33 63 13_AM 6.pdf

REPAIR BUILDING 606, GENERAL INSTRUCTION BUILDING W912DS19C0034

USMA, WEST POINT, NY PN 94078

SECTION 33 63 13

EXTERIOR UNDERGROUND STEAM DISTRIBUTION SYSTEM

02/25

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.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO M 300 (2003; R 2017) Standard Specification for Inorganic Zinc-Rich Primer

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 B40.100 (2022) Pressure Gauges and Gauge Attachments

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2019) Standard Specification for Carbon Structural Steel

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

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

ASTM A134/A134M (2019) Standard Specification for Pipe, Steel, Electric-Fusion (Arc)-Welded (Sizes NPS 16 and Over)

ASTM A135/A135M (2021) Standard Specification for Electric-Resistance-Welded Steel Pipe

ASTM A139/A139M (2022) Standard Specification for Electric-Fusion (ARC)-Welded Steel Pipe (NPS 4 and over)

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

SECTION 33 63 13 Page 1 Addendum #6 10/8/2025

Steel for Moderate and High Temperature Service

ASTM A240/A240M (2024b) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM C547 (2022a) Standard Specification for Mineral Fiber Pipe Insulation

ASTM C1728 (2023) Standard Specification for Flexible Insulation

NACE INTERNATIONAL (NACE)

NACE SP0169 (2024) Control of External Corrosion on Underground or Submerged Metallic Piping Systems

1.2 DEFINITIONS

The following definitions are applicable:

1.2.1 Pre-engineered System

A complete underground heat distribution and condensate return system including all required components such as steam pipe, condensate return pipe, fittings, anchors, pipe supports, insulation, protective casing, and cathodic protection, for the system supplied. Include all piping and components to a point at least 6 inches inside the building and valve manhole. Do not use any part of the building or valve manhole structure as an anchor point.

1.2.2 Direct-Buried

A system which is buried without the need for a field-fabricated protective enclosure such as a concrete trench or tunnel.

1.2.3 UHDS Types

1.2.3.1 Drainable-Dryable-Testable (DDT) Direct-Buried System

A factory-fabricated system including an air and water-tight outer protective casing, air space and an insulated carrier pipe. Drains and vents are provided at the end plates of the system (in manholes or buildings). The drains are normally capped but the caps can be removed to drain water which can leak into the air space if there is a failure in the casing or the carrier pipe. The vents allow water vapor to escape and provide a tell-tale sign of leakage.

1.3 DESCRIPTION

1.3.1 Scope

The work includes the design and fabrication; furnishing; installing, and testing of a direct buried underground insulated steam pipe, insulated steel condensate return pipe, consisting of piping as indicated, cathodic protection system(where required by this specification), together with all

SECTION 33 63 13 Page 2 fittings and appurtenances necessary for a complete and operable system.

Gland type end seals will not be permitted. Drainable, dryable, testable (DDT) systems with fiberglass casings will not be permitted.

1.3.2 UHDS Design

Submit a Certificate of Satisfactory Operation certifying that at least three systems installed by the UHDS manufacturer within the previous 5 years have and are operating satisfactorily, not later than 30 days after notice to proceed. The UHDS manufacturer must be responsible for the complete design of the UHDS, the product to be supplied, fabrication, witnessing installation and testing of the system within the design parameters established by the contract drawings and specifications, and in compliance with the detailed design. The complete design of the UHDS must be sealed by a Professional Engineer in the employ of the UHDS manufacturer.

1.3.3 Cathodic Protection

Provide cathodic protection for systems with coated steel casings in accordance with paragraph CATHODIC PROTECTION INSTALLATION.

1.3.4 Operating Characteristics

Provide steam supply system with an operating temperature of 300 degrees F and an operating pressure of 70 psig. Condensate return system with an operating temperature of 210 degrees F and an operating pressure of 60 psig.

1.3.5 Rated Characteristics

Provide thermal expansion calculations for the piping using the following design characteristics and installation temperature. The system design conditions for steam, condensate, supply return must be a temperature of 500 degrees F and a pressure of 665 psig. For calculation purposes, ensure the installation temperature is not higher than the ambient temperature at the site: 8 degrees F.

