OSUT_1_23_23_00_Refrigerant_Piping.pdf

OUST-AR RANGE PROJECTS FY19

SECTION 23 23 00

REFRIGERANT PIPING

10/07

PART 1 GENERAL

1.1 REFERENCES

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

AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI)

AHRI 710 (2004) Standard for Performance Rating of Liquid-Line Driers

AHRI 720 (2002) Refrigerant Access Valves and Hose Connectors

AHRI 750 (2007) Thermostatic Refrigerant Expansion Valves

AHRI 760 (2007) Solenoid Valves for Use With Volatile Refrigerants

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING

ENGINEERS (ASHRAE)

ASHRAE 15 & 34 (2007; Std 15 Errata 2007, 2009, & Addenda a-e; Std 34 Errata 2007, 2008, Addenda a-y, aa-ae) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants

ASHRAE 17 (2008) Method of Testing Capacity of Thermostatic Refrigerant Expansion Valves

AMERICAN WELDING SOCIETY (AWS)

AWS A5.8/A5.8M (2004; Errata 2004) Specification for Filler Metals for Brazing and Braze Welding

AWS BRH (2007) Brazing Handbook

AWS D1.1/D1.1M (2008; Errata 2009) Structural Welding Code - Steel

AWS Z49.1 (2005) Safety in Welding, Cutting and Allied Processes

ASME INTERNATIONAL (ASME)

ASME B1.20.1 (1983; R 2006) Pipe Threads, General Purpose (Inch)

ASME B16.11 (2009) Forged Fittings, Socket-Welding and Threaded

ASME B16.21 (2005) Nonmetallic Flat Gaskets for Pipe Flanges

ASME B16.22 (2001; R 2005) Standard for Wrought Copper and Copper Alloy Solder Joint Pressure Fittings

ASME B16.26 (2006) Standard for Cast Copper Alloy Fittings for Flared Copper Tubes

ASME B16.3 (2006) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.5 (2009) Standard for Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24

ASME B16.9 (2007) Standard for Factory-Made Wrought Steel Buttwelding Fittings

ASME B31.1 (2007; Addenda 2008; Addenda 2009) Power Piping

ASME B31.5 (2006) Refrigeration Piping and Heat Transfer Components

ASME B31.9 (2008) Building Services Piping

ASME B40.100 (2005) Pressure Gauges and Gauge Attachments

ASME BPVC SEC IX (2007; Addenda 2008) Boiler and Pressure Vessel Code; Section IX, Welding and Brazing Qualifications

ASTM INTERNATIONAL (ASTM)

ASTM A 193/A 193M (2009) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service

ASTM A 334/A 334M (2004a) Standard Specification for Seamless and Welded Carbon and Alloy-Steel Tubes for Low-Temperature Service

ASTM A 53/A 53M (2007) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A 653/A 653M (2009a) Standard Specification for Steel

Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM B 117 (2009) Standing Practice for Operating Salt Spray (Fog) Apparatus

ASTM B 280 (2008) Standard Specification for Seamless Copper Tube for Air Conditioning and Refrigeration Field Service

ASTM B 32 (2008) Standard Specification for Solder Metal

ASTM B 62 (2009) Standard Specification for Composition Bronze or Ounce Metal Castings

ASTM B 75 (2002) Standard Specification for Seamless Copper Tube

ASTM B 75M (1999; R 2005) Standard Specification for Seamless Copper Tube (Metric)

ASTM B 813 (2000; R 2009) Standard Specification for Liquid and Paste Fluxes for Soldering of Copper and Copper Alloy Tube

ASTM D 3308 (2006) PTFE Resin Skived Tape

ASTM D 520 (2000; R 2005) Zinc Dust Pigment

ASTM E 84 (2009c) Standard Test Method for Surface Burning Characteristics of Building Materials

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2009) Standard for Pipe Hangers and Supports - Materials, Design and Manufacture

MSS SP-69 (2003; R 2004) Standard for Pipe Hangers and Supports - Selection and Application

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-310-04 (2007) Seismic Design for Buildings

1.2 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Refrigerant Piping System; G, AE

Drawings, at least 5 weeks prior to beginning construction, provided in adequate detail to demonstrate compliance with contract requirements. Drawings shall consist of:

a. Piping layouts which identify all valves and fittings.

b. Plans and elevations which identify clearances required for maintenance and operation.

SD-03 Product Data

Refrigerant Piping System

Manufacturer's standard catalog data, at least 5 weeks prior to the purchase or installation of a particular component, highlighted to show material, size, options, performance charts and curves, etc. in adequate detail to demonstrate compliance with contract requirements. Include in the data manufacturer's recommended installation instructions and procedures. Provide data for the following components as a minimum:

a. Piping and Fittings

b. Valves

c. Piping Accessories

d. Pipe Hangers, Inserts, and Supports

Spare Parts

Spare parts data for each different item of equipment specified in Army projects only.

Qualifications; G, AE

Six copies of qualified procedures, and list of names and identification symbols of qualified welders and welding operators, prior to non-factory welding operations.

Refrigerant Piping Tests; G, AE

A schedule, at least 2 weeks prior to the start of related testing, for each test. Identify the proposed date, time, and location for each test.

Demonstrations; G, AE

A schedule, at least 2 weeks prior to the date of the proposed training course, which identifies the date, time, and location for the training.

Verification of Dimensions

A letter, at least 2 weeks prior to beginning construction, including the date the site was visited, conformation of existing conditions, and any discrepancies found.

