bafbrwhq15181.pdf

SECTION 15181 REPAIR WING HEADQUARTERS, BLDG 706

HYDRONIC PIPING CRWU 06-2071

06/09/09 15181-1 BUCKLEY AFB

SECTION 15181 - HYDRONIC PIPING

PART 1 - GENERAL

1.01 SUMMARY:

A. This Section includes pipe and fitting materials, joining methods, special-duty valves, and specialties for the following:

1. Hot-water heating piping.

2. Air-vent piping.

1.02 REFERENCES:

A. Applicable Standards (Latest Edition):

1. American Welding Society (AWS):

a. A5.8 - Specification for Filler Metals for Brazing and Braze Welding.

b. D.1/D1.1M - Structural Welding Code - Steel.

c. Brazing Handbook.

2. ASME International (ASME):

a. B1.20.1 - Pipe Threads, General Purpose, Inch.

b. B16.5 - Pipe Flanges and Flanged Fittings, NPS 1/2 to NPS 24.

c. B16.21 - Nonmetallic Flat Gaskets for Pipe Flanges.

d. B16.22 - Wrought Copper and Copper Alloy Solder Joint Pressure Fittings.

e. B18.2.1 - Square and Hex Bolts and Screws - Inch Series.

f. B31 - Code for Pressure Piping.

g. B31.9 - Building Services Piping.

h. Boiler and Pressure Vessel Code: Section IV, "Heating Boilers;" Section VIII, "Pressure Vessels," Division 1; Section IX, "Welding and Brazing Qualifications."

3. ASTM International (ASTM):

a. A47/A47M - Ferritic Malleable Iron Castings.

b. B32 - Solder Metal.

c. B75 - Seamless Copper Tube.

d. B75M - Seamless Copper Tube [Metric].

e. B88 - Seamless Copper Water Tube.

f. B88M - Seamless Copper Water Tube [Metric].

g. B306 - Copper Drainage Tube (DWV).

h. B584 - Copper Alloy Sand Castings for General Applications.

i. B813 - Liquid and Paste Fluxes for Solder Applications of Copper and copper Alloy

Tube.

j. B828 - Practice for Making Capillary Joints by Soldering of Copper and Copper

Alloy Tube and Fittings.

4. Copper Development Association Inc. (CDA):

a. Copper Tube Handbook.

5. Manufacturers Standardization Society of the Valve and Fittings Industry Inc. (MSS):

a. SP-58 - Pipe Hangers and Supports - Materials, Design and Manufacture.

b. SP-107 - Transition Union Fittings for Joining Metal and Plastic Products.

1.03 DEFINITIONS:

A. PTFE: Polytetrafluoroethylene.

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1.04 PERFORMANCE REQUIREMENTS:

A. Hydronic piping components and installation shall be capable of withstanding the following minimum working pressure and temperature:

1. Hot-Water Heating Piping: 100 psig (689 kPa) at 200oF (93oC).

2. Air-Vent Piping: 80 psig (552 kPa) 200oF (93oC).

1.05 SUBMITTALS:

A. General: Submit each item in accordance with SECTION 15050 - BASIC MECHANICAL

MATERIALS AND METHODS.

B. Product Data: For each type of the following:

1. Pressure-seal fittings.

2. Valves: Include flow and pressure drop curves based on manufacturer's testing for calibrated-orifice balancing valves and automatic flow-control valves.

3. Air control devices.

4. Hydronic specialties.

C. Welding certificates.

D. Field quality-control test reports.

E. Operation and Maintenance Data: For air control devices, hydronic specialties, and special-duty valves to include in emergency, operation, and maintenance manuals.

1.06 QUALITY ASSURANCE:

A. Steel Support Welding: Qualify processes and operators according to AWS D1.1/D1.1M.

B. Welding: Qualify processes and operators according to ASME Boiler and Pressure Vessel

Code: Section IX.

1. Comply with provisions in ASME B31.

2. Certify that each welder has passed AWS qualification tests for welding processes involved and that certification is current.

C. ASME Compliance: Comply with ASME B31.9 for materials, products, and installation.

Safety valves and pressure vessels shall bear the appropriate ASME label. Fabricate and stamp air separators and expansion tanks to comply with ASME Boiler and Pressure Vessel Code:

Section VIII, Division 1.

PART 2 - PRODUCTS

2.01 COPPER TUBE AND FITTINGS:

A. Drawn-Temper Copper Tubing: ASTM B88, Type L (ASTM B88M, Type B).

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

1. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

a. Anvil International, Inc.

b. S. P. Fittings; a division of Star Pipe Products.

c. Victaulic Company of America.