1.4 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. 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

Heat Distribution System; G , AE

SD-03 Product Data

Interruption of Existing Service; G

UHDS Manufacturer's Representative Reports

Work Plan; G

Quality Assurance Plan; G

SECTION 33 63 13 Page 3

Piping, Pipe Fittings, and Insulation

Data Sheets; G, AE

SD-05 Design Data

Pipe-stress and System Expansion Calculations; G, AE

Design Life Calculations for the Cathodic Protection System; G, AE

Manufacturer's Data Sheets; G , AE

SD-06 Test Reports

Tests; G

Thermal Performance Test; G

Operational Test; G

SD-07 Certificates

Manufacturer; G

Manufacturer's Representative; G

UHDS Design; G

Certificate of Compliance; G

Testing Firm; G

Welding; G

SD-10 Operation and Maintenance Data

Heat Distribution System; G

1.5 QUALITY ASSURANCE

1.5.1 Manufacturer

The UHDS manufacturer is the company responsible for the design and manufacture of the pre-engineered system. Submit certification of past experience stating that the UHDS manufacturer regularly and currently manufactures direct-buried systems, and that the designs of the system and equipment to be provided for this project conform to specification requirements. Submit an original certification signed by a principal officer of the UHDS manufacturer at least 2 weeks prior to the start of work; indicate the location, type of system, size of system, point of contact (POC) including phone number, for information verification. The UHDS manufacturer directs the installation of the system and has a representative on the jobsite; submit a Work Plan indicating when various items of work and tests are to be carried out and when its representative will be present at the job site. The Contractor must submit a proposed schedule of activities, no later than 7 days after notice to proceed. The manufacturer must submit a list of characteristics indicating what defects or damage will necessitate replacement. The manufacturer must submit a

SECTION 33 63 13 Page 4

Quality Assurance Plan not later than 7 days after notice to proceed for fabrication, delivery, storage, installation and testing of the system.

The manufacturer must submit manufacturer's data sheets for all coatings and indicating thicknesses of insulation for carrier pipes.

1.5.2 Manufacturer's Representative

Submit a letter from the system manufacturer, at least 2 weeks prior to the start of work, listing the experience and training of the manufacturer's representative, who must be a person who regularly performs the duties specified, is certified in writing by the UHDS manufacturer to be technically qualified and experienced in the installation of the system, and authorized by the manufacturer to make and sign the daily reports specified. The UHDS manufacturer's representative must be under the direct employ and supervision of the UHDS manufacturer.

1.5.3 Corrosion Engineer

Corrosion engineer refers to a person who by knowledge of the physical sciences and the principles of engineering and mathematics, acquired by professional education and related practical experience, is qualified to engage in the practice of corrosion control. Such person is permitted to be a licensed professional corrosion engineer or certified as being qualified by the National Association of Corrosion Engineers (NACE), if such licensing or certification includes 3 years experience in corrosion control on underground metallic surfaces of the type under this contract.

NACE certification must be technologist, corrosion specialist, or cathodic protection specialist. The corrosion engineer must make at least three visits to the project site. The first of these visits must include obtaining soil resistivity data, acknowledging the type of pipeline coatings to be used, and reporting to the Contractor the type of cathodic protection required. Once the submittals are approved and the materials delivered, the corrosion engineer must revisit the site to ensure the Contractor understands installation practices and laying out the components. The third visit must involve testing the installed cathodic protection systems and training applicable personnel on proper maintenance techniques. The corrosion engineer must supervise, inspect, and test the installation and performance of the cathodic protection system.

1.5.4 Testing Firm

Submit a Certificate of Qualification from the independent testing firm or firms, not later than 7 days after notice to proceed. The Testing Firm must be able to certify that: weld examination methods and procedures, and the interpretation of radiographic films, will be performed in accordance with ASME B31.1 ; the firm intends to utilize the proper film exposure, techniques, and penetrameter to produce density and geometric sharpness in sufficient clarity to determine presence of defects; and that all radiographic films will be reviewed and interpreted, and reading reports signed, by not less than a Certified American Society for Nondestructive Testing Level III Radiographer.

1.5.5 Contract Drawings

The contract drawings accompanying this specification provide information on:

a. The size of carrier pipes, approximate length, and site location of the system.

SECTION 33 63 13 Page 5

b. The routing and elevation of the piping along the route.

c. Location and design of manholes.

d. The obstacles that must be avoided along the path.

e. Location of piping anchors.

f. Operating pressure and temperature of system.

1.5.6 Delivery, Storage, and Handling

Maintain equipment and material placed on the job in the custody of the Contractor until final acceptance whether or not the Contractor has been reimbursed for the equipment and material by the Government. The Contractor is solely responsible for the protection of the equipment and material against damage from any source while stored or during installation. Protect materials against damage from UV light, and entry of water and mud, by installing watertight protection on open ends at all times. Immediately replace sections of the casing or carrier piping found to have been subjected to full or partial submergence in water (which would allow the insulation to become wet). Cover materials awaiting installation to protect from UV degradation.

PART 2 PRODUCTS

2.1 STANDARD PRODUCTS

Approval by Contracting Officer is required for products or services of the UHDS manufacturer. Provide for this project a designed system and equipment which is of current production and that essentially duplicate systems that have been in satisfactory use for at least 5 years prior to bid opening at three locations. Provide systems that have been operated under pressure, temperature, and site characteristics which are equal to or more severe than the operating conditions in this specification and that have distributed the same medium. Ensure the system is supported by a service organization that can reach the site after a service call within 48 hours. Submit cut sheets for piping, pipe fittings, and insulation to be used in this system.

2.2 FACTORY FABRICATED, DIRECT-BURIED DDT SYSTEMS

2.2.1 DDT Steam Carrier Pipes

Requirements are in accordance with paragraph HEAT DISTRIBUTION PIPING.

2.2.2 DDT Condensate Carrier Pipes

Provide steel, schedule 80 carrier piping for condensate return systems.

Pipe requirements are in accordance with the paragraph HEAT DISTRIBUTION PIPING. Do not locate condensate pipes in conduit casings which contain steam pipes or any other piping.

2.2.3 DDT Carrier Pipe Insulation

Provide carrier pipe insulation conforming to minimum thicknesses and type listed in Tables 1 and 2 as required for temperature specified under paragraph RATED CHARACTERISTICS.

SECTION 33 63 13 Page 6

2.2.4 Insulation Banding and Scrim

Stainless steel bands and clips, at least 0.5 inches wide, conforming to ASTM A240/A240M (304 stainless steel), at a maximum spacing 18 inches over the scrim to secure the insulation onto the carrier pipe; use a minimum of two bands for each 4 foot section of insulation. Scrim must be vinyl-coated fiberglass with 18 by 16 mesh (number of filaments per 1 inch ) and made of 0.013 inch diameter vinyl-coated fibrous glass yarn.

2.2.5 Casing

Provide casing consisting of smooth-wall steel, electric resistance spiral welded, conforming to ASTM A134/A134M , ASTM A135/A135M , or ASTM A139/A139M and the values tabulated below. Provide eccentric connectors between casing sections as needed to provide drainage of casing section between manholes and between manholes and buildings.

Casing Diameter (inches) Minimum Thickness (inches)

6 - 26 0.250

2.2.6 Casing End Plates, Vents, and Drains

Make end plates of ASTM A36/A36M steel, minimum thickness 0.5 inches for conduit pipe sizes above 12 inches and 0.375 inches for conduit pipe sizes 12 inches and less. Provide 1 inch ASTM A53/A53M, Schedule 40, galvanized vent riser pipe on the end plate, vent opening. Extend vent pipe to top of manhole and terminate 12 inches above grade with a 180 degree bend.

Provide a 1 inch drain at the bottom and vent at the top. Provide brass plugs and half coupling, constructed with welded steel and weld to the end plate; plug drains; do not plug vents.

2.2.7 Air Space

Provide continuous 1 inch minimum air space between carrier pipe insulation and casing.

2.2.8 Casing Coating

Coating must be rated for a minimum of 25 years by the manufacturer for continuous service at a temperature of 230 degrees F. Apply coating in accordance with the coating manufacturer's instructions, factory-inspect for holidays and make repairs as necessary.

2.2.8.1 Fusion-Bonded Epoxy

Use fusion-bonded epoxy casing coating with a minimum thickness of 0.04 inches.

2.2.8.2 Urethane Elastomer

Use urethane elastomer coating with a minimum thickness of 0.04 inches.

2.2.9 Coating of End Plates and conduit Sections Extending in Manholes

Coat end plates and conduit extending into manholes with a zinc-rich

SECTION 33 63 13 Page 7 coating conforming to AASHTO M 300, Type IA except that volatile organic compounds must not exceed 2.8 pounds/gallon. Apply zinc-rich coating in accordance with the coating manufacturer's requirements including surface preparation. Do not apply additional top coat.

2.2.10 Carrier Pipe Guides

Space carrier pipe guides 10 feet on centers maximum, no more than 5 feet from pipe ends, with a minimum of three guides per elbow section. Design guides to allow thermal expansion without damage, provide proper pipe guiding, and to allow horizontal movement in two directions as required at expansion loops and bends. Design supports to permit flow of water and air vapor through the support. Extend pipe insulation through the pipe guides and protect by steel sleeves. Design guides to negate metal-to-metal contact between the casing and the carrier pipe. Do not compress insulation or non-metallic material used to ensure no metal-to-metal contact by the weight of the carrier pipe when full of water.

2.2.11 Anchor Plates

Anchor plate must be ASTM A36/A36M steel, welded to carrier pipe and casing, 0.5 inches minimum thickness, with passages for air flow and water drainage through the annular air space in the system. Coat exterior surface of the anchor plate with the same coating material as the casing.

2.2.12 Field Connection of Casing Sections

Field connect casing using a compatible steel section, welded to casing sections, coated on all surfaces with UHDS manufacturer's coating field repair compound, and covered with a 0.05 inch minimum thickness polyethylene shrink sleeve designed for a service temperature exceeding 500 degrees F.

2.2.13 Manufacturer's Identification

Provide embossed brass or stainless steel tag, hung by brass or stainless steel chain at each end of each conduit or insulated piping in the manholes and buildings. Identify UHDS manufacturer's name, date of installation, Government contract number, and manufacturer's project number.

2.3 PIPE INSULATION TYPE AND MINIMUM THICKNESS

Comply with EPA requirements in accordance with Section 01 33 29 SUSTAINABILITY REQUIREMENTS AND REPORTING. Materials containing asbestos will not be permitted. The minimum thickness of insulation for the heat distribution system must be in accordance with Tables 1 and 2 in which the insulations listed have passed the 96 hour boiling water test.

SECTION 33 63 13 Page 8

TABLE 1 - MINIMUM PIPE INSULATION THICKNESS (inches)

For Steam (16 to 408 psig)

INSULATIONS For Drainable/Dryable Systems

Nominal Pipe Diameter (inches)

Mineral Wool ASTM C547 Type III Grade A

Aerogel ASTM C1728 Type III Grade 1A

1.0 3.0 1.0

1.5 3.0 1.5

2.0 3.0 1.5

2.5 3.0 1.5

3.0 3.0 1.5

4.0 3.5 2.0

5.0 3.5 2.0

6.0 3.5 2.0

8.0 3.5 2.0

TABLE 2 - MINIMUM PIPE INSULATION THICKNESS (inches) CONDENSATE RETURN

INSULATIONS For Drainable/Dryable Systems

Nominal Pipe Diameter (inches)

Mineral Wool ASTM C547 Type III Grade A

Aerogel ASTM C1728 Type III Grade 1A

1.0 1.5 1.0

1.5 1.5 1.0

2.0 1.5 1.0

2.5 1.5 1.0

3.0 2.0 1.0

2.4 HEAT DISTRIBUTION PIPING

2.4.1 Steam Pipe

Pipe material must be steel; seamless, ASTM A53/A53M, Grade B or ASTM A106/A106M , Grade B; or electric resistance welded ASTM A53/A53M, Grade B; Schedule 40. ASTM A53/A53M, Type F furnace butt welded pipe will not be allowed. Joints will not be allowed in factory fabricated straight section of the carrier pipe. Provide factory fabricated piping sections as part of an expansion loop or bend with all welded joints 100 percent radiographed inspected in accordance with ASME B31.1 . Ensure radiographs are reviewed and interpreted by a Certified American Society for Nondestructive Testing (ASNT) Level III radiographer, employed by the testing firm, who will sign the reading report.

2.4.2 Condensate Pipe

Pipe material must be steel; seamless, ASTM A53/A53M, Grade B or

SECTION 33 63 13 Page 9

ASTM A106/A106M , Grade B, schedule 80; electric resistance welded ASTM A53/A53M, Grade B; Schedule 80. ASTM A53/A53M, Type F furnace butt welded pipe is not allowed. Joints will not be allowed in the factory fabricated straight section of the carrier pipe. Provide factory fabricated piping sections, as part of an expansion loop or bend with all welded joints 100 percent radiographed inspected in accordance with ASME B31.1 . Ensure radiographs are reviewed and interpreted by an ASNT Certified Level II radiographer, employed by the testing firm, who will sign the reading report.

2.4.3 Joints

Provide butt-weld joints, except socket-weld joints are permitted for pipe sizes 2 inches and smaller. Dye penetrant inspection may be used in place of 100 percent radiographic inspection for pipe sizes 2 inches and below.

Indicate location and elevation of all field joints on detailed design layout drawings. Split-ring welding rings may be used.

2.4.4 Fittings

Radiographically inspect welds in factory fittings. Ensure radiographs are reviewed and interpreted by a Certified ASNT Level III radiographer, employed by the testing firm, who will sign the reading report. The Contracting Officer may review all inspection records, and if any welds inspected are found unacceptable in accordance with ASME B31.1 , remove, replace, and radiographically reexamine the fitting at no cost to the government.

2.4.4.1 Butt-Welded

Fittings must be steel, ASTM A234/A234M , Grade B, ASME B16.9 , same schedule as adjoining pipe. Provide long radius elbows unless otherwise indicated. Provide full size or reducing tees as required, with interior surfaces smoothly contoured. Split-ring welding rings may be used.

2.4.4.2 Socket-Welded

Use forged steel ASME B16.11 ; 2000 pound class fittings for pipe sizes 2 inch and below. Dye penetrant inspection may be used in lieu of radiographic inspection of welded fittings for pipe sizes 2 inch and below.

2.5 EXPANSION JOINTS, LOOPS AND BENDS

Ensure stresses are less than the maximum allowable stress from the Power Piping Code ( ASME B31.1 ). Submit pipe-stress and system-expansion calculations for each expansion compensation elbow using a finite element computer generated three-dimensional analysis, no later than 7 days after notice to proceed. Demonstrate with calculations that pipe stresses from temperature changes are within the allowable requirements in ASME B31.1 and that the anchors and the guides will withstand the resultant forces.

Include all analysis node points in the detailed design layout drawings.

As a minimum, include node stresses, forces, moments, and displacements in computer analysis results. Ensure calculations are stamped by a registered Professional Engineer in the employ of the UHDS manufacturer.

Provide detailed design layout drawings and stress and anchor force calculations for all loops and bends. Show locations of all anchors, guides, and supports. Base the calculations on design characteristics (pressures and temperatures), specified, for both the supply and return lines.

SECTION 33 63 13 Page 10

PART 3 EXECUTION

3.1 PREPARATION

3.1.1 Job Conditions

Phasing of demolition and construction must be as shown on contract drawings.

3.1.2 Interruption of Existing Service

Submit schedule of proposed outages and interruptions of existing services, 14 days in advance. Arrange, phase, and perform work and provide temporary facilities, materials, equipment, and connections to utilities, to assure adequate heat distribution service for existing installations at all times. Only necessary interruptions required for making connections will be permitted, and only at times when approval is obtained from the Contracting Officer. All interruptions are to be scheduled with and approved by the Contracting Officer.

3.1.3 Connecting to Existing Work

Submit changes required to the UHDS design due to interferences or conflicts upon realization of interferences or conflicts. Connect new work to existing work to complete piping connections that enable pressure tests with successful outcomes per the requirements of this specification. Make connection only in manholes. Where an existing structure must be cut or existing utilities interfere, bypass, remove, replace or relocate, restore and repair such obstructions. Obtain approval from the UHDS designer and the Contracting Officer for any changes required to the UHDS design as a result of interferences or conflicts. Restore disturbed or damaged work to its prior condition.

3.1.4 Coordination

Coordinate the location of all items of equipment and work of all trades.

Maintain operability and maintainability of the equipment and systems.

3.1.5 Grading

Unless otherwise shown on the contract drawings or the detailed design layout drawings, grade steam/condensate lines uniformly downward no less than 1.0 inch in 20 feet to the lower point of entry between manholes or building entries.

3.1.6 Variations

Submit any variations from the approved detailed design layout drawings to the Contracting Officer for approval. Ensure variations are signed and sealed by the UHDS manufacturers' professional engineer responsible for the complete design of the UHDS.

3.2 DEMOLITION

3.2.1 Demolition Procedures

Perform work in accordance with requirements for phasing. Remove pipe, valves, fittings, insulation, and hangers, including the connection to the

SECTION 33 63 13 Page 11 structure and any fastenings. Seal openings in manhole or building walls after removal of piping. Material and equipment removed is the property of the Contractor and will be removed from the Government property within 1 week and do not store in operating areas. Perform flame cutting with adequate fire protection facilities available as required by safety codes and Contracting Officer.

3.2.2 Asbestos Removal

Remove asbestos in conformance with Section 02 82 00 ASBESTOS REMEDIATION.

3.3 PIPE, PIPING JOINTS AND FITTINGS

3.3.1 Joint Preparation

Clean pipe and fittings inside and outside before and after assembly.

Remove dirt, scale, and other foreign matter from inside the piping by use of a pipe swab or pipe pig before connecting pipe sections, valves, equipment, or fittings. Use eccentric connectors as needed between casing sections to provide drainage of casing section between manholes and between manholes and buildings.

3.3.2 Direction Changes

Make changes in direction with factory-built reinforced fittings.

Field-fabricated fittings and miters are not permitted.

3.4 WELDING

A Certification of Acceptability of all welds made in the field, upon completion of the project. This certification consists of a letter signed by an official of the independent testing firm or firms examining welds, stating that all provisions of this specification have been complied with, and that all welds inspected radiographically have met the acceptability standards specified. The Contractor will be responsible for welding quality and must:

a. Conduct tests of the welding procedures used in the work, determine the suitability of the procedures used, determine that the welds made will meet the required tests, and determine that the welding operators have the ability to make sound welds under standard conditions.

b. Comply with ASME B31.1 .

c. Perform all welding operations required for construction and installation of the heat distribution system.