SD-06 Test Reports

Refrigerant Piping Tests

Six copies of the report in bound 8 1/2 by 11 inch booklets documenting all phases of the tests performed. The report shall include initial test summaries, all repairs/adjustments made, and the final test results.

SD-07 Certificates

Service Organization; G, AE

A certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. The service organizations shall be reasonably convenient to the equipment installation and be able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.

SD-10 Operation and Maintenance Data

Maintenance Operation and Maintenance Manuals

Data Package 2 in accordance with Section 01 78 23 OPERATION AND

MAINTENANCE DATA.

Six complete copies of an operation manual in bound 8 1/2 by 11 inch booklets listing step-by-step procedures required for system startup, operation, abnormal shutdown, emergency shutdown, and normal shutdown at least 4 weeks prior to the first training course. The booklets shall include the manufacturer's name, model number, and parts list. The manuals shall include the manufacturer's name, model number, service manual, and a brief description of all equipment and their basic operating features.

Six complete copies of maintenance manual in bound 8 1/2 x 11 inch booklets listing routine maintenance procedures, possible breakdowns and repairs, and a trouble shooting guide. The manuals shall include piping layouts and simplified wiring and control diagrams of the system as installed.

1.3 QUALITY ASSURANCE

1.3.1 Qualifications

Piping shall be welded in accordance with the qualified procedures using performance qualified welders and welding operators. Procedures and welders shall be qualified in accordance with ASME BPVC SEC IX. Welding procedures qualified by others, and welders and welding operators qualified by another employer may be accepted as permitted by ASME B31.1. Notify the Contracting Officer 24 hours in advance of tests to be performed at the work site, if practical. The welder or welding operator shall apply the personally assigned symbol near each weld made, as a permanent record.

Structural members shall be welded in accordance with Section 40 17 26.00 20

WELDING PRESSURE PIPING.

1.3.2 Contract Drawings

Because of the small scale of the drawings, it is not possible to indicate all offsets, fittings, and accessories that may be required. Carefully investigate the plumbing, fire protection, electrical, structural and finish conditions that would affect the work to be performed and arrange such work accordingly, furnishing required offsets, fittings, and accessories to meet such conditions.

1.4 DELIVERY, STORAGE, AND HANDLING

Protect stored items from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Proper protection and care of all material both before and during installation is the Contractor's responsibility. Replace any materials found to be damaged at the Contractor's expense. During installation, cap piping and similar openings to keep out dirt and other foreign matter.

1.5 MAINTENANCE

1.5.1 General

Operation and maintenance data shall comply with the requirements of Section 01 78 23 OPERATION AND MAINTENANCE DATA and as specified herein.

1.5.2 Extra Materials

Submit spare parts data for each different item of equipment specified, after approval of detail drawings and not later than 3 months prior to the date of beneficial occupancy. The data shall include a complete list of parts and supplies, with current unit prices and source of supply, a recommended spare parts list for 1 year of operation, and a list of the parts recommended by the manufacturer to be replaced on a routine basis.

PART 2 PRODUCTS

2.1 STANDARD COMMERCIAL PRODUCTS

a. Provide materials and equipment which are standard products of a manufacturer regularly engaged in the manufacturing of such products, that are of a similar material, design and workmanship and that have been in satisfactory commercial or industrial use for 2 years prior to bid opening.

b. The 2 year use shall include applications of equipment and materials under similar circumstances and of similar size. The 2 years experience shall be satisfactorily completed by a product which has been sold or is offered for sale on the commercial market through advertisements, manufacturer's catalogs, or brochures. Products having less than a 2 year field service record will be acceptable if a certified record of satisfactory field operation, for not less than 6000 hours exclusive of the manufacturer's factory tests, can be shown.

c. Products shall be supported by a service organization. System components shall be environmentally suitable for the indicated locations.

d. Exposed equipment moving parts, parts that produce high operating temperature, parts which may be electrically energized, and parts that may be a hazard to operating personnel shall be insulated, fully enclosed, guarded, or fitted with other types of safety devices.

Install safety devices so that proper operation of equipment is not impaired. Welding and cutting safety requirements shall be in accordance with AWS Z49.1.

2.2 ELECTRICAL WORK

Electrical equipment and wiring shall be in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Field wiring shall be in accordance with manufacturer's instructions.

2.3 REFRIGERANT PIPING SYSTEM

Refrigerant piping, valves, fittings, and accessories shall be in accordance with ASHRAE 15 & 34 and ASME B31.5, except as specified herein.

Refrigerant piping, valves, fittings, and accessories shall be compatible with the fluids used and capable of withstanding the pressures and temperatures of the service. Refrigerant piping, valves, and accessories used for refrigerant service shall be cleaned, dehydrated, and sealed (capped or plugged) prior to shipment from the manufacturer's plant.

2.4 PIPE, FITTINGS AND END CONNECTIONS (JOINTS)

2.4.1 Steel Pipe

Steel pipe for refrigerant service shall conform to ASTM A 53/A 53M, Schedule 40, Type E or S, Grades A or B. Type F pipe shall not be used.

2.4.1.1 Welded Fittings and Connections

Butt-welded fittings shall conform to ASME B16.9. Socket-welded fittings shall conform to ASME B16.11. Welded fittings shall be identified with the appropriate grade and marking symbol. Welded valves and pipe connections (both butt-welds and socket-welds types) shall conform to ASME B31.9.

2.4.1.2 Threaded Fittings and Connections

Threaded fitting shall conform to ASME B16.3. Threaded valves and pipe connections shall conform to ASME B1.20.1.

2.4.1.3 Flanged Fittings and Connections

Flanges shall conform to ASME B16.5, Class 150. Gaskets shall be nonasbestos compressed material in accordance with ASME B16.21, 1/16 inch thickness, full face or self-centering flat ring type. This gaskets shall contain aramid fibers bonded with styrene butadeine rubber (SBR) or nitrile butadeine rubber (NBR). Bolts, nuts, and bolt patterns shall conform to ASME B16.5. Bolts shall be high or intermediate strength material conforming to ASTM A 193/A 193M.

2.4.2 Steel Tubing

Tubing shall be cold-rolled, electric-forged, welded-steel in accordance with ASTM A 334/A 334M, Grade 1. Joints and fittings shall be socket type provided by the steel tubing manufacturer.

2.4.3 Copper Tubing

Copper tubing shall conform to ASTM B 280 annealed or hard drawn as required. Copper tubing shall be soft annealed where bending is required and hard drawn where no bending is required. Soft annealed copper tubing shall not be used in sizes larger than 1-3/8 inches. Joints shall be brazed except that joints on lines 7/8 inchand smaller may be flared. Cast copper alloy fittings for flared copper tube shall conform to ASME B16.26 and ASTM B 62. Wrought copper and bronze solder-joint pressure fittings shall conform to ASME B16.22 and ASTM B 75. Joints and fittings for brazed joint shall be wrought-copper or forged-brass sweat fittings. Cast sweat-type joints and fittings shall not be allowed for brazed joints.

Brass or bronze adapters for brazed tubing may be used for connecting tubing to flanges and to threaded ends of valves and equipment.

2.4.4 Solder

Solder shall conform to ASTM B 32, grade Sb5, tin-antimony alloy for service pressures up to 150 psig. Solder flux shall be liquid or paste form, non-corrosive and conform to ASTM B 813.

2.4.5 Brazing Filler Metal

Filler metal shall conform to AWS A5.8/A5.8M, Type BAg-5 with AWS Type 3 flux, except Type BCuP-5 or BCuP-6 may be used for brazing copper-to-copper joints.

2.5 VALVES

Valves shall be designed, manufactured, and tested specifically for refrigerant service. Valve bodies shall be of brass, bronze, steel, or ductile iron construction. Valves 1 inch and smaller shall have brazed or socket welded connections. Valves larger than 1 inch shall have tongue-and-groove flanged end connections. Threaded end connections shall not be used, except in pilot pressure or gauge lines where maintenance disassembly is required and welded flanges cannot be used. Internal parts shall be removable for inspection or replacement without applying heat or breaking pipe connections. Valve stems exposed to the atmosphere shall be stainless steel or corrosion resistant metal plated carbon steel.

Direction of flow shall be legibly and permanently indicated on the valve body. Control valve inlets shall be fitted with integral or adapted strainer or filter where recommended or required by the manufacturer.

Purge, charge and receiver valves shall be of manufacturer's standard configuration.

2.5.1 Refrigerant Stop Valves

Valve shall be the globe or full-port ball type with a back-seating stem especially packed for refrigerant service. Valve packing shall be replaceable under line pressure. Valve shall be provided with a handwheel operator and a seal cap. Valve shall be the straight or angle pattern design as indicated.

2.5.2 Check Valves

Valve shall be the swing or lift type as required to provide positive shutoff at the differential pressure indicated. Valve shall be provide with resilient seat.

2.5.3 Liquid Solenoid Valves

Valves shall comply with AHRI 760 and be suitable for continuous duty with applied voltages 15 percent under and 5 percent over nominal rated voltage at maximum and minimum encountered pressure and temperature service conditions. Valves shall be direct-acting or pilot-operating type, packless, except that packed stem, seal capped, manual lifting provisions shall be furnished. Solenoid coils shall be moisture-proof, UL approved, totally encapsulated or encapsulated and metal jacketed as required.

Valves shall have safe working pressure of 400 psi and a maximum operating pressure differential of at least 200 psi at 85 percent rated voltage.

Valves shall have an operating pressure differential suitable for the refrigerant used.

2.5.4 Expansion Valves

Valve shall conform to AHRI 750 and ASHRAE 17. Valve shall be the diaphragm and spring-loaded type with internal or external equalizers, and bulb and capillary tubing. Valve shall be provided with an external superheat adjustment along with a seal cap. Internal equalizers may be utilized where flowing refrigerant pressure drop between outlet of the valve and inlet to the evaporator coil is negligible and pressure drop across the evaporator is less than the pressure difference corresponding to 2 degrees F of saturated suction temperature at evaporator conditions.

Bulb charge shall be determined by the manufacturer for the application and such that liquid will remain in the bulb at all operating conditions. Gas limited liquid charged valves and other valve devices for limiting evaporator pressure shall not be used without a distributor or discharge tube or effective means to prevent loss of control when bulb becomes warmer than valve body. Pilot-operated valves shall have a characterized plug to provide required modulating control. A de-energized solenoid valve may be used in the pilot line to close the main valve in lieu of a solenoid valve in the main liquid line. An isolatable pressure gauge shall be provided in the pilot line, at the main valve. Automatic pressure reducing or constant pressure regulating expansion valves may be used only where indicted or for constant evaporator loads.

2.5.5 Safety Relief Valves

Valve shall be the two-way type, unless indicated otherwise. Valve shall bear the ASME code symbol. Valve capacity shall be certified by the National Board of Boiler and Pressure Vessel Inspectors. Valve shall be of an automatically reseating design after activation.

2.5.6 Evaporator Pressure Regulators, Direct-Acting

Valve shall include a diaphragm/spring assembly, external pressure adjustment with seal cap, and pressure gauge port. Valve shall maintain a constant inlet pressure by balancing inlet pressure on diaphragm against an adjustable spring load. Pressure drop at system design load shall not exceed the pressure difference corresponding to a 2 degrees F change in saturated refrigerant temperature at evaporator operating suction temperature. Spring shall be selected for indicated maximum allowable suction pressure range.

2.5.7 Refrigerant Access Valves

Refrigerant access valves and hose connections shall be in accordance with

AHRI 720.

2.6 PIPING ACCESSORIES

2.6.1 Filter Driers

Driers shall conform to AHRI 710. Sizes 5/8 inch and larger shall be the full flow, replaceable core type. Sizes 1/2 inch and smaller shall be the sealed type. Cores shall be of suitable desiccant that will not plug, cake, dust, channel, or break down, and shall remove water, acid, and foreign material from the refrigerant. Filter driers shall be constructed so that none of the desiccant will pass into the refrigerant lines.

Minimum bursting pressure shall be 1,500 psi.

2.6.2 Sight Glass and Liquid Level Indicator

2.6.2.1 Assembly and Components

Assembly shall be pressure- and temperature-rated and constructed of materials suitable for the service. Glass shall be borosilicate type.

Ferrous components subject to condensation shall be electro-galvanized.

2.6.2.2 Gauge Glass

Gauge glass shall include top and bottom isolation valves fitted with automatic checks, and packing followers; red-line or green-line gauge glass; elastomer or polymer packing to suit the service; and gauge glass guard.

2.6.2.3 Bull's-Eye and Inline Sight Glass Reflex Lens

Bull's-eye and inline sight glass reflex lens shall be provided for dead-end liquid service. For pipe line mounting, two plain lenses in one body suitable for backlighted viewing shall be provided.

2.6.2.4 Moisture Indicator

Indicator shall be a self-reversible action, moisture reactive, color changing media. Indicator shall be furnished with full-color-printing tag containing color, moisture and temperature criteria. Unless otherwise indicated, the moisture indicator shall be an integral part of each corresponding sight glass.

2.6.3 Vibration Dampeners

Dampeners shall be of the all-metallic bellows and woven-wire type.

2.6.4 Flexible Pipe Connectors

Connector shall be a composite of interior corrugated phosphor bronze or Type 300 Series stainless steel, as required for fluid service, with exterior reinforcement of bronze, stainless steel or monel wire braid.

Assembly shall be constructed with a safety factor of not less than 4 at300 degrees F. Unless otherwise indicated, the length of a flexible connector shall be as recommended by the manufacturer for the service intended.

2.6.5 Strainers

Strainers used in refrigerant service shall have brass or cast iron body, Y-or angle-pattern, cleanable, not less than 60-mesh noncorroding screen of an area to provide net free area not less than ten times the pipe diameter with pressure rating compatible with the refrigerant service. Screens shall be stainless steel or monel and reinforced spring-loaded where necessary for bypass-proof construction.

2.6.6 Pressure and Vacuum Gauges

Gauges shall conform to ASME B40.100 and shall be provided with throttling type needle valve or a pulsation dampener and shut-off valve. Gauge shall be a minimum of 3-1/2 inches in diameter with a range from 0 psig to approximately 1.5 times the maximum system working pressure. Each gauge range shall be selected so that at normal operating pressure, the needle is within the middle-third of the range.

2.6.7 Temperature Gauges

Temperature gauges shall be the industrial duty type and be provided for the required temperature range. Gauges shall have Fahrenheit scale in 2 degrees graduations scale (black numbers) on a white face. The pointer shall be adjustable. Rigid stem type temperature gauges shall be provided in thermal wells located within 5 feet of the finished floor. Universal adjustable angle type or remote element type temperature gauges shall be provided in thermal wells located 5 to 7 feet above the finished floor.

Remote element type temperature gauges shall be provided in thermal wells located 7 feet above the finished floor.

2.6.7.1 Stem Cased-Glass

Stem cased-glass case shall be polished stainless steel or cast aluminum, 9 inches long, with clear acrylic lens, and non-mercury filled glass tube with indicating-fluid column.

2.6.7.2 Bimetallic Dial

Bimetallic dial type case shall be not less than 3-1/2 inches, stainless steel, and shall be hermetically sealed with clear acrylic lens.

Bimetallic element shall be silicone dampened and unit fitted with external calibrator adjustment. Accuracy shall be one percent of dial range.

2.6.7.3 Liquid-, Solid-, and Vapor-Filled Dial

Liquid-, solid-, and vapor-filled dial type cases shall be not less than 3-1/2 inches, stainless steel or cast aluminum with clear acrylic lens.

Fill shall be nonmercury, suitable for encountered cross-ambients, and connecting capillary tubing shall be double-braided bronze.

2.6.7.4 Thermal Well

Thermal well shall be identical size, 1/2 or 3/4 inch NPT connection, brass or stainless steel. Where test wells are indicated, provide captive plug-fitted type 1/2 inch NPT connection suitable for use with either engraved stem or standard separable socket thermometer or thermostat.

Mercury shall not be used in thermometers. Extended neck thermal wells shall be of sufficient length to clear insulation thickness by 1 inch.

2.6.8 Pipe Hangers, Inserts, and Supports

Pipe hangers, inserts, guides, and supports shall conform to MSS SP-58 and

MSS SP-69.

2.6.9 Escutcheons

Escutcheons shall be chromium-plated iron or chromium-plated brass, either one piece or split pattern, held in place by internal spring tension or set screws.

