DIVISION 23 – HEATING VENTILATING AND AIR CONDITIONING...G. Welded Joints: Construct joints...

McKinley Elementary School Boiler Replacement Project 120 West 500 South Tremonton, Utah

DIVISION 23 TABLE OF CONTENTS 230000-1

DIVISION 23 – HEATING VENTILATING AND AIR CONDITIONING

230500 Common Work Results For HVAC

230513 Common Motor Requirements For HVAC Equipment

230519 230533 230529

Meters And Gages

General Piping Valves For HVAC Piping Hangers And Supports For HVAC Piping And Equipment

230548 230550 230553

Vibration Isolation And Seismic Restraints Operation And Maintenance Manuals Identification For HVAC Piping And Equipment

230593

Testing, Adjusting, And Balancing For HVAC

230719 HVAC Piping Insulation

230900 Direct Digital Control System

231123 Facility Natural-Gas Piping

232113 Hydronic Piping

232123 Hydronic Pumps

235218 Boiler Controls

239000 Variable Frequency Drives


COMMON WORK RESULTS FOR HVAC 230500 - 1

SECTION 230500 - COMMON WORK RESULTS FOR HVAC

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes the following:

1. Piping materials and installation instructions common to most piping systems. 2. Transition fittings. 3. Dielectric fittings. 4. Grout. 5. HVAC demolition. 6. Equipment installation requirements common to equipment sections. 7. Painting and finishing. 8. Concrete bases. 9. Supports and anchorages.

1.3 DEFINITIONS

A. Finished Spaces: Spaces other than mechanical and electrical equipment rooms, furred spaces, pipe and duct chases, unheated spaces immediately below roof, spaces above ceilings, unexcavated spaces, crawlspaces, and tunnels.

B. Exposed, Interior Installations: Exposed to view indoors. Examples include finished occupied spaces and mechanical equipment rooms.

C. Exposed, Exterior Installations: Exposed to view outdoors or subject to outdoor ambient temperatures and weather conditions. Examples include rooftop locations.

D. Concealed, Interior Installations: Concealed from view and protected from physical contact by building occupants. Examples include above ceilings and chases.

E. Concealed, Exterior Installations: Concealed from view and protected from weather conditions and physical contact by building occupants but subject to outdoor ambient temperatures. Examples include installations within unheated shelters.

F. The following are industry abbreviations for plastic materials:

1. CPVC: Chlorinated polyvinyl chloride plastic. 2. PE: Polyethylene plastic. 3. PVC: Polyvinyl chloride plastic.



G. The following are industry abbreviations for rubber materials:

1. EPDM: Ethylene-propylene-diene terpolymer rubber. 2. NBR: Acrylonitrile-butadiene rubber.

1.4 SUBMITTALS

A. Product Data: For the following:

1. Transition fittings. 2. Dielectric fittings.

B. Welding certificates.

1.5 QUALITY ASSURANCE

A. Steel Support Welding: Qualify processes and operators according to AWS D1.1, "Structural Welding Code--Steel."

B. Steel Pipe Welding: Qualify processes and operators according to ASME Boiler and Pressure Vessel Code: Section IX, "Welding and Brazing Qualifications."

1. Comply with provisions in ASME B31 Series, "Code for Pressure Piping." 2. Certify that each welder has passed AWS qualification tests for welding processes

involved and that certification is current.

C. Electrical Characteristics for HVAC Equipment: Equipment of higher electrical characteristics may be furnished provided such proposed equipment is approved in writing and connecting electrical services, circuit breakers, and conduit sizes are appropriately modified. If minimum energy ratings or efficiencies are specified, equipment shall comply with requirements.

1.6 DELIVERY, STORAGE, AND HANDLING

A. Deliver pipes and tubes with factory-applied end caps. Maintain end caps through shipping, storage, and handling to prevent pipe end damage and to prevent entrance of dirt, debris, and moisture.

B. Store plastic pipes protected from direct sunlight. Support to prevent sagging and bending.

1.7 COORDINATION

A. Arrange for pipe spaces, chases, slots, and openings in building structure during progress of construction, to allow for HVAC installations.

B. Coordinate installation of required supporting devices and set sleeves in poured-in-place concrete and other structural components as they are constructed.



C. Coordinate requirements for access panels and doors for HVAC items requiring access that are concealed behind finished surfaces. Access panels and doors are specified in Division 08 Section "Access Doors and Frames."

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. In other Part 2 articles where subparagraph titles below introduce lists, the following requirements apply for product selection:

1. Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified.

2.2 PIPE, TUBE, AND FITTINGS

A. Refer to individual Division 23 piping Sections for pipe, tube, and fitting materials and joining methods.

B. Pipe Threads: ASME B1.20.1 for factory-threaded pipe and pