 vehicle to reach the facility.

1-2.0 PROJECT LOCATION

QQQA RCAG Facility 34.84634, -117.04822 Barstow, San Bernardino County, CA 92311 (Site access requires 4x4 vehicle.)

1-3.0 WARRANTY

The Contractor must warrant all materials, equipment and labor for all work performed under this contract. This warranty must be for a period of one calendar year beginning upon the date of contract acceptance inspection (CAI). The warranty must be unconditional, and the Contractor must furnish all labor and materials required to repair or replace defective or failed portions of the contract work. Warranty repair work must be performed in the same manner as new work in accordance with the technical requirements of this specification. Any warranty repairs must be completed by the Contractor within a maximum of 24 hours after notification by the Government for any failure which causes a mechanical system to be inoperative. Other failures or defects which have no operational impact to the facility must be corrected within a maximum of 15 calendar days after notification by the Government. The specific items of work performed under warranty must then themselves be unconditionally warranted for a period of one calendar year beginning upon the date of completion of the repair work.

Also, guarantee that each piece of apparatus must have a capacity or performance of not less than that specified or indicated on drawings, when the apparatus is operating under specified design conditions.

1-4.0 SUBMITTALS

Within seven (7) calendar days after the date of contract award, the Contractor must submit to the Contracting Officer a list of all materials and equipment to be used under this contract. This list must include a brief description of the materials or equipment, the name of the manufacturer, and the model or type number.

The use of brand name with, or without, an or approved equal statement following the purchase description in this specification or on the project drawings is intended to promote competition by encouraging the offering of products that are equal in all material respects to the brand name products cited in such descriptions. The reference by brand name does not indicate a preference for the products mentioned but identifies a product known to furnish the quality and characteristics that meet the requirements of this specification. All characteristics of a specified brand name product which are essential to the Government are described in this specification or on the project drawings. The Contractor must obtain product literature from the manufacturer of the specified brand name product to determine its general quality and functional characteristics and must use that information in making any desired substitutions.

Where the Contractor elects to use the manufacturer and model number specified herein, no further technical information or shop drawings need to be submitted. Where the Contractor desires to utilize the products of another manufacturer or where no make or model is specified, a complete set of shop drawings and descriptive literature must be submitted. Contractor must submit three (2) copies of descriptive literature, shop drawings, and/or samples to the RE for approval for any item he wishes to submit as equal to the brand name(s) as specified.

Information must be submitted within seven (7) calendar days after the date of contract award and must include, but not be limited to the following, where applicable:

(1) Air conditioning equipment

(2) Ductwork and accessories

(3) Insulation

(4) Controls

(5) Electrical equipment

(6) Piping and accessories

Shop drawings must include manufacturer's catalog data and certified capacity data.

Information submitted must be complete to enable the item to be evaluated from an engineering viewpoint and must be sufficient to show compliance with this specification.

The project drawings are designed for the particular manufacturer and model specified.

However, where required to show specific details of equipment interface, attachment, support, wiring, etc., the Contractor must provide any additional shop drawings or descriptive literature for any equipment, including that specified, as required by the Contracting Officer or the RE.

The Contractor must carefully select equipment and materials, furnish shop drawings and other documentation required above, place and confirm orders for equipment and materials, and schedule all delivery dates in a manner which conforms with the performance time and advance acquisition time allotted by this contract.

Notice-To-Proceed with on-site work will not be granted until the Contractor certifies to the Contracting Officer that all required materials and equipment, as approved by the Government, are in his possession and ready for installation.

1-5.0 PERFORMANCE TIME

The Contractor must be required to commence work under this contract within one day after the date of Notice-To-Proceed, prosecute the work diligently and complete the entire work ready for use no later than 30 calendar days after the date of Notice-To- Proceed.

Prior to the effective date of the Notice-To-Proceed with on-site work, a maximum of 21 calendar days lead time after the date of Contract Award will be allowed to obtain the required materials and equipment. All shop drawing submissions must also be accomplished during this lead time. The time required from submission of shop drawings to approval by the Government will not be included in the above specified lead time. Notice-To-Proceed with on-site work will not be granted until the Contractor certifies to the Contracting Officer that all required materials and equipment, as approved by the Government, are in his possession and ready for installation. The Contracting Officer will coordinate the Notice-To-Proceed date with the Contractor to ensure his ability to commence work upon that date.

1-6.0 WORK SCHEDULE

All work must be scheduled and performed between the hours of 6:00 AM to 5:00 PM except when prior approval has been obtained from the Resident Engineer. Alternate work schedules such as 10 hours per day for 4 days per week are acceptable. Total work time per week must not exceed 40 hours, including holidays. All work schedules proposing more than 8 hours of work per day must be approved in advance by the R.E.

No work must be scheduled or performed on Saturdays, Sundays or federal holidays.

1-7.0 AVAILABILITY OF UTILITIES

Water is not available for the Contractor’s use.

Electricity for power tools is available for the Contractor’s use. Contractor must only use power from sources designated by the local FAA SSC personnel.