2.7 FABRICATION

2.7.1 Factory Coating

Unless otherwise specified, equipment and component items, when fabricated from ferrous metal, shall be factory finished with the manufacturer's standard finish, except that items located outside of buildings shall have weather resistant finishes that will withstand 125 hours exposure to the salt spray test specified in ASTM B 117 using a 5 percent sodium chloride solution. Immediately after completion of the test, the specimen shall show no signs of blistering, wrinkling, cracking, or loss of adhesion and no sign of rust creepage beyond 1/8 inch on either side of the scratch mark. Cut edges of galvanized surfaces where hot-dip galvanized sheet steel is used shall be coated with a zinc-rich coating conforming to ASTM D 520, Type I.

2.7.2 Factory Applied Insulation

Refrigerant suction lines between the cooler and each compressor and cold gas inlet connections to gas cooled motors Refrigerant pumps and exposed chilled water lines on absorption chillers shall be insulated with not less than 3/4 inch thick unicellular plastic foam. Factory insulated items installed outdoors are not required to be fire-rated. As a minimum, factory insulated items installed indoors shall have a flame spread index no higher than 75 and a smoke developed index no higher than 150. Factory insulated items (no jacket) installed indoors and which are located in air plenums, in ceiling spaces, and in attic spaces shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50.

Flame spread and smoke developed indexes shall be determined by ASTM E 84.

Insulation shall be tested in the same density and installed thickness as the material to be used in the actual construction. Material supplied by a manufacturer with a jacket shall be tested as a composite material.

Jackets, facings, and adhesives shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50 when tested in accordance with ASTM E 84.

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with all details of the work, perform a verification of dimensions in the field, and advise the Contracting Officer of any discrepancy before performing any work.

3.2 INSTALLATION

Pipe and fitting installation shall conform to the requirements of ASME B31.1. Pipe shall be cut accurately to measurements established at the jobsite, and worked into place without springing or forcing, completely clearing all windows, doors, and other openings. Cutting or other weakening of the building structure to facilitate piping installation will not be permitted without written approval. Pipe or tubing shall be cut square, shall have burrs removed by reaming, and shall permit free expansion and contraction without causing damage to the building structure, pipe, joints, or hangers.

3.2.1 Directional Changes

Changes in direction shall be made with fittings, except that bending of pipe 4 inches and smaller will be permitted, provided a pipe bender is used and wide weep bends are formed. Mitering or notching pipe or other similar construction to form elbows or tees will not be permitted. The centerline radius of bends shall not be less than 6 diameters of the pipe. Bent pipe showing kinks, wrinkles, flattening, or other malformations will not be accepted.

3.2.2 Functional Requirements

Piping shall be installed 1/2 inch/10 feet of pipe in the direction of flow to ensure adequate oil drainage. Open ends of refrigerant lines or equipment shall be properly capped or plugged during installation to keep moisture, dirt, or other foreign material out of the system. Piping shall remain capped until installation. Equipment piping shall be in accordance with the equipment manufacturer's recommendations and the contract drawings. Equipment and piping arrangements shall fit into space allotted and allow adequate acceptable clearances for installation, replacement, entry, servicing, and maintenance.

3.2.3 Fittings and End Connections

3.2.3.1 Threaded Connections

Threaded connections shall be made with tapered threads and made tight with PTFE tape complying with ASTM D 3308 or equivalent thread-joint compound applied to the male threads only. Not more than three threads shall show after the joint is made.

3.2.3.2 Brazed Connections

Brazing shall be performed in accordance with AWS BRH, except as modified herein. During brazing, the pipe and fittings shall be filled with a pressure regulated inert gas, such as nitrogen, to prevent the formation of scale. Before brazing copper joints, both the outside of the tube and the inside of the fitting shall be cleaned with a wire fitting brush until the entire joint surface is bright and clean. Brazing flux shall not be used.

Surplus brazing material shall be removed at all joints. Steel tubing joints shall be made in accordance with the manufacturer's recommendations. Joints in steel tubing shall be painted with the same material as the baked-on coating within 8 hours after joints are made.

Tubing shall be protected against oxidation during brazing by continuous purging of the inside of the piping using nitrogen. Piping shall be supported prior to brazing and not be sprung or forced.

3.2.3.3 Welded Connections

Welded joints in steel refrigerant piping shall be fusion-welded. Branch connections shall be made with welding tees or forged welding branch outlets. Pipe shall be thoroughly cleaned of all scale and foreign matter before the piping is assembled. During welding the pipe and fittings shall be filled with an inert gas, such as nitrogen, to prevent the formation of scale. Beveling, alignment, heat treatment, and inspection of weld shall conform to ASME B31.1. Weld defects shall be removed and rewelded at no additional cost to the Government. Electrodes shall be stored and dried in accordance with AWS D1.1/D1.1M or as recommended by the manufacturer.

Electrodes that have been wetted or that have lost any of their coating shall not be used.

3.2.3.4 Flared Connections

When flared connections are used, a suitable lubricant shall be used between the back of the flare and the nut in order to avoid tearing the flare while tightening the nut.

3.2.3.5 Flanged Connections

When steel refrigerant piping is used, union or flange joints shall be provided in each line immediately preceding the connection to each piece of equipment requiring maintenance, such as compressors, coils, chillers, control valves, and other similar items. Flanged joints shall be assembled square end tight with matched flanges, gaskets, and bolts. Gaskets shall be suitable for use with the refrigerants to be handled.