3.4.1 Qualification of Welders

Rules of procedure for qualification of all welders and general requirements for fusion welding must conform with the applicable portions of ASME B31.1 and also as outlined below.

3.4.2 Examining Welders

Examine each welder to determine the ability of the welder to meet the required qualifications. Test welders for welds in all positions, including welds with the axis horizontal (not rolled) and with the axis vertical. Each welder must:

SECTION 33 63 13 Page 12

a. Weld only in positions in which they have qualified.

b. Identify welds with the specific code marking signifying name and number assigned.

3.4.3 Examination Results

Furnish a list of welders' names and corresponding code markings. Retest welders which fail to meet the prescribed welding qualifications. Welders who fail the second test are disqualified for work on this project.

3.4.4 Beveling

Make field and shop bevels by mechanical means or by flame cutting. Where beveling is done by flame cutting, thoroughly clean surfaces of scale and oxidation just prior to welding.

3.4.5 Alignment

Utilize split welding rings for field joints on carrier pipes above 2 inches to assure proper alignment, complete weld penetration, and prevention of weld spatter reaching the interior of the pipe. Make field joints 2 inches and smaller with welding sockets.

3.4.6 Erection

Do not split, bend, flatten, or otherwise damage piping before, during, or after installation. Where the pipe temperature falls to 32 degrees F or lower, heat the pipe to approximately 100 degrees F for a distance of 1 foot on each side of the weld before welding, and finish the weld before the pipe cools to 32 degrees F.

3.4.7 Defective Welds

Replace and reinspect defective welds in accordance with ASME B31.1 .

Repairing defective welds by adding weld material over the defect or by peening is not be permitted. Ensure welders responsible for defective welds are tested for qualification.

3.4.8 Electrodes

Store electrodes in a dry, heated area, and keep free of moisture and dampness during fabrication operations. Do not use electrodes that have lost part of their coating.

3.4.9 Radiographic Testing

An approved independent testing firm regularly engaged in radiographic testing must perform radiographic examination of 100 percent of the field welds in the carrier piping of direct-buried systems in accordance with ASME B31.1 . Provide the following: a set of films showing each weld inspected, a reading report evaluating the quality of each weld, and a location plan showing the physical location where each weld is to be found in the completed project, prior to installing casing field joints, backfilling, and hydrostatic testing. Ensure all radiographs are reviewed and interpreted by a Certified American Society for Nondestructive Testing Level III radiographer, employed by the testing firm, who will sign the reading report. The Contracting Officer may review all inspection

SECTION 33 63 13 Page 13 records, and if any welds inspected are found unacceptable, the Contractor must remove, reweld, and radiographically reexamine at no cost to the Government.

3.5 HEAT DISTRIBUTION SYSTEM INSTALLATION

Submit a complete description of the design and assembly of the system, materials of construction and field installation instructions, not later than 21 days prior to the start of field measurements. Include sufficient system details to show that the specified minimum insulation thickness has been met. A detailed design layout of the system (plan and elevation views) showing size, type, elevations, and location of each component to be used in the system, the design and location of anchors, pipe guides, pipe supports, expansion loops, Z-bends, L-bends, end seals, leak plates, joint locations, pipe and insulation thickness and sizes, types, and movements, connection to manhole and building wall penetrations, and including, if applicable, transition point design to aboveground or other type systems. Also, if applicable, type and details of the cathodic protection system to be used. Ensure detailed design layout drawings are stamped by a registered Professional Engineer. The UHDS manufacturer's representative will oversee the delivery, storage, and installation and testing of the system. Perform work in accordance with the requirements specified and with the printed instructions of the manufacturer. These specifications take precedence over the printed instructions if conflicts arise. Submit printed instructions to the Contracting Officer prior to system installation. Submit operation and maintenance manual listing routine maintenance procedures, possible breakdowns and repairs, procedures for recording conduit temperatures biannually, and troubleshooting guides, before completion of work. Include in the Manual as-built piping layout of the system with final elevations. Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA.

3.5.1 Verification of Final Elevations

After all temporary supports have been removed, and prior to covering the top of the casing with backfill material, measure and record the elevation of the top of the casing in the trench at every completed field joint, 1/3 points along each pipe section and top of elbows. Check these measurements against the contract drawings and confirm that the conduit system has been installed to the elevations shown on the contract drawings. Ensure slope is uniform to within 0.1 percent. Record these measurements, include in the UHDS manufacturer's representative daily report, and give to the Contracting Officer prior to covering the casing with backfill material.