2. Grooved-End Copper Fittings: ASTM B75 (ASTM B75M), copper tube or ASTM B584, bronze casting.

3. Grooved-End-Tube Couplings: Rigid pattern, unless otherwise indicated; gasketed C. Copper, Mechanically Formed Tee Option: For forming T-branch on copper water tube.

1. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

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a. T-DRILL Industries Inc.

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

2.02 JOINING MATERIALS:

A. Pipe-Flange Gasket Materials: Suitable for chemical and thermal conditions of piping system contents.

1. ASME B16.21, nonmetallic, flat, asbestos free, 1/8-inch (3.2-mm) maximum thickness unless thickness or specific material is indicated.

a. Full-Face Type: For flat-face, Class 125, cast-bronze flanges.

B. Brazing Filler Metals: AWS A5.8, BCuP Series, copper-phosphorus alloys for joining copper with copper; or BAg-1, silver alloy for joining copper with bronze or steel.

C. Gasket Material: Thickness, material, and type suitable for fluid to be handled and working temperatures and pressures.

2.03 VALVES:

A. Gate, Globe, Check, Ball, and Butterfly Valves: Comply with requirements specified in

SECTION 15110 - VALVES.

B. Automatic Temperature-Control Valves, Actuators, and Sensors: Comply with requirements specified in SECTION 15900 - HVAC INSTRUMENTATION AND CONTROL.

C. Bronze, Calibrated-Orifice, Balancing Valves:

1. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

a. Armstrong Pumps, Inc.

b. Bell & Gossett Domestic Pump; a division of ITT Industries.

c. Griswold Controls.

d. Taco.

2. Body: Bronze, ball or plug type with calibrated orifice or venturi.

3. Ball: Brass or stainless steel.

4. Plug: Resin.

5. Seat: PTFE.

6. End Connections: Threaded or socket.

7. Pressure Gage Connections: Integral seals for portable differential pressure meter.

8. Handle Style: Lever, with memory stop to retain set position.

9. CWP Rating: Minimum 125 psig (860 kPa).

10. Maximum Operating Temperature: 250oF (121oC).

D. Diaphragm-Operated Safety Valves:

1. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

a. Armstrong Pumps, Inc.

b. Bell & Gossett Domestic Pump; a division of ITT Industries.

c. Conbraco Industries, Inc.

d. Watts Regulator Co.; a division of Watts Water Technologies, Inc.

2. Body: Bronze or brass.

3. Disc: Glass and carbon-filled PTFE.

4. Seat: Brass.

5. Stem Seals: EPDM O-rings.

6. Diaphragm: EPT.

7. Wetted, Internal Work Parts: Brass and rubber.

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8. Inlet Strainer: Bronze, removable without system shutdown.

9. Valve Seat and Stem: Noncorrosive.

10. Valve Size, Capacity, and Operating Pressure: Comply with ASME Boiler and Pressure

Vessel Code: Section IV, and selected to suit system in which installed, with operating pressure and capacity factory set and field adjustable.

E. Automatic Flow-Control Valves:

1. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

a. Flow Design Inc.

b. Griswold Controls.

2. Body: Brass or ferrous metal.

3. Piston and Spring Assembly: Corrosion resistant, tamper proof, self cleaning, and removable.

4. Combination Assemblies: Include bonze or brass-alloy ball valve.

5. Identification Tag: Marked with zone identification, valve number, and flow rate.

6. Size: Same as pipe in which installed.

7. Performance: Maintain constant flow, plus or minus 5 percent over system pressure fluctuations.

8. Minimum CWP Rating: 175 psig (1207 kPa).

9. Maximum Operating Temperature: 200oF (93oC).

2.04 AIR CONTROL DEVICES:

A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

1. Amtrol, Inc.

2. Armstrong Pumps, Inc.

3. Bell & Gossett Domestic Pump; a division of ITT Industries.

4. Taco.

B. Manual Air Vents:

1. Body: Bronze.

2. Internal Parts: Nonferrous.

3. Operator: Screwdriver or thumbscrew.

4. Inlet Connection: NPS 1/2 (DN 15).

5. Discharge Connection: NPS 1/8 (DN 6).

6. CWP Rating: 150 psig (1035 kPa).

7. Maximum Operating Temperature: 225oF (107oC).

C. Automatic Air Vents:

1. Body: Bronze or cast iron.

2. Internal Parts: Nonferrous.

3. Operator: Noncorrosive metal float.

4. Inlet Connection: NPS 1/2 (DN 15).

5. Discharge Connection: NPS 1/4 (DN 8).

6. CWP Rating: 150 psig (1035 kPa).

7. Maximum Operating Temperature: 240oF (116oC).

2.05 HYDRONIC PIPING SPECIALTIES:

A. Y-Pattern Strainers:

1. Body: ASTM A126, Class B, cast iron with bolted cover and bottom drain connection.

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2. End Connections: Threaded ends for NPS 2 (DN 50) and smaller; flanged ends for NPS 2-1/2 (DN 65) and larger.