3.2.4 Valves

3.2.4.1 General

Refrigerant stop valves shall be installed on each side of each piece of equipment such as compressors condensers, evaporators, receivers, and other similar items in multiple-unit installation, to provide partial system isolation as required for maintenance or repair. Stop valves shall be installed with stems horizontal unless otherwise indicated. Ball valves shall be installed with stems positioned to facilitate operation and maintenance. Isolating valves for pressure gauges and switches shall be external to thermal insulation. Safety switches shall not be fitted with isolation valves. Filter dryers having access ports may be considered a point of isolation. Purge valves shall be provided at all points of systems where accumulated noncondensable gases would prevent proper system operation. Valves shall be furnished to match line size, unless otherwise indicated or approved.

3.2.4.2 Expansion Valves

Expansion valves shall be installed with the thermostatic expansion valve bulb located on top of the suction line when the suction line is less than 2-1/8 inches in diameter and at the 4 o'clock or 8 o'clock position on lines larger than 2-1/8 inches. The bulb shall be securely fastened with two clamps. The bulb shall be insulated. The bulb shall installed in a horizontal portion of the suction line, if possible, with the pigtail on the bottom. If the bulb must be installed in a vertical line, the bulb tubing shall be facing up.

3.2.4.3 Valve Identification

Each system valve, including those which are part of a factory assembly, shall be tagged. Tags shall be in alphanumeric sequence, progressing in direction of fluid flow. Tags shall be embossed, engraved, or stamped plastic or nonferrous metal of various shapes, sized approximately 1-3/8 inch diameter, or equivalent dimension, substantially attached to a component or immediately adjacent thereto. Tags shall be attached with nonferrous, heavy duty, bead or link chain, 14 gauge annealed wire, nylon cable bands or as approved. Tag numbers shall be referenced in Operation and Maintenance Manuals and system diagrams.

3.2.5 Vibration Dampers

Vibration damper shall be provided in the suction and discharge lines on spring mounted compressors. Vibration dampers shall be installed parallel with the shaft of the compressor and shall be anchored firmly at the upstream end on the suction line and the downstream end in the discharge line.

3.2.6 Strainers

Strainers shall be provided immediately ahead of solenoid valves and expansion devices. Strainers may be an integral part of an expansion valve.

3.2.7 Filter Dryer

A liquid line filter dryer shall be provided on each refrigerant circuit located such that all liquid refrigerant passes through a filter dryer.

Dryers shall be sized in accordance with the manufacturer's recommendations for the system in which it is installed. Dryers shall be installed such that it can be isolated from the system, the isolated portion of the system evacuated, and the filter dryer replaced. Dryers shall be installed in the horizontal position except replaceable core filter dryers may be installed in the vertical position with the access flange on the bottom.

3.2.8 Sight Glass

A moisture indicating sight glass shall be installed in all refrigerant circuits down stream of all filter dryers and where indicated. Site glasses shall be full line size.

3.2.9 Discharge Line Oil Separator

Discharge line oil separator shall be provided in the discharge line from each compressor. Oil return line shall be connected to the compressor as recommended by the compressor manufacturer.

3.2.10 Accumulator

Accumulators shall be provided in the suction line to each compressor.

3.2.11 Flexible Pipe Connectors

Connectors shall be installed perpendicular to line of motion being isolated. Piping for equipment with bidirectional motion shall be fitted with two flexible connectors, in perpendicular planes. Reinforced elastomer flexible connectors shall be installed in accordance with manufacturer's instructions. Piping guides and restraints related to flexible connectors shall be provided as required.

3.2.12 Temperature Gauges

Temperature gauges shall be located specifically on, but not limited to the following: the sensing element of each automatic temperature control device where a thermometer is not an integral part thereof, the liquid line leaving a receiver, and the suction line at each evaporator or liquid cooler.

Thermal wells for insertion thermometers and thermostats shall extend beyond thermal insulation surface not less than 1 inch.

3.2.13 Pipe Hangers, Inserts, and Supports

Pipe hangers, inserts, and supports shall conform to MSS SP-58 and MSS SP-69, except as modified herein. Pipe hanger types 5, 12, and 26 shall not be used. Hangers used to support piping 2 inches and larger shall be fabricated to permit adequate adjustment after erection while still supporting the load. Piping subjected to vertical movement, when operating temperatures exceed ambient temperatures, shall be supported by variable spring hangers and supports or by constant support hangers.

3.2.13.1 Hangers

Type 3 shall not be used on insulated piping. Type 24 may be used only on trapeze hanger systems or on fabricated frames.

3.2.13.2 Inserts

Type 18 inserts shall be secured to concrete forms before concrete is placed. Continuous inserts which allow more adjustments may be used if they otherwise meet the requirements for Type 18 inserts.

3.2.13.3 C-Clamps

Type 19 and 23 C-clamps shall be torqued in accordance with MSS SP-69 and have both locknuts and retaining devices, furnished by the manufacturer.

Field-fabricated C-clamp bodies or retaining devices are not acceptable.

3.2.13.4 Angle Attachments

Type 20 attachments used on angles and channels shall be furnished with an added malleable-iron heel plate or adapter.

3.2.13.5 Saddles and Shields

Where Type 39 saddle or Type 40 shield are permitted for a particular pipe attachment application, the Type 39 saddle, connected to the pipe, shall be used on all pipe 4 inches and larger when the temperature of the medium is 60 degrees F or higher. Type 40 shields shall be used on all piping less than 4 inches and all piping 4 inches and larger carrying medium less than 60 degrees F. A high density insulation insert of cellular glass shall be used under the Type 40 shield for piping 2 inches and larger.