3.5.2 Excavation, Trenching, and Backfilling

Perform excavation, trenching, and backfilling as required by the UHDS manufacturer's design and as specified in Section 31 00 00 EARTHWORK. Lay pipe on a 12 inch minimum sand bed and backfill with sand on all sides to a minimum of 6 inches as measured from outside of casing. Provide a firm and stable foundation for the system. Ensure foundation and backfill is free from rocks or substances which could damage the system coating.

Install concrete anchor and thrust blocks in undisturbed earth. Do not commence backfilling until system has been satisfactorily pressure tested (both hydrostatic test of carrier and, for DDT systems, pneumatic test of casing). Minimum depth of burial to the top of the casing is 24 inches or depth required for piping to be below the frost line, whichever is greater. Maximum depth of burial to the top of the casing is 10 feet.

SECTION 33 63 13 Page 14

3.5.3 UHDS Manufacturer's Representative Responsibilities

The UHDS Manufacturer's representative must be present at the job site and witness when the following types of work are being performed:

a. Inspection, unloading, and storage.

b. Inspection of trench prior to commencing installation of system.

c. Inspection of concrete anchors and thrust blocks.

d. Hydrostatic testing of carrier piping.

e. Field joint closure work.

f. Pneumatic testing of DDT system casing.

g. Holiday test of conduit coating.

h. Repair of any coating.

i. Installation of cathodic protection system.

j. Initial backfill up to 10 inches above the top of the casing.

k. Verification of final elevations. Elevation readings must be witnessed and recorded.

l. Testing of cathodic protection system.

m. Startup and operational tests

Notify the Contractor immediately of any problems. Notify the Contracting Officer of problems requiring immediate action; otherwise, note any problems encountered and indicate the corrective actions taken in the daily reports.

3.5.4 UHDS Manufacturer's Representative Reports

The UHDS manufacturer representative must: prepare and sign a written daily report; present the original daily report to the Contracting Officer no later than one working day after it is prepared, and forward one copy to the manufacturer's main office. State whether or not the condition and quality of the materials used and the delivery, storage, installation and testing of the system are in accordance with the drawings, specifications, and manufacturer's printed instructions and are satisfactory in all respects. When any work connected with the installation is unsatisfactory, state what corrective action has been taken or list the UHDS manufacturer's recommendations for corrective action. Identify any condition that could result in an unsatisfactory installation, including such items as open conduit ends left in the trench overnight and improper manhole entries. Ensure daily reports are to be reviewed, signed and sealed, on a weekly basis, by the registered engineer responsible for the system design. Submit signed and sealed copies of the daily reports with the payment request. Requests for payment will be denied if the weekly review is not accomplished. Upon completion of the work and before final acceptance, submit notarized Certificate of Compliance signed by a principal officer of both the manufacturing and the contracting firm, SECTION 33 63 13 Page 15 stating that the installation is satisfactory and in accordance with plans, specifications, and manufacturer's instructions to the Contracting Officer. Retain a copy of all daily reports and the Certificate of Compliance for 5 years after final acceptance of the system by the Government.

3.5.5 Protection

Protect casing coating from damage during unloading, storage, rigging and installation. Protect casing and carrier pipe ends from water intrusion during unloading, storage, rigging and installation. Protect piping and all accessories from damage due to exposure to UV light.

3.5.6 Defective Material

The UHDS Manufacturer's Representative must take prompt action to remove from the site all damaged or defective material, subject to rejection in accordance with the quality assurance provisions included in the manufacturer's submittals and printed instructions, and must order prompt replacement of such material.

3.5.7 Cathodic Protection Installation

Provide cathodic protection for all steel casing systems and all buried exposed metal. Assume that 25 percent of the exterior of the UHDS is exposed metal. Submit design life calculations for the cathodic protection system in accordance with NACE SP0169, not later than 7 days after notice to proceed. Ensure calculations are stamped by an NACE qualified corrosion engineer. Provide cathodic protection systems with a minimum design life of 25 years and conforming to Section 26 42 13 GALVANIC (SACRIFICIAL) ANODE CATHODIC PROTECTION (GACP) SYSTEM. Provide dielectric pipe flanges and unions and isolation devices at all points necessary. Provide test stations at grade on each section of the piping system. Isolation flanges and unions must be rated for the service temperature and pressure.

3.6 TESTS

Submit a proposed test procedure and proposed samples of test data sheets for each required test, 30 days prior to the proposed test date. The procedure must contain a complete description of the proposed test with calibration curves or test results furnished by an independent testing laboratory of each instrument, meter, gauge, and thermometer to be used in the tests. Do not commence test until the procedure has been approved.