Sanitary facilities are not available for the Contractor's use at Government expense.

The Contractor must provide, install and maintain, for the duration of the work, temporary outside toilet facilities for the use of the workmen, superintendent, and Government personnel at the project site. The toilet facilities must be housed in a weather-tight, elevated and floored structure located advantageously and provided with suitable light and ventilation and an exterior door with latch. Toilets must be cleaned, equipped and sanitary at all times.

Public telephone service is not available for the Contractor's use at the project location.

The Government will not be responsible for receiving telephone calls, taking messages or contacting Contractor personnel to deliver messages.

Trash removal must be the Contractor’s responsibility. Furnish appropriate waste receptacles and service to pickup and transport all waste material to an approved commercial dump or waste processing facility. All equipment and debris removed from the HVAC system must be disposed of in accordance with applicable federal, state, and local requirements.

1-8.0 PERFORMANCE OF WORK BY CONTRACTOR

The Contractor must accomplish a minimum of 25% of the contract work by personnel employed by his own organization.

1-9.0 PRECONSTRUCTION CONFERENCE

A preconstruction conference will be held at the site between the representatives of the Government and the Contractor prior to the start of work.

1-10.0 SECURITY REQUIREMENTS

The Contractor must comply with all security requirements of the FAA facility. Daily escort is required.

1-11.0 SITE VISIT

Interested bidders to make arrangements for a site visit by contacting:

Sharon Wu, ME FAA Engineering Services

(424) 327-0784 – Cell

Address:

QQQA RCAG Facility 34.84634, -117.04822 Barstow, San Bernardino County, CA 92311 (Site access requires 4x4 vehicle.)

1-12.0 GOVERNMENT FURNISHED MATERIALS (GFM)

None.

1-12.1 CONTRACTOR FURNISHED MATERIALS

All.

1-13.0 LIST OF PROJECT CONSTRUCTION DRAWINGS (ATTACHMENTS)

DRAWING NUMBER TITLE

QQQ-20013605-M001 MECHANICAL SCHEDULES

QQQ-20013605-M002 MECHANICAL PLAN & SECTION

QQQ-20013605-M003 DETAILS

QQQ-20013605-M004 ELECTRICAL SINGLE LINE DIAGRAM

1-14.0 WASTE MANAGEMENT

Contractor must comply with all federal, state and local waste regulations of the disposal of all waste. A waste disposal plan must be prepared for any transporting, storing and/or location. It is encouraged that any recyclable material be handled appropriately.

1-15.0 WORK SITE AREA

Keep a clean and well maintained work area indoor and outdoor. All debris and waste must be cleaned and properly disposed of at end of daily work and prior to final inspection.

1-16.0 INSPECTION

A final inspection will be conducted by qualified personnel that the project has met all requirements and specifications. The inspection will verify that all purchased components perform to manufacturer’s requirements as well as all cleaning and verification called out in statement of work is satisfactory.

1-17.0 GENERAL NOTES

1-17.1 PR Notes

1. Request contracting bid walk.

2. Request licensed mechanical contractor for installation.

DIVISION 2

CONSTRUCTION REQUIREMENTS

2-1.0 SCOPE

The Contractor must furnish all labor, equipment and materials to accomplish the following:

Only one air conditioning split system may be replaced at a time; one split system air conditioner must remain fully operational at all times to maintain space temperature set point.

Demolition:

2. Remove two each – split system air conditioning units, associated electrical, controls, refrigerant piping, condensate piping, supply air plenum, and stand.

Installation:

3. Provide two each – split system air conditioning units, including associated electrical, controls, refrigerant piping, condensate piping, supply air plenum, and stand.

4. Provide the following:

a. 5 sets of spare filters (Farr 30/30 or equal) per air conditioning unit installed

b. 1 spare sets of fuses for each fused disconnect

The air conditioning systems specified herein and shown on the drawings must be complete, functional, and operational in all respects.

2-2.0 CODES AND STANDARDS

All labor and material must be in strict conformance with the rules and regulations of the Air Conditioning and Refrigeration Institute (ARI), National Fire Protection Association (NFPA), American Society for Testing and Materials (ASTM), and American Society of Mechanical Engineers (ASME), where such standards have been established for the particular item of equipment used.

All equipment and materials must be installed in accordance with the manufacturer's instructions. A copy of the manufacturer's installation instructions must be maintained on site and made available to the Resident Engineer (R.E.) before any equipment is installed or any work with that material begins.

2-3.0 APPLICABLE DOCUMENTS

The following standard publications, of the issues currently in force, form a part of this specification. The Contractor must perform all work not included in this specification in accordance with these publications:

Federal Aviation Administration FAA Standard 019f, Lightning and Surge Protection, Grounding, Bonding and Shielding Requirements for Facilities and Electronic Equipment

Federal Aviation Administration FAA-C-1217h, Electrical Work, Interior

Federal Aviation Administration FAA-C-1391e, Electrical Work, Exterior

International Code Council International Building Code, Latest Edition

International Code Council International Mechanical Code, Latest Edition

International Code Council International Plumbing Code, Latest Edition

Sheet Metal and Air Conditioning HVAC Duct Construction Contractors National Association Standards, Metal and (SMACNA) Flexible, Latest Edition

SMACNA Seismic Restraint Manual: Guidelines for Mechanical Systems, 3rd Ed., 2008

National Fire Protection National Electrical Code Association Latest Edition

(Manufacturer of Installed Equipment Installation Instructions, Equipment) Applicable Edition Specified or Approved For Model Number

2-4.0 AIR DISTRIBUTION

Items not shown in detail nor covered by detailed specifications must be as set forth in the SMACNA HVAC Duct Construction Standards, Metal and Flexible. The project drawings show the general location, orientation, and alignment of duct, registers, grilles, and other devices. The Contractor must be responsible for field verification of the system layout and must determine the exact location of all components to avoid interference with building structure, light fixtures, ceiling grid, other mechanical systems, etc. Any duct offsets, transitions, adapters, or special supports required for installation must be furnished by the Contractor at no additional expense to the Government.

2-4.1 Sheet Metal Ductwork Sheet metal ductwork must be constructed of galvanized steel sheets. Ducts must conform to the dimensions indicated and must be straight and smooth on the inside, with joints neatly finished. Duct transverse joints must be by a bolted preformed angle with integral gasket and sealant configured to give maximum rigidity to the joint with an airtight seal. Transverse joints must be Ductmate 25 or 35, or approved equal, with the type and installation in accordance with the manufacturer’s instructions. Longitudinal seams must be "Pittsburgh lock" construction. All edges and slips must be hammered down to leave a smooth interior duct finish. All seams and joints in duct system, other than transverse joints with integral seal, and all joints where ducts pass through building walls must be sealed to withstand a pressure of plus or minus 4” of water gage and finished to a smooth surface and made completely airtight. Apply sealant in accordance with manufacturer's recommendations. Sealant must be Rectorseal Air-Lock 181, or approved equal. All sealants must be water based; Petroleum based sealants will not be permitted due to their inherent hazardous vapors. Sealant on exposed duct must be applied in a manner which results in a smooth surface free of runs, cracks, holes and splatter on adjacent surfaces. Following curing, the adhesive must be painted with two coats of exterior latex enamel of a color to match the duct.

All new ducts and modified portions of existing ducts must be anchored securely to the framing in the building. Attachments and hangers must be selected and installed to safely support the load, to prevent sagging of the duct, and to restrain horizontal movement of the duct. Ducts must be so constructed and installed as to be completely free from vibration under all conditions of operation. Supports must be attached only to structural framing members or to concrete surfaces with expansion anchors. Where supports are required between structural framing members, RE approved intermediate metal framing must be provided.

2-4.2 Duct Liner

2-4.2.1 Acoustical Duct Lining All supply and return duct must be provided with acoustical liner. Acoustical duct lining must be fibrous glass, flexible type, with vapor barrier designed exclusively for lining duct. For service in low-velocity duct systems, the air-side surface of the liner must be capable of withstanding air velocity of 5,000 feet per minute without delamination or erosion. The surface coating must be formulated with an anti-microbial agent so it will not support the growth of fungus or bacteria. The material thickness must be 1” thick for duct located indoors and 2” thick for duct located outdoors. Thermal conductivity must be no greater than .25 BTU-Inch per square foot per °F per hour at 75 °F. Liner Noise Reduction Coefficient (NRC) must be .70 minimum for 1" thick and 1.00 minimum for 2" thick material. NRC must be calculated in accordance with ASTM standard E795. Air friction correction factor must not exceed 1.05 at 1,000 feet per minute air velocity. The acoustical liner must conform to the fire hazard classification requirements of the National Fire Protection Association.

The lining must be applied in cut-to-size pieces attached to the interior of the duct with fire resistant adhesive. Top and bottom pieces must lap the side pieces and, in addition, must be secured with welded pins, adhered clips, metal, nylon or high impact plastic, and speed washers or welding cuphead pins on maximum 12 inch centers.

Lining must not be folded at corners or treated in any manner that reduces thickness and impairs insulating properties of material. Liner must be neatly butted without gaps at transverse joints and must be coated with adhesive at such joints. All exposed edges of liner must be coated with lagging adhesive to prevent delamination. Lagging adhesive must be Foster Sealfas 30-36, or approved equal. Duct liner must be Johns- Manville "Permacote Linacoustic Standard", or approved equal.

2-4.2.2 Rigid Liner Board All supply and return duct must be provided with interior liner insulation. Duct liner must be fibrous glass, rigid type, with vapor barrier designed exclusively for lining duct. For service in low-velocity duct systems, the air-side surface of the liner must be capable of withstanding air velocity of 5,000 feet per minute without delamination or erosion. The surface coating must be formulated with an anti-microbial agent so it will not support the growth of fungus or bacteria The material thickness must be 1” thick for duct located indoors and 2” thick for duct located outdoors. Thermal conductivity must be no greater than .23 BTU-Inch per square foot per °F per hour at 75 °F. Air friction correction factor must not exceed 1.05 at 1,000 feet per minute air velocity. The acoustical liner must conform to the fire hazard classification requirements of the National Fire Protection Association.

