33 61 13.13_AM 6.pdf

REPAIR BUILDING 606, GENERAL INSTRUCTION BUILDING W912DS19C0034

USMA, WEST POINT, NY PN 94078

SECTION 33 61 13.13

PREFABRICATED UNDERGROUND HYDRONIC ENERGY DISTRIBUTION

02/16

PART 1 GENERAL

1.1 SUMMARY

The system consists of a buried prefabricated chilled water distribution system including service connections to a point 6 inches inside of the building. The contract drawings show the specific arrangement of piping, sizes and grades of pipe, and other details. The system is designed for an operating pressure of 125 psig and an operating temperature of 43 degrees F for chilled water.

1.2 REFERENCES

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

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B16.9 (2024) Factory-Made Wrought Buttwelding Fittings

ASME B16.11 (2022) Forged Fittings, Socket-Welding and Threaded

ASME B31.1 (2024) Power Piping

ASME BPVC SEC IX (2017; Errata 2018) BPVC Section IX-Welding, Brazing and Fusing Qualifications

ASTM INTERNATIONAL (ASTM)

ASTM A53/A53M (2024) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A105/A105M (2023) Standard Specification for Carbon Steel Forgings for Piping Applications

ASTM A106/A106M (2019a) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A234/A234M (2024) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM B88 (2022) Standard Specification for Seamless Copper Water Tube

ASTM C518 (2021) Standard Test Method for

SECTION 33 61 13.13 Page 1 Addendum #6 10/8/2025

Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus

ASTM C591 (2022) Standard Specification for Unfaced Preformed Rigid Cellular Polyisocyanurate Thermal Insulation

ASTM D1784 (2020) Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds

ASTM D2241 (2020) Standard Specification for Poly(Vinyl Chloride) (PVC) Pressure-Rated Pipe (SDR Series)

ASTM D2564 (2020) Standard Specification for Solvent Cements for Poly(Vinyl Chloride) (PVC) Plastic Piping Systems

ASTM D3139 (2019) Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals

ASTM D3350 (2021) Polyethylene Plastics Pipe and Fittings Materials

ASTM F477 (2014; R 2021) Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe

1.3 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for Contractor Quality Control approval. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification 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

Fabrication and Assembly Drawings; G, AE

SD-03 Product Data

Support of the Equipment; G, AE

Markers For Underground Piping; G, AE

SD-07 Certificates

Welding

Written Certification

SD-10 Operation and Maintenance Data

SECTION 33 61 13.13 Page 2

Maintenance;

1.4 QUALITY ASSURANCE

Weld piping in accordance with qualified procedures using performance qualified welders and welding operators. Qualify procedures and welders 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 . Prior to welding operations, submit a copy of qualified procedures and a list of names and identification symbols of qualified welders and welding operators. Notify the Contracting Officer 24 hours in advance of tests performed at the work site, if practicable. Apply welder's personal assigned symbol near each weld made as a permanent record. Weld structural members in accordance with Section 05 05 23.16 STRUCTURAL WELDING.

1.5 DELIVERY, STORAGE, AND HANDLING

After delivery to the jobsite, protect all materials and equipment from anything which could cause damage to the material or equipment. Seal piping at each end to keep the interior clean and free of dirt and debris. Keep fittings together and keep their interior surfaces clean at all times. Keep insulation dry and clean.

PART 2 PRODUCTS

2.1 STANDARD PRODUCTS

Provide system components which are standard products of a manufacturer regularly engaged in the manufacture of the product and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Provide a service organization that is, in the opinion of the Contracting Officer, convenient to the site.

Equipment items must be supported by service organizations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. These service organizations must be reasonably convenient to the equipment installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.

a. Submit detail drawings consisting of fabrication and assembly drawings, for all parts of the work in sufficient detail to check conformity with the requirements of the contract documents, prior to installation. In the detail drawings show complete piping, wiring and schematic diagrams and any other details to demonstrate that the system has been coordinated and will properly function as a unit.