Perform pressure tests (hydrostatic, pneumatic) and operational tests to demonstrate leak-tightness of all piping systems. Pressure test heat distribution system in conformance with specified requirements and printed instructions for the system supplied; include carrier piping and casing.

Test the carrier pipe hydrostatically. Do not use mercury in thermometers required for the tests.

3.6.1 Holiday Testing of Direct-Buried System Steel Casings

Test entire exterior surface of the casing including the bottom exterior surface for faults in coating after installation in trench prior to backfilling, using test method and voltage recommended by coating manufacturer. If any holidays are found, repair them and retest the coating. Do not backfill the system until all holidays are eliminated.

SECTION 33 63 13 Page 16

3.6.2 Pneumatic, Hydrostatic and Operational Tests

Before conducting heat distribution system tests, flush lines with high pressure water until discharge shows no foreign matter.

3.6.2.1 Pneumatic Test

Pneumatically test the casing of DDT systems after welding and before field coating using air as the test medium. Use a test pressure of 15 psig.

Keep persons not working on the test operations out of the testing area while testing is proceeding. Make the test on the system as a whole or on sections that can be isolated. Test joints in sections prior to backfilling when trenches must be backfilled before the completion of other pipeline sections. Continue the test for 24 hours from the time of the initial readings to the final readings of pressure and temperature.

Do not make the initial test readings of the instrument for at least 1 hour after the casing has been subjected to the full test pressure, and make neither the initial nor final readings at times of rapid changes in atmospheric conditions. There must no indication of reduction of pressure during the test after corrections have been made for changes in atmospheric conditions in conformity with the relationship T(1)P(2)=T(2)P(1), in which T and P denote absolute temperature and pressure, respectively, and the numbers denote initial (1) and final (2) readings. Measure pressure with a pressure gauge conforming to ASME B40.100 . A throttling type needle valve or a pulsation dampener and shutoff valve may be included. The diameter of the face must be at least

4.5 inches with a measurable range of 0 to 15 psig and graduations of not greater than 0.1 psig. During the test, isolate the entire system from all compressors and other sources of air pressure. Test each joint while under test pressure by means of soap and water or an equivalent nonflammable solution prior to backfilling or concealing any work. All labor, materials and equipment for conducting the tests must be furnished by the Contractor and are subject to inspection at all times during the tests. Maintain proper safety precautions for air pressure testing at all times during the tests.

3.6.2.2 Hydrostatic Test

Test carrier piping hydrostatically before insulation is applied at field joints and prove tight at a pressure 1.5 times the heat distribution supply design pressure of 70 psig for 2 hours. There must be no indication of reduction of pressure during the test. Measure pressure with a device calibrated as to be read in increments of not greater than

0.1 psi.

3.6.2.3 Operational Test

Prior to acceptance of the installation, subject system to operating tests simulating actual operating conditions to demonstrate satisfactory functional and operating efficiency. Cover a period of no less than 6 hours for each portion of system tested. Submit for approval a schedule of the tests to be performed 14 days in advance. Provide calibrated instruments, equipment, facilities, and labor at no additional cost to the Government. When failures occur, repair problems and repeat test.

3.6.3 Deficiencies

Correct deficiencies discovered at the Contractor's expense. Major deficiencies, or failure to correct deficiencies, can be considered cause

SECTION 33 63 13 Page 17 for rejecting the entire installation.

3.7 BURIED UTILITY WARNING AND IDENTIFICATION

3.7.1 Plastic Marking Tape

Supply and install polyethylene plastic tape manufactured specifically for warning and identifying buried utility lines. Bury tape above the pipe during the trench backfilling operation and bury approximately 12 inches below grade. Tape must be polyethylene with a metallic core. Use tape that is acid- and alkali-resistant with a minimum strength of 1750 psi lengthwise and 1500 psi crosswise with an elongation factor of 350 percent. Ensure tape is manufactured with integral wires, foil backing, or other means to enable detection by a metal detector when the tape is buried up to 3 feet deep. Encase the metallic core of the tape in a protective jacket or provide with other means to protect it from corrosion. Ensure tape is a type specifically manufactured for marking and locating metallic underground utilities. Provide tape that is 6 inches wide and printed with a caution and identification of the piping system over the entire tape length. Tape must be yellow with bold black letters. Tape color and lettering must be unaffected by moisture and other substances contained in the backfill material.

-- End of Section --

SECTION 33 63 13 Page 18

2.5 EXPANSION JOINTS, LOOPS AND BENDS

3.6.3 Deficiencies