3. Strainer Screen: 40-mesh startup strainer, and perforated stainless-steel basket with 50 percent free area.

4. CWP Rating: 125 psig (860 kPa).

PART 3 - EXECUTION

3.01 PIPING APPLICATIONS:

A. Hot-water heating piping, aboveground, NPS 2 (DN 50) and smaller shall be the following:

1. Type L (B), drawn-temper copper tubing, wrought-copper fittings, and brazed joints.

B. Hot-water heating piping, aboveground, NPS 2-1/2 (DN 65) and larger shall be the following:

1. Type L (B), drawn-temper copper tubing, wrought-copper fittings, and brazed joints.

C. Air-Vent Piping:

1. Inlet: Same as service where installed with metal-to-plastic transition fittings for plastic piping systems according to the piping manufacturer's written instructions.

2. Outlet: Type K (A), annealed-temper copper tubing with soldered or flared joints.

3.02 VALVE APPLICATIONS:

A. Install shutoff-duty valves at each branch connection to supply mains, and at supply connection to each piece of equipment.

B. Install calibrated-orifice, balancing valves at each branch connection to return main.

C. Install calibrated-orifice, balancing valves in the return pipe of each heating or cooling terminal.

D. Install safety valves at hot-water generators and elsewhere as required by ASME Boiler and

Pressure Vessel Code. Install drip-pan elbow on safety-valve outlet and pipe without valves to the outdoors; and pipe drain to nearest floor drain or as indicated on Drawings. Comply with ASME Boiler and Pressure Vessel Code: Section VIII, Division 1, for installation requirements.

3.03 PIPING INSTALLATIONS:

A. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems. Indicate piping locations and arrangements if such were used to size pipe and calculate friction loss, expansion, pump sizing, and other design considerations. Install piping as indicated unless deviations to layout are approved on Coordination Drawings.

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

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

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

E. Install piping to permit valve servicing.

F. Install piping at indicated slopes.

G. Install piping free of sags and bends.

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

I. Install piping to allow application of insulation.

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

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K. Install groups of pipes parallel to each other, spaced to permit applying insulation and servicing of valves.

L. Install drains, consisting of a tee fitting, NPS 3/4 (DN 20) ball valve, and short NPS 3/4 (DN 20) threaded nipple with cap, at low points in piping system mains and elsewhere as required for system drainage.

M. Install piping at a uniform grade of 0.2 percent upward in direction of flow.

N. Reduce pipe sizes using eccentric reducer fitting installed with level side up.

O. Install branch connections to mains using tee fittings in main pipe, with the branch connected to the bottom of the main pipe. For up-feed risers, connect the branch to the top of the main pipe.

P. Install valves according to Division 15 Section "Valves."

Q. Install unions in piping, NPS 2 (DN 50) and smaller, adjacent to valves, at final connections of equipment, and elsewhere as indicated.

R. Install flanges in piping, NPS 2-1/2 (DN 65) and larger, at final connections of equipment and elsewhere as indicated.

S. Install strainers on inlet side of each control valve, pressure-reducing valve, solenoid valve, in-line pump, and elsewhere as indicated. Install NPS 3/4 (DN 20) nipple and ball valve in blowdown connection of strainers NPS 2 (DN 50) and larger. Match size of strainer blowoff connection for strainers smaller than NPS 2 (DN 50).

T. Identify piping as specified in SECTION 15075 - MECHANICAL IDENTIFICATION.

3.04 HANGERS AND SUPPORTS:

A. Hanger, support, and anchor devices are specified in SECTION 15060 - HANGERS AND

SUPPORTS. Comply with the following requirements for maximum spacing of supports.