The liner board must be applied to all interior surfaces of the entire duct system. The smooth, black surface must face the airstream. Cut all liner pieces to assure tight overlapped corner joints with no metal exposed to the airstream. The top pieces must be supported by the side pieces. Adhere liner to the duct with full coverage of adhesive approved by the liner manufacturer. Coat all leading edges and transfer joints with an edge treatment approved by the liner manufacturer. The liner board must also be secured to the duct with mechanical fasteners. Fasteners must be the “adhered pin, press-on-head” type. Secure the fasteners to the metal duct with approved adhesive;

do not spot weld the pins due to the damage it causes to the duct galvanizing. Space the fasteners per the liner manufacturer’s schedule for 0-2500 fpm velocity. Liner board must be Johns-Manville Permacote Linacoustic R-300, or equal.

2-4.3 Turning Vanes Turning vanes must be provided in all supply and return air duct square and rectangular elbows. Vanes must be of the small, curved, double-walled type for uniform air distribution and change of direction with minimum turbulence and pressure loss. Air must leave turning vanes parallel to sidewalls of the duct. Turning vanes must be constructed per SMACNA.

2-4.4 Not used.

2-4.5 Not used.

2-4.6 Not used.

2-4.7 Duct Support

Ducts exposed to view must be supported from overhead by trapeze hangers consisting of two steel rods supporting a steel channel (Unistrut P-2000, or equal) which the duct must rest upon. Hangers must be spaced not over 8 feet on center and at each change of direction. Size and install hangers per SMACNA Section IV. Anchor ducts securely to prevent vibration under all conditions of operation.

Ducts supported from walls or from floor or other structures below must be by galvanized steel angle welded or bolted to ensure a rigid structure. The Contractor must be responsible for selecting the proper size of steel members to support the required duct weight for the specified height above the supporting surface and to withstand any wind or seismic loading specified in this contract.

2-4.8 Air Distribution Devices

2-4.8.1 Aluminum Grilles

Supply air grilles must be extruded .055 inch thickness aluminum and must include two sets of individually adjustable extruded aluminum louvers on 3/4" spacing. The front louver set must be vertical and the rear set horizontal. Supply grilles must be Titus model 272FL, or approved equal.

2-5.0 AIR CONDITIONING EQUIPMENT

Equipment make and model and all performance data must be in accordance with the data table on the project drawings. The minimum/maximum performance data specified must not be below the minimum nor above the maximum by more than 5% of the specified value.

2-5.0.1 Split System Air Conditioner The system major components including heat pump or condensing unit, refrigeration flow controls, air handling unit, and evaporator coil must be all sized, selected, and assembled by one equipment manufacturer. That manufacturer must provide certified performance data for the total system to show compliance with the data table on the project drawings.

2-6.0 PIPING

The Contractor must check all dimensions and must establish all lines and levels affecting piping and other work specified herein. Such lines, grades, and levels must be checked with the work of other trades, as well as, existing conditions to assure proper clearance of piping and equipment. The Contractor must be held responsible for correctness of lines, grades, and levels so established and must provide all fittings and accessories required to satisfy field conditions affecting pipe installation.

Pipe must be cut accurately to measurements established at the site by the Contractor and must be worked into place without springing or forcing. Piping must be run parallel with the lines of the building unless otherwise indicated. A clearance of not less than one inch must be kept between pipe, or finished covering, and other work or the different piping services. Branch connections and changes in pipe size must be made with standard pipe fittings. Change in direction must be made with fittings.

Allowance must be made throughout for expansion and contraction of piping. Flexibility must be provided by use of one or more turns to allow piping to spring without straining.

Pipes in exposed locations must be grouped and be neatly aligned. Vertical pipes must be accurately plumbed. Horizontal pipes must be installed parallel to structural members and level or at a uniform slope when a pitch is required. Groups of vertical pipes must be aligned parallel to a wall whenever practicable, otherwise, they must be aligned 90 degrees to a wall. Groups of horizontal pipes must be aligned either horizontally or vertically.

2-6.1 Pipe Hangers and Supports All piping must be supported, anchored, and guided in a manner such that expansion and contraction will take place in the direction desired and vibration and undue strain on equipment will be prevented. Hangers must have means of vertical adjustment after piping is in place. Supports on flat surfaces must be with "Unistrut" P-2558 pipe strap bolted to P-1000 channel, or approved equal. Location of hangers must be coordinated with the structural work to assure that structural members will support the load under operating conditions.