Show on the drawings proposed layout, method of compensation for pipe expansion and contraction, anchorage of equipment and appurtenances, and equipment relationship to other parts of the work including clearances required for maintenance and operation.

b. Submit the manufacturer's or system fabricator's written certification stating that the distribution system furnished meets all the requirements of this specification. Clearly identify on the drawings any proposed deviations from the requirements of the contract documents.

SECTION 33 61 13.13 Page 3

2.2 PIPING AND CASING MATERIALS

2.2.1 General

Provide metallic pressure pipe, fittings, and piping accessories that conform to the requirements of ASME B31.1 and are types suitable for the temperature and pressure of the water.

2.2.2 Piping

2.2.2.1 Steel Pipe

Provide piping conforming to ASTM A53/A53M, Grade B, standard weight, black or to ASTM A106/A106M , Grade B, standard weight.

2.2.2.2 Copper Tubing

Provide tubing conforming to ASTM B88, Type K or L.

2.2.2.3 Polyvinyl Chloride (PVC) Pipe

Provide PVC piping conforming to ASTM D2241 with a Standard Thermoplastic Pipe Dimension Ratio (SDR) of 26 and PVC 1120 or 1220 as the material.

2.2.3 Casings

2.2.3.1 Polyvinyl Chloride (PVC) Casing

Provide PVC casings that conform to ASTM D1784, Class 12454-B with a minimum thickness equal to the greater of 1/100 the diameter of the casing or 60 mils.

2.2.3.2 Polyethylene (PE) Casing

Provide polyethylene casings conforming to ASTM D3350, Type III, Class C, Category 3 or 4, Grade P 34 with thickness as follows:

Casing Diameter (inches) Minimum Thickness (mils)

10 and smaller 125

10 to 18 150

2.3 PIPING CONNECTIONS

2.3.1 Steel Pipe

Weld all steel pipe 0.75 inch and larger. Provide steel welding fittings conforming to the requirements of ASTM A105/A105M or ASTM A234/A234M .

Provide welding fittings conforming to ASME B16.9 for buttweld fittings and ASME B16.11 for socket-weld fittings. Use long radius buttwelding elbows conforming to ASME B16.9 whenever space permits.

2.3.2 Plastic Pipe

a. Provide adhesive bell and spigot type end connections for pipe, fittings, flanges, and couplings. Threaded piping, including pipe, SECTION 33 61 13.13 Page 4 fittings, flanges, and couplings, will not be permitted.

b. Flanged Connections: Provide flat face flanged connections between plastic piping and metal piping suitable for connection to ASME Class 150 flanges.

2.3.2.1 Plastic Fittings

Provide plastic fittings of the same type and grade of material as the piping to which they will be connected and furnished by the manufacturer who supplies the pipe. Provide temperature and pressure rating for fittings not less than those of the connecting piping.

2.3.2.2 Polyvinyl Chloride (PVC)

Provide solvent welded or connected using bell and spigot connections for polyvinyl chloride (PVC) pipe with solvent used to connect fittings and pipe conforming to the requirements of ASTM D2564. Bell and spigot joints utilizing elastomeric seals conforming to the requirements of ASTM D3139. The elastomeric seals must conform to ASTM F477.

2.4 END SEALS

Provide pre-insulated sections of pipe with complete sealing of the insulation to provide a permanent water and vapor seal at each end of the pre-insulated section of piping. Provide field modified pre-insulated sections of piping with an end seal which is equivalent to the end seals furnished with the pre-insulated section of piping. Test and certify end seals in accordance with paragraph Casing and End Seal Testing and Certification.

2.4.1 Types

Provide end seals of one of the following types:

a. Carrying the outer casing over tapered pipe insulation ends and extending it to the carrier pipe. Provide sufficient surface bonding area between the casing and the carrier pipe.

b. Using specially designed molded caps made of polyethylene or rubber of standard manufactured thickness. Provide a minimum of 1.5 inch surface bonding area between the cap and both the casing and carrier pipe.

c. Using elastomeric-ring end seals designed and dimensioned to fit in the annular space between the casing and the carrier pipe.

d. Using a waterproof mastic seal vapor barrier over the exposed insulation ends.

e. Shrink sleeves.

2.4.2 Casing and End Seal Testing and Certification

Demonstrate that testing and certification procedures by an independent testing laboratory, for casings and end seals, are capable of resisting penetration of water into the casing and insulation. Perform the test on each type of prefabricated system to be furnished. Provide hot and cold cycle testing followed by immersion in a water filled chamber with a head

SECTION 33 61 13.13 Page 5 pressure, consisting of 14 days of temperature cycling. Circulate a fluid with a temperature of 40 degrees F through the carrier pipe alternating every 24-hours with a fluid with a temperature of 75 degrees F for a chilled water service. While the hot and cold cycle test is being performed, the test sample is either buried or encased in dry bedding sand with a minimum of 12 inches of sand all around the test sample. Restrain the 3 inches diameter carrier pipe of the test sample during the test period. Provide an insulation thickness not to exceed the maximum thickness provided for the piping in the project. Do not exceed transition times for temperature cycle testing of 15 minutes in going from cold to hot and 30 minutes in going from hot to cold. The fluid in the carrier pipe may be water, oil or heat transfer fluid. Immerse the test sample in a water filled chamber following the hot and cold cycling test.

Provide a pressure of not less than 20 feet of water head pressure at the highest point over the entire length of the 8 foot test sample for a minimum of the 48 hour test period. Provide water containing a dye penetrant to check for end seal leakage. Upon completion of the pressure test, cut the test sample open using a light that will readily show the presence of the dye that was in the water, inspect the test sample.

Evidence of the dye inside the test sample indicates that the end seal is not acceptable and cannot be certified.

2.5 INSULATION

2.5.1 Factory Applied Insulation

Provide factory insulated pre-fabricated pipe and fittings with polyurethane (polyisocyanurate) foam meeting the requirements of ASTM C591 having a density not less than 2 pounds per cubic foot (pcf). Provide the polyurethane (polyisocyanurate) foam completely filling the annular space between the carrier pipe and the casing with an insulation thickness of a minimum of 1.5 inches. Provide an insulation thermal conductivity factor not exceeding the numerical value of 0.15 Btu-inch/square foot-degree F-hour at 75 degrees F, when tested in accordance with ASTM C518. Provide a manufacturer's certification that the insulated pipe is free of insulation voids.

2.5.2 Field Applied Insulation

Provide polyurethane (polyisocyanurate) field applied insulation for fittings, and field casing closures and other piping system accessories, as required, with thickness matching adjacent piping insulation thickness. For buried fittings and accessories, provide field applied polyurethane (polyisocyanurate) insulation to match adjacent piping with a protective covering matching the pipe casing. Provide shrink sleeves with a minimum thickness of 50 mils over casing connection joints.

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with all details of the project, verify all dimensions in the field and advise the Contracting Officer of any discrepancy before performing the project.

3.2 INSTALLATION

For all pre-insulated, prefabricated systems, obtain the services of a trained representative of the pipe system manufacturer to instruct the

SECTION 33 61 13.13 Page 6

Contractor's work forces in the installation procedures to ensure that the system is installed in accordance with the manufacturer's published instructions and the plans and specifications. Provide a manufacturer's representative who regularly performs such duties for the manufacturer.

Furnish the Contracting Officer a list of names of personnel trained and certified by the pipe system manufacturer in the installation of this system. Only personnel whose names appear on a less than one year old list will be allowed to install the system.

3.3 PIPING SYSTEMS

3.3.1 Buried Insulated Systems

Provide carrier pipe, insulation, casing, end seals, fittings and accessories for buried insulated systems.

3.4 THRUST BLOCKS

Install thrust blocks at the locations shown or recommended by the pipe system manufacturer. Provide thrust blocks in accordance with manufacturer's recommendations. For systems requiring thrust blocks, at a minimum, provide thrust blocks at all changes in direction, changes in size, valves and terminal ends, such as plugs, caps and tees with concrete having a compressive strength of not less than 2000 psi after 28 days in accordance with Section 03 30 00 CAST-IN-PLACE CONCRETE. Place thrust blocks between solid ground and the fitting to be anchored. Unless otherwise indicated or directed, pour the base and the thrust bearing sides of the thrust blocks directly against undisturbed earth. The sides of the thrust blocks not subject to thrust may be poured against forms.