3.2.13.6 Horizontal Pipe Supports

Horizontal pipe supports shall be spaced as specified in MSS SP-69 and a support shall be installed not over 1 foot from the pipe fitting joint at each change in direction of the piping. Pipe supports shall be spaced not over 5 feet apart at valves. Pipe hanger loads suspended from steel joist with hanger loads between panel points in excess of 50 pounds shall have the excess hanger loads suspended from panel points.

3.2.13.7 Vertical Pipe Supports

Vertical pipe shall be supported at each floor, except at slab-on-grade, and at intervals of not more than 15 feet not more than 8 feet from end of risers, and at vent terminations.

3.2.13.8 Pipe Guides

Type 35 guides using, steel, reinforced polytetrafluoroethylene (PTFE) or graphite slides shall be provided where required to allow longitudinal pipe movement. Lateral restraints shall be provided as required. Slide materials shall be suitable for the system operating temperatures, atmospheric conditions, and bearing loads encountered.

3.2.13.9 Steel Slides

Where steel slides do not require provisions for restraint of lateral movement, an alternate guide method may be used. On piping 4 inches and larger, a Type 39 saddle shall be used. On piping under 4 inches, a Type 40 protection shield may be attached to the pipe or insulation and freely rest on a steel slide plate.

3.2.13.10 High Temperature Guides with Cradles

Where there are high system temperatures and welding to piping is not desirable, then the Type 35 guide shall include a pipe cradle, welded to the guide structure and strapped securely to the pipe. The pipe shall be separated from the slide material by at least 4 inches, or by an amount adequate for the insulation, whichever is greater.

3.2.13.11 Multiple Pipe Runs

In the support of multiple pipe runs on a common base member, a clip or clamp shall be used where each pipe crosses the base support member.

Spacing of the base support members shall not exceed the hanger and support spacing required for an individual pipe in the multiple pipe run.

3.2.13.12 Seismic Requirements

Piping and attached valves shall be supported and braced to resist seismic loads as specified under UFC 3-310-04 and Sections 13 48 00 SEISMIC

PROTECTION FOR MISCELLANEOUS EQUIPMENT and 22 05 48.00 20 MECHANICAL SOUND, VIBRATION, AND SEISMIC CONTROL. Structural steel required for reinforcement to properly support piping, headers, and equipment but not shown shall be provided under this section. Material used for support shall be as specified under Section 05 12 00 STRUCTURAL STEEL.

3.2.13.13 Structural Attachments

Attachment to building structure concrete and masonry shall be by cast-in concrete inserts, built-in anchors, or masonry anchor devices. Inserts and anchors shall be applied with a safety factor not less than 5. Supports shall not be attached to metal decking. Masonry anchors for overhead applications shall be constructed of ferrous materials only. Structural steel brackets required to support piping, headers, and equipment, but not shown, shall be provided under this section. Material used for support shall be as specified under Section 05 12 00 STRUCTURAL STEEL.

3.2.14 Pipe Alignment Guides

Pipe alignment guides shall be provided where indicated for expansion loops, offsets, and bends and as recommended by the manufacturer for expansion joints, not to exceed 5 feet on each side of each expansion joint, and in lines 4 inches or smaller not more than 2 feet on each side of the joint.

3.2.15 Pipe Anchors

Anchors shall be provided wherever necessary or indicated to localize expansion or to prevent undue strain on piping. Anchors shall consist of heavy steel collars with lugs and bolts for clamping and attaching anchor braces, unless otherwise indicated. Anchor braces shall be installed in the most effective manner to secure the desired results using turnbuckles where required. Supports, anchors, or stays shall not be attached where they will injure the structure or adjacent construction during installation or by the weight of expansion of the pipeline. Where pipe and conduit penetrations of vapor barrier sealed surfaces occur, these items shall be anchored immediately adjacent to each penetrated surface, to provide essentially zero movement within penetration seal. Detailed drawings of pipe anchors shall be submitted for approval before installation.

3.2.16 Building Surface Penetrations

Sleeves shall not be installed in structural members except where indicated or approved. Sleeves in nonload bearing surfaces shall be galvanized sheet metal, conforming to ASTM A 653/A 653M, Coating Class G-90, 20 gauge.

Sleeves in load bearing surfaces shall be uncoated carbon steel pipe, conforming to ASTM A 53/A 53M, Standard weight. Sealants shall be applied to moisture and oil-free surfaces and elastomers to not less than 1/2 inch depth. Sleeves shall not be installed in structural members.

3.2.16.1 Refrigerated Space

Refrigerated space building surface penetrations shall be fitted with sleeves fabricated from hand-lay-up or helically wound, fibrous glass reinforced polyester or epoxy resin with a minimum thickness equal to equivalent size Schedule 40 steel pipe. Sleeves shall be constructed with integral collar or cold side shall be fitted with a bonded slip-on flange or extended collar. In the case of masonry penetrations where sleeve is not cast-in, voids shall be filled with latex mixed mortar cast to shape of sleeve and flange/external collar type sleeve shall be assembled with butyl elastomer vapor barrier sealant through penetration to cold side surface vapor barrier overlap and fastened to surface with masonry anchors.

Integral cast-in collar type sleeve shall be flashed with not less than 4 inches of cold side vapor barrier overlap of sleeve surface. Normally noninsulated penetrating round surfaces shall be sealed to sleeve bore with mechanically expandable seals in vapor tight manner and remaining warm and cold side sleeve depth shall be insulated with not less than 4 inches of foamed-in-place rigid polyurethane or foamed-in-place silicone elastomer.