Hangers and clamps applied to bare copper must be electrolytically coated or padded with felt. Hangers applied to piping specified to be insulated must be sized for the outside diameter of the insulation. Furnish a rigid non-compressible urethane or calcium silicate block (Dow Corning Trymer, or approved equal) insulation insert of 1" minimum thickness or of equal thickness to the adjoining insulation, whichever is greater, and 12" maximum length at each hanger. Spacing between supports must be not more than 6 feet for tubing up to 1-1/2 inches in diameter and 10 feet for tubing 2 inches and larger. Also, support at each change of direction. Where concentrated loads, such as valves, flanges, and accessories occur, the above spacing does not apply and each location must be supported.

Where necessary to maintain support spacing, structural members must be bridged to suit hanger locations.

2-6.2 Not used.

2-6.7 Refrigeration Systems

2-6.7.1 Refrigerant Piping Refrigerant piping must be fabricated from Type L, ACR quality hard drawn copper tubing and standard weight wrought copper fittings. Swaged joints must not be used.

Ells must be long radius type. Tubing cuts must be made square, using a sharp wheel cutter or fine tooth hacksaw, reamed after cutting to remove burrs. Refrigerant piping having joints to be high temperature brazed must be blown out with dry nitrogen gas and a small amount of this gas must be allowed to flow during and after brazing. The gas must be allowed to flow until the temperature of the tubing is below the oxidation point. Extreme care must be exercised to prevent overheating and subsequent pitting, burning or annealing of the base pipe material. Any joints which show pitting, burning, or other evidence of overheating will be rejected by the Government and must be replaced by the Contractor.

Joints must be made with high strength, silver/copper brazing alloy. Brazing alloy must be composed of 15% silver/80% copper with a liquidus temperature of 1480°F and a tensile strength of 85,000 psi minimum. Brazing alloy must be J.W. Harris "Stay-Silv 15", or approved equal.

Where high brazing temperature is not acceptable such as at valves and other specialty fittings with non-removable parts and where approved by the R.E., join the piping utilizing silver-tin alloy solder with a liquidus temperature of no greater than 535°F to prevent damage to temperature sensitive parts. Tensile strength must be 15,000 psi minimum. Solder must be used only for piping operating at a temperature below 150°F and must not be used for any hot gas lines. Solder must be J.W. Harris “Stay-Brite 8”, or approved equal. Following soldering, clean all acid, flux, carbon or other contaminations from the pipe joint.

2-6.7.2 Refrigerant Pipe High Pressure Leak Testing After the installation of refrigerant piping fabricated and installed by the Contractor is complete, the entire refrigerant circuit must be tested by the Contractor in the Resident Engineer's presence to prove it is absolutely tight. (This requirement does not apply to package type air conditioners and other self contained systems which were factory tested by the manufacturer and whose refrigerant circuits were not opened or otherwise modified by the Contractor's activities). All expansion and compressor valves must be open to pressure. The test pressure must be achieved using dry nitrogen to 400 psi and held for a period of 2 hours. If, during that time, the test pressure drops by more than 5 psi, the Contractor must visually test the entire system for leaks including the compressor, coils, refrigerant connections to the controls, valves, and piping joints using liquid soap application (or other product intended for visual leak identification) and visual inspection for bubbles created by leaks. If leaks are found, the test pressure must be relieved, the leak repaired, and the test repeated. To repair a leak, the joint must be taken apart, thoroughly cleaned and remade in the same manner as new work, with nitrogen flowing in the line whenever heat is applied.

2-6.7.3 Evacuation After the refrigerant system has been high pressure leak tested and found to be tight, the test pressure must be relieved. Evacuation of the system must be performed during a period when the ambient air around all components is 60°F or above during at least some part of the evacuation period, unless otherwise approved by the R.E. Evacuation lines must be copper tubing or high vacuum rubber tubing. Service gauge hoses are not satisfactory. The entire system must be evacuated to 500 microns (= 0.02 inches) of mercury absolute. The system must be evacuated from both high and low sides together. An electronic instrument capable of reading down to 50 microns must be used to measure the vacuum. Under no circumstances will a dial type pressure gauge be acceptable for measuring the vacuum. When the desired vacuum has been obtained (500 microns of Hg. absolute), the pump must be shut off and the vacuum maintained for at least two hours.

During the two hour period monitor the vacuum pressure every 15 minutes. An initial rise in pressure during the first hour followed by a constant pressure reading not exceeding 1500 microns during the entire second hour is acceptable. Any rise in absolute pressure which continues at a constant rate during the second hour is probably an indication of a leak which must be located and repaired and the above specified high pressure leak testing procedure repeated.

If the absolute pressure is successfully maintained, the vacuum must then be broken with the proper refrigerant to atmospheric pressure or above and the system charged.

2-6.7.4 Charging The refrigerant system must be charged with the specified refrigerant in the amount necessary in accordance with the condensing unit manufacturer's instructions. The amount of charge for each system must be determined by weight, recorded and included in the refrigeration startup report as specified below.