Locate thrust blocks so that the joints for all fittings will be accessible for repair wherever possible. Do not embed joints in concrete unless the assembly has previously been hydrostatically tested. Provide thrust blocks resisted by piles or tie rods to solid foundations in muck or peat, or replace peat or muck with ballast of sufficient stability to resist the thrust blocks.

3.5 INSTALLATION OF PIPING SYSTEMS

Prepare pipe ends to match factory coated ends and install the piping system in accordance with the manufacturer's instructions without springing or forcing other than what has been calculated for cold spring allowing free expansion and contraction without damage to joints or hangers. Provide transition fittings approved by the manufacturer of the piping system for connections between different types of pipe and system components.

3.5.1 Pitching of Horizontal Piping

Pitch horizontal pipe at a grade of not less than1 inch in 20 feet toward the drain points unless otherwise indicated.

3.5.2 Open Ends

Provide an approved cap or plug for open ends of pipelines and equipment during installation.

3.5.3 Cutting Prefabricated Piping Sections

Provide new end seals similar to factory applied end seal for field cut

SECTION 33 61 13.13 Page 7 prefabricated pipe sections in accordance with the manufacturer's instructions.

3.5.4 Joints

3.5.4.1 Welded Joints

Provide welded joints between sections of pipe and between pipe and fittings where specified or indicated.

3.5.4.2 Threaded Joints

No threaded joints are allowed to be used belowground. Make joints tight with polytetrafluoroethylene tape applied to the male threads only with no more than 3 threads showing after the joint is made up.

3.5.4.3 Grooved Mechanical Joints

Provide grooved fittings, couplings, and grooving tools with products of the same manufacturer. Prepare grooves complying with the tolerances specified by the coupling manufacturer in accordance with the coupling manufacturer's instructions. Measure field made groove diameters using a "go/no-go" gauge, vernier or dial caliper, narrow-land micrometer, or other method specifically approved by the coupling manufacturer for the intended application. Measure and record each groove width and dimension from end of pipe for each change in grooving tool setup to verify compliance with coupling manufacturer's tolerances. Grooved joints are not allowed in concealed locations.

3.5.4.4 Nonmetallic Pipe Joints

Install nonmetallic pipe joints in accordance with the written instructions of the manufacturer.

3.5.5 Expansion Loops

If expansion compensation is needed, provide expansion loops and expansion bends (Z- and L- type) factory fabricated of casing, insulation, and carrier piping identical to that furnished for straight runs. Properly design expansion loops and bends in accordance with the allowable stress limits indicated in ASME B31.1 for the type of pipe used, and size to accommodate pipe movement. Ship expansion loops and bends to the jobsite in the maximum size sections feasible to minimize the number of field joints. Make field joints in straight runs of the expansion loops and bends, keeping the number to a minimum. For steel pipe, cold springing is not allowed when sizing the expansion loops and bends. Cold spring piping one-half the calculated maximum operational expansion during field assembly is allowed. Pipe stress in expansion loops and bends must conform to ASME B31.1 .

3.5.6 Anchors

Provide factory fabricated, by the prefabricated system manufacturer, anchor design in accordance with the published data of the manufacturer and for prefabricated systems. Prevent water penetration, condensation, or vapor transmission from wetting/contacting the insulation.

SECTION 33 61 13.13 Page 8

3.5.7 Field Casing Closures

Execution of field insulation and encasement of joints are to be accomplished after the visual and pressure tests specified are completed and in accordance with the manufacturer's written instructions. Provide foamed in place polyurethane insulation with thickness dimensions and casing materials not less than those of the adjoining prefabricated section. Install a standard polyethylene heat shrink sleeve with a 6 inch minimum overlap at each end of the casing.

3.5.8 Underground Warning Tape

Provide underground 0.004 inch thick, 6 inches wide, printed with repetitive caution warnings along its length, polyethylene tape warning tape buried above the piping during the trench backfilling approximately12 inchesdeep. Provide tapes, yellow in color with black letters; color and lettering must not be affected by moisture or other substances contained in the backfill material.