B. Install the following pipe attachments:

1. Adjustable steel clevis hangers for individual horizontal piping less than 20 feet (6 m) long.

2. Adjustable roller hangers and spring hangers for individual horizontal piping 20 feet (6 m) or longer.

3. Pipe Roller: MSS SP-58, Type 44 for multiple horizontal piping 20 feet (6 m) or longer, supported on a trapeze.

4. Spring hangers to support vertical runs.

5. Provide copper-clad hangers and supports for hangers and supports in direct contact with copper pipe.

C. Install hangers for drawn-temper copper piping with the following maximum spacing and minimum rod sizes:

1. NPS 3/4 (DN 20): Maximum span, 5 feet (1.5 m); minimum rod size, 1/4 inch (6.4 mm).

2. NPS 1 (DN 25): Maximum span, 6 feet (1.8 m); minimum rod size, 1/4 inch (6.4 mm).

3. NPS 1-1/2 (DN 40): Maximum span, 8 feet (2.4 m); minimum rod size, 3/8 inch (10 mm).

4. NPS 2 (DN 50): Maximum span, 8 feet (2.4 m); minimum rod size, 3/8 inch (10 mm).

5. NPS 2-1/2 (DN 65): Maximum span, 9 feet (2.7 m); minimum rod size, 3/8 inch (10 mm).

D. Support vertical runs at roof, at each floor, and at 10-foot (3-m) intervals between floors.

3.05 PIPE JOINT CONSTRUCTION:

A. Join pipe and fittings according to the following requirements and Division 15 Sections specifying piping systems.

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

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

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

Chapter, using copper-phosphorus brazing filler metal complying with AWS A5.8.

E. Threaded Joints: Thread pipe with tapered pipe threads according to ASME B1.20.1. Cut threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and restore full ID. Join pipe fittings and valves as follows:

1. Apply appropriate tape or thread compound to external pipe threads unless dry seal threading is specified.

2. Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or damaged. Do not use pipe sections that have cracked or open welds.

F. Flanged Joints: Select appropriate gasket material, size, type, and thickness for service application. Install gasket concentrically positioned. Use suitable lubricants on bolt threads.

3.06 HYDRONIC SPECIALTIES INSTALLATION:

A. Install automatic air vents at high points of system piping in mechanical equipment rooms only. Manual vents at heat-transfer coils and elsewhere as required for air venting.

3.07 TERMINAL EQUIPMENT CONNECTIONS:

A. Sizes for supply and return piping connections shall be the same as or larger than equipment connections.

B. Install control valves in accessible locations close to connected equipment.

C. Install bypass piping with globe valve around control valve. If parallel control valves are installed, only one bypass is required.

D. Install ports for pressure gauges and thermometers at coil inlet and outlet connections according to SECTION 15122 - METERS AND GAUGES.

3.08 FIELD QUALITY CONTROL:

A. Prepare hydronic piping according to ASME B31.9 and as follows:

1. Leave joints, including welds, uninsulated and exposed for examination during test.

2. Provide temporary restraints for expansion joints that cannot sustain reactions due to test pressure. If temporary restraints are impractical, isolate expansion joints from testing.

3. Flush hydronic piping systems with clean water; then remove and clean or replace strainer screens.

4. Isolate equipment from piping. If a valve is used to isolate equipment, its closure shall be capable of sealing against test pressure without damage to valve. Install blinds in flanged joints to isolate equipment.

5. Install safety valve, set at a pressure no more than one-third higher than test pressure, to protect against damage by expanding liquid or other source of overpressure during test.

B. Perform the following tests on hydronic piping:

1. Use ambient temperature water as a testing medium unless there is risk of damage due to freezing. Another liquid that is safe for workers and compatible with piping may be used.

2. While filling system, use vents installed at high points of system to release air. Use drains installed at low points for complete draining of test liquid.

3. Isolate expansion tanks and determine that hydronic system is full of water.

SECTION 15181 REPAIR WING HEADQUARTERS, BLDG 706

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4. Subject piping system to hydrostatic test pressure that is not less than 1.5 times the system's working pressure. Test pressure shall not exceed maximum pressure for any vessel, pump, valve, or other component in system under test. Verify that stress due to pressure at bottom of vertical runs does not exceed 90 percent of specified minimum yield strength or 1.7 times "SE" value in Appendix A in ASME B31.9.

5. After hydrostatic test pressure has been applied for at least 10 minutes, examine piping, joints, and connections for leakage. Eliminate leaks by tightening, repairing, or replacing components, and repeat hydrostatic test until there are no leaks.

6. Prepare written report of testing.

C. Perform the following before operating the system:

1. Open manual valves fully.

2. Inspect air vents at high points of system and determine if all are installed and operating freely (automatic type), or bleed air completely (manual type).

3. Set temperature controls so all coils are calling for full flow.

4. Verify lubrication of motors and bearings.

END OF SECTION 15181