2-6.7.5 Refrigerant Pipe Medium Pressure Leak Testing After the system is high pressure leak tested, evacuated and charged as specified above, electronically test for leaks with the compressor(s) and blower(s) off using an electronic refrigerant leak detector. The refrigerant pressure will be at its saturation pressure depending upon the current ambient temperature. The Contractor must test the entire system for leaks including the compressor, evaporator and condenser coils, refrigerant connections to the controls, valves, and piping joints.

If the above test is successful, start the compressor(s) and blower(s) and repeat the above test on the entire high pressure side of the refrigeration system from the hot gas discharge side of the compressor to the inlet side of the expansion valve or capillary tube and all joints and components in between. The refrigerant pressure will be at its highest saturation or superheated pressure depending upon the current condensing temperature.

If leaks are found, the refrigerant must be removed and recovered. To repair a leak, the joint must be taken apart, thoroughly cleaned and remade in the same manner as new work, with nitrogen flowing in the line whenever heat is applied. Following repair, repeat the high pressure testing, evacuation, charging and medium pressure testing sequence specified above.

Document the ambient temperatures and refrigerant pressures measured during the entire testing process and include in the refrigeration startup report as specified below.

2-6.8 Insulation After tests have been successfully completed and pipe surfaces have been cleaned and dried, insulation must be installed on pipe, valves and equipment of all new and modified piping systems.

2-6.8.1 Cold Surface Insulation All refrigerant suction piping, condensate drain piping located indoors, and any cold surfaces subject to condensation must be insulated. These piping systems, both indoor and outdoor, must be covered with a flexible, elastomeric thermal insulation with a minimum nominal wall thickness of 1" or as shown on the project drawings.

Polyethylene or fiberglass insulations are not acceptable. Maximum thermal conductivity must be .27 BTU-In. per sq. ft.-hour-°F at 75°F mean temperature. Water vapor permeability must not exceed 0.20 perm-inch per ASTM test procedure E96, procedure B. Water absorption must not exceed 5% by weight per ASTM test procedure D1056. Flame spread rating must not exceed 25 and smoke developed rating must not exceed 50 per ASTM test procedure E84. Insulation must be capable of preventing condensation on piping with a surface temperature of 35°F in ambient air temperature of 85°F dry bulb, 70% relative humidity. Pipe insulation must be either unslit for installation as pipe is being assembled or must have factory longitudinal slit with tape or mastic sealed joint. Field cutting along insulation’s length to allow installation over installed pipe must not be acceptable. Pipe insulation must be Armacell AP Armaflex or AP Armaflex SS, or equal. Sheet and roll insulation must be Armacell Armaflex Sheet and Roll, or equal.

2-6.8.2 Not used

2-6.8.3 Insulation Installation Insulation must be applied on clean dry surface after all tests are completed and must be continuous through walls and equipment openings. Insulation on all cold surfaces where vapor barrier jackets are used must be applied with a continuous, unbroken vapor seal. Piping at supports must rest upon 1" thick rigid insulation inserts as specified above. Metal shield must be applied between hangers or supports and the pipe insulation. Shield must be formed 18 gauge sheet metal to fit rigid insulation insert and must be in two halves.

Fittings at all locations must be insulated with miter-cut pipe insulation, with insulation sheet cut to size or with insulation tape of the same material as straight pipe insulation.

All butt joints and seams must be sealed with insulation adhesive. All outdoor insulation must be covered with 0.016 inch thick aluminum with longitudinal Z-joint and secured with 2-inch side locking straps at butt joints. The aluminum must be carefully cut and mitered around elbows and fittings for a smooth jacket which totally conceals all insulation.

2-7.0 FILTERS

The air conditioning equipment must not be operated until filters have been installed.

Filters must be disposable, 1" thick, pleated media type with minimum 11 pleats per lineal foot of filter width. Filter efficiency must be 25-30% minimum per ASHRAE Standard 52.1 test methods. Filters must be Eco-Air model E35 or Farr model 30/30, or equal. Filters must be easily accessible. At the time of final contract acceptance a set of new filters must be installed and five (5) sets of spare filters must be provided for each system installed or modified.

2-8.0 CONTROLS

The Contractor must furnish and install automatic temperature controls as specified herein and as shown on the project drawings. All controls must be electric or electronic.

Control device make and model numbers, or approved equal, must be as shown on the diagrams on the project drawings.

Upon completion of the contract work, the Contractor must demonstrate to the RE that all controls are properly calibrated and provide the sequence of operation specified.

Provide a minimum of three (3) working days advance notice before this demonstration.

2-8.1 Relays All control relays must be plug-in type with blade terminals and a separate matching socket for wire terminations. All relays must be furnished with a light emitting diode (LED) which illuminates when the relay coil is energized. A relay brand name known to meet the requirements of this specification is Idec type RHXB-UL with type SHXB-05 socket where X = the number of relay poles.

2-9.0 ELECTRICAL

Items not shown in detail or covered by detailed specifications must be as set forth in the National Electrical Code.

2-9.1 Conduit Fittings All conduit inside building must be electric metallic tubing (EMT) with compression ring type fittings. All conduit outside building must be rigid steel with threaded fittings.

Conduit below ground must be rigid steel with a factory applied plastic coating. All flexible conduit, both inside and outdoors, must be metallic, liquid tight, and must be a maximum of 4’.

Conduits must be installed parallel or at right angles to the building. Conduits must be securely supported and fastened in place at intervals of not more than 5 feet and at each change of direction. Support from building structural steel, walls, or other R.E.

approved structural components. Fasteners must be conduit hangers or one-hole malleable iron pipe straps with appropriate screws or bolts for the surface material.

Conduits must not be supported from metal roof decking. Suspended ceiling support wires must not be used for the support of conduits. Changes in direction must be symmetrical bends or cast-metal fittings. Each conduit entrance to outlet boxes, panel boards, and equipment cabinets must be fitted with a lock nut and insulated throat connector.

2-9.2 Wire All wire must have copper conductors. Size must be American Wire Gauge (AWG) with size for power circuits as shown on the project drawings. Size for all control circuits must be #16 AWG. Power wire #10 AWG and smaller may be stranded or solid; #8 and larger wire, and all control wire, must be stranded. Insulation must be type THHN or THWN for power wire and type MTW for control wire and must be color coded as follows:

Single Phase Three Phase

120 Volts 208/240 Volts 120/208 or 240 Volts 277/480 Volts Line-Black Line 1-Black Phase A-Black Phase A-Yellow Neutral-White Line 2-Red Phase B-Red Phase B-Brown Neutral-White Phase C-Blue Phase C-Orange Neutral-White Neutral-Gray All Circuits:

Ground Green Control Black with numbered adhesive markers on both ends or multiconductor with unique continuous color coded insulation

Power wires #8 and smaller must have continuous colored insulation. Wires #6 and larger may utilize continuous colored insulation or colored tape. Where conductors are color coded with tape, they must be half lapped for a minimum length of 3 inches in all junction and pull boxes, accessible raceways, panelboards, outlets, switches and equipment cabinets.

All wire must be continuous; no splices will be permitted unless specified on the project drawings. Wires must not be installed until all conduit and fittings are in place. All wires must be drawn into conduit simultaneously and with adequate lubricating compound to prevent damage to insulation.

Control wiring installed within control panels must be neatly routed between the control components and must run parallel and perpendicular to the sides of the panel. Wires which run diagonally from component to component will not be acceptable. Wiring must have sufficient slack to prevent tension on the termination connector. Route wires between components in the most direct path possible without overshoots and loopbacks. Wires must be run in open slot wiring duct (Thomas & Betts model 91XXX, or equal with size as required for application.) or bundles of wires must be neatly secured with nylon self-locking cable ties. Terminate all control wires with spade type, crimped terminals; Exception: Devices such as relays and terminal blocks which utilize clamp type terminals must not require crimped terminals on the wire. Wrapping of wires around screw heads must not be acceptable. All wires exiting the control panel must terminate on a screw terminal block with each terminal marked the same as on the control schematic on the project drawings.

2-9.3 Grounding All noncurrent carrying metallic parts of the electrical system must be grounded with an insulated wire sized and installed in accordance with Article 250 of the National Electrical Code. Ground wire must be connected to ground bus in each power panel, to ground lug on receptacles, and to enclosure or frame of major electrical devices such as safety switches, motors, motor starters, terminal cabinets, light fixtures, etc. Connection of wire to these devices must be with a separate machine screw and nut which bonds to a clean, bare metal surface. Self tapping screws are not acceptable for this purpose.

Screws which are used for support of the enclosure must not be used for this purpose.

All ferrous conduit must be equipped with insulated grounding bushings at each end and the equipment grounding conductor must be bonded to the bushings with a bonding jumper the same size as the equipment grounding conductor.

2-9.4 Not Used.

2-9.5 Not Used.

2-9.6 Safety Switches Safety switches must be NEMA rated as heavy duty. Enclosures must be NEMA type 1 in indoor locations and NEMA type 3R in outdoor or damp locations unless shown on the project drawings to be a different type for the specific application. Switches must be of the number of poles, voltage and amperage ratings shown on the project drawings.

Furnish fuse clips to receive cartridge type dual element fuses in all poles if fusible switches are required on the project drawings. Switches must be the quick-make, quick-break type with visible blades. Switch handles must be the extended arm type for easy identification of position. Switches which utilize rocker arm type handles or have concealed blades are not acceptable. Switch handles must be capable of being secured in both the on and off positions by use of a Government owned and installed padlock with a 5/16" diameter shackle. The switch cover must also be capable of being secured in the closed position with a separate Government owned and installed padlock with a 5/16" diameter shackle. The Contractor must modify the switch as required to achieve these locking capabilities. The switch must be grounded with a separate lug secured to the enclosure's bare metal with a bolt and nut. The use of the switches' neutral bus with, or without, a grounding electrode screw bonding to the enclosure is not a satisfactory enclosure ground. A brand name safety switch known to meet the salient characteristics of this specification is Square D, Class 3110, Heavy Duty.

2-10.0 FIRE PROTECTION

All indoor insulating and acoustical materials, vapor barrier, covering and wrapping materials permanently attached or installed separately must not exceed flame spread 25 and smoke developed 50, as rated by Underwriter's Laboratories.

All conduits and pipes which penetrate floors (except ground floor) of multistory buildings and which penetrate fire barrier walls as designated in the Uniform Mechanical Code must have the excess void or cavity sealed with firestop compound. Compound must be Underwriters Laboratories, Inc. listed for use in through-penetration firestop system. Firestop must be "Flamesafe" Cat. No. FS 900 as manufactured by International Protective Coatings, Inc., or approved equal.

2-11.0 DEMOLITION

Any existing furniture, cabinets, equipment racks or other items which obstruct the Contractor's access to the work area must either be temporarily relocated by the Contractor to a storage area designated by the R.E. or be covered in a manner as to provide suitable access while protecting the Government property from construction damage. At the completion of all work, the Contractor must return all such items to their original location.

Any unused conduit, wire, duct, pipe, structural supports or other fittings associated with equipment or devices to be removed under this contract must also be removed.

All conduit must be totally removed unless approved by the R.E to only remove it back to the first existing junction box or electrical fitting. Remove all unused wire back to the source power panel. Any circuit which must continue to operate must be rewired for continuity. Seal all unused conduit with electrical plugs.

All refrigerant, as classified by the Environmental Protection Agency (EPA), must be recovered, decontaminated and recycled in accordance with "The National Recycling And Emissions Reduction Program" of the EPA. Intentional venting of covered refrigerant gasses is subject to criminal penalties.

Remove unused structural support angles, channels, bolts, and similar hardware. Patch any holes and openings resulting from removed equipment, hardware, conduit, duct, or pipe with the same material as that of the penetrated surface (ie: concrete floor openings must be filled with concrete). Paint patch to match adjacent undisturbed surface.

After removal of floor supported equipment, clean and/or replace any floor finish or covering to match adjacent undisturbed floor covering. Acoustical ceiling tiles or T-bar grid members which have holes resulting from removed duct or diffusers must be removed and replaced with new components of equal quality and appearance to the adjacent undamaged ceiling.

Any equipment or material to be removed, unless shown to be given to the R.E., must become the property of the Contractor and must be transported from the site and disposed in a legal manner.

2-12.0 Not Used.

2-13.0 Not Used.

2-14.0 IDENTIFICATION

The air conditioning equipment must be identified to show designator. Identify safety switches, power panels, cabinets, etc. to show equipment served, voltage, phase, and fuse amperage rating. Identify control panel and all controls to show function.

Identification must be by plastic engraved nameplates with white letters and black background. Letter size must be 1/8" for controls, 3/16" for devices on control panel covers and 3/8" for safety switches, air conditioning equipment and other equipment devices. Nameplates must be secured to equipment, cabinets and to controls with adhesive backing. In addition, nameplates installed outdoors must be secured with two screws.

Identify all new and modified pipes to show contents (i.e.: Chilled Water Supply, Refrigerant Suction, etc.) and flow direction. Identification must be with color coded, printed plastic bands secured around the entire circumference of pipe insulation. Bands must be "Setmark" as manufactured by Seton Nameplate Corp., or approved equal.

Install bands on maximum 10 foot intervals and at each change of pipe direction.

2-15.0 CLEANING

Ducts, plenums, and casings must be thoroughly cleaned of all debris and blown free of all small particles of rubbish and dust before installing outlet faces. Equipment must be wiped clean, with all traces of oil, dust, dirt or paint spots removed.

The contractor must be responsible for repairs to any construction damage to government owned property.

2-16.0 Not Used.

2-17.0 REFRIGERATION STARTUP REPORT

After completion of the installation or modification of any refrigeration system, the following information must be recorded and submitted to the R.E. for approval.

Furnish a legible handwritten or typewritten report documenting refrigeration system test data which must include the following:

1) System Number

2) Area Served

3) Date of Test

4) Name of Individual Certifying Test

5) Outdoor Air Temperature

6) Evaporator Entering Air Temperature

7) Type of Refrigerant

Show items 8 thru 21 for each refrigerant circuit:

8) Test Pressure and Ambient Temperature During Medium Pressure Leak Testing

9) Weight of Refrigerant in Each Circuit

10) Refrigerant Suction Pressure

11) Saturated Suction Temperature (show from chart)

12) Superheated Suction Temperature

13) Superheat (calculated value)

14) Refrigerant Condensing Pressure

15) Saturated Condensing Temperature (show from chart)

16) Subcooled Liquid Temperature

17) Subcooling (calculated value)

18) Motor Amps (Nameplate) (Show for each compressor)

19) Motor Amps (Measured) "

20) Motor Volts (Nameplate) "

21) Motor Volts (Measured) "

22) A/C Unit Amps (Nameplate) (Show total for unit with all compressors…