3.6 EARTHWORK

Perform earthwork in accordance with Section 31 00 00 EARTHWORK.

3.7 ELECTRICAL WORK

Perform electrical work in accordance with either Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION or Section 33 71 01 OVERHEAD

TRANSMISSION AND DISTRIBUTION.

3.8 TESTING

Conduct tests before, during, and after installation of the system.

Provide all instruments, equipment, facilities, and labor required to properly conduct the tests. Provide test pressure gauges for a specific test with dials indicating not less than 1.5 times nor more than 2 times the test pressure.

3.8.1 Carrier Pipe Cleaning and Testing

Test distribution piping as required before backfilling, with all joints exposed. The area between joints may be backfilled as necessary to prevent pipe movement.

3.8.1.1 Cleaning Carrier Pipe

Prior to testing, clean the interior of the carrier pipe of foreign materials by thorough flushing with clean water with a circulating water velocity between 2 and 3 m/s (7 and 10 feet per second) for a minimum of 4 hours. Provide temporary and/or supplementary pumps if required to ensure that required velocity is achieved. Clean system strainers after the flushing operation is complete. Temporary strainers must be installed as required. Leave water in the system after flushing for testing of the system to ensure the pipe will maintain pressure and is not leaking.

3.8.1.2 Hydrostatic Pressure Cycling and Tests

Hydrostatic pressure tests consist of 4 cycles; .each cycle consisting of a 10 minute period with the first cycle at 150 psig followed by a 5 minute period at a pressure less than 50 psig. Begin the next cycle immediately

SECTION 33 61 13.13 Page 9 following the completion of the previous cycle with the pressure rise and drop no more than 100 psi per minute. Locate the pressure gauge and take the pressure measurement at the opposite end of the system from where the pressure is applied. After completion of the hydrostatic pressure cycling, perform the first hydrostatic pressure test proving the system tight at a pressure of 1.5 times the working pressure up to 150 psig and held for a minimum of 1 hour. Disconnect the pressurizing apparatus from the system before starting the 1 hour pressure holding period. Correct any test failures and repeat the hydrostatic pressure cycling and first hydrostatic pressure test until the system can hold the required pressure for at least 1 hour.

3.8.1.3 Operational Test

Perform operational test on the complete system or testable portions thereof and conduct with full design flows and operating temperatures in all runs of piping as if in service, to demonstrate satisfactory function and operating effectiveness. The operational test will have two cycles.

Each cycle must consist of a 6-hour period with treated water in the system at the maximum operating temperature of 58 degrees F and maximum flow rate, and a period of at least 6-hours with no flow. Supply temporary pumps, piping connections, boilers, chillers and the gauges required to circulate the water at the desired temperatures and flow rates. Re-circulate water through supply lines and return through the return piping to demonstrate that the pressure drop is compatible with the flow rate and size of pipe and to show that obstructions do not exist in the piping system. Any unusual indicated pressure drop will be investigated and any obstructions removed. Repair any leaks found. After any obstructions have been removed and any leaks repaired, repeat the operational test until successfully passed.

3.8.1.4 Final Hydrostatic Test

After successful completion of the operational test, pressurize system to

1.5 times the working pressure up to 150 psig and hold for a minimum of 4 hours. Disconnect pressurizing apparatus prior to the start of the 4-hour pressure holding period. Upon test failure, determine the cause of the failure, correct and repeat all of the hydrostatic pressure cycling and pressure tests.

3.9 MAINTENANCE

Submit 6 hard copies of operation and 6 copies of maintenance manuals for the equipment furnished, 1 complete set prior to performance testing and the remainder upon acceptance. Provide details in the operation manuals showing the step-by-step procedures required for equipment startup, operation, and shutdown. Include in the operation manuals the manufacturer's name, model number, parts list, and brief description of all equipment and their basic operating features. List in the maintenance manuals routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides. Include in the maintenance manuals piping and equipment layout and simplified wiring and control diagrams of the equipment system as installed. Provide approved manuals prior to the field performance testing.

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SECTION 33 61 13.13 Page 10

3.9 MAINTENANCE