Vapor barrier sealant shall be applied to finish warm side insulation surface. Warm side of penetrating surface shall be insulated beyond vapor barrier sealed sleeve insulation for a distance which prevents condensation. Wires in refrigerated space surface penetrating conduit shall be sealed with vapor barrier plugs or compound to prevent moisture migration through conduit and condensation therein.

3.2.16.2 General Service Areas

Each sleeve shall extend through its respective wall, floor, or roof, and shall be cut flush with each surface. Pipes passing through concrete or masonry wall or concrete floors or roofs shall be provided with pipe sleeves fitted into place at the time of construction. Sleeves shall be of such size as to provide a minimum of 1/4 inch all-around clearance between bare pipe and sleeves or between jacketed-insulation and sleeves. Except in pipe chases or interior walls, the annular space between pipe and sleeve or between jacket over-insulation and sleeve shall be sealed in accordance with Section 07 92 00 JOINT SEALANTS.

3.2.16.3 Waterproof Penetrations

Pipes passing through roof or floor waterproofing membrane shall be installed through a 17 ounce copper sleeve, or a 0.032 inch thick aluminum sleeve, each within an integral skirt or flange. Flashing sleeve shall be suitably formed, and skirt or flange shall extend not less than 8 inches from the pipe and be set over the roof or floor membrane in a troweled coating of bituminous cement. The flashing sleeve shall extend up the pipe a minimum of 2 inches above the roof or floor penetration. The annular space between the flashing sleeve and the bare pipe or between the flashing sleeve and the metal-jacket-covered insulation shall be sealed as indicated. Penetrations shall be sealed by either one of the following methods.

a. Waterproofing Clamping Flange: Pipes up to and including 10 inches in diameter passing through roof or floor waterproofing membrane may be installed through a cast iron sleeve with caulking recess, anchor lugs, flashing clamp device, and pressure ring with brass bolts.

Waterproofing membrane shall be clamped into place and sealant shall be placed in the caulking recess.

b. Modular Mechanical Type Sealing Assembly: In lieu of a waterproofing clamping flange and caulking and sealing of annular space between pipe and sleeve or conduit and sleeve, a modular mechanical type sealing assembly may be installed. Seals shall consist of interlocking synthetic rubber links shaped to continuously fill the annular space between the pipe/conduit and sleeve with corrosion protected carbon steel bolts, nuts, and pressure plates. Links shall be loosely assembled with bolts to form a continuous rubber belt around the pipe with a pressure plate under each bolt head and each nut.

After the seal assembly is properly positioned in the sleeve, tightening of the bolt shall cause the rubber sealing elements to expand and provide a watertight seal rubber sealing elements to expand and provide a watertight seal between the pipe/conduit seal between the pipe/conduit and the sleeve. Each seal assembly shall be sized as recommended by the manufacturer to fit the pipe/conduit and sleeve involved. The Contractor electing to use the modular mechanical type seals shall provide sleeves of the proper diameters.

3.2.16.4 Fire-Rated Penetrations

Penetration of fire-rated walls, partitions, and floors shall be sealed as specified in Section 07 84 00 FIRESTOPPING.

3.2.16.5 Escutcheons

Finished surfaces where exposed piping, bare or insulated, pass through floors, walls, or ceilings, except in boiler, utility, or equipment rooms, shall be provided with escutcheons. Where sleeves project slightly from floors, special deep-type escutcheons shall be used. Escutcheon shall be secured to pipe or pipe covering.

3.2.17 Access Panels

Access panels shall be provided for all concealed valves, vents, controls, and items requiring inspection or maintenance. Access panels shall be of sufficient size and located so that the concealed items may be serviced and maintained or completely removed and replaced. Access panels shall be as specified in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.

3.2.18 Field Applied Insulation

Field installed insulation shall be as specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS, except as defined differently herein.

3.2.19 Field Painting

Painting required for surfaces not otherwise specified, and finish painting of items only primed at the factory are specified in Section 09 90 00

PAINTS AND COATINGS.

3.2.19.1 Color Coding

Color coding for piping identification is specified in Section 09 90 00

PAINTS AND COATINGS.

3.2.19.2 Color Coding Scheme

A color coding scheme for locating hidden piping shall be in accordance with Section 22 00 00 PLUMBING, GENERAL PURPOSE.

3.3 CLEANING AND ADJUSTING

Clean uncontaminated system(s) by evacuation and purging procedures currently recommended by refrigerant and refrigerant equipment manufacturers, and as specified herein, to remove small amounts of air and moisture. Systems containing moderate amounts of air, moisture, contaminated refrigerant, or any foreign matter shall be considered contaminated systems. Restoring contaminated systems to clean condition including disassembly, component replacement, evacuation, flushing, purging, and re-charging, shall be performed using currently approved refrigerant and refrigeration manufacturer's procedures. Restoring contaminated systems shall be at no additional cost to the Government as determined by the Contracting Officer. Water shall not be used in any procedure or test.

3.4 TRAINING COURSE

Conduct a training course for 8 members of the operating staff as designated by the Contracting Officer. The training period shall consist of a total 8 hours of normal working time and start after the system is functionally completed but prior to final acceptance tests. The field posted instructions shall cover all of the items contained in the approved operation and maintenance manuals as well as demonstrations of routine maintenance operations.

3.5 REFRIGERANT PIPING TESTS

After all components of the refrigerant system have been installed and connected, subject the entire refrigeration system to pneumatic, evacuation, and startup tests as described herein. Conduct tests in the presence of the Contracting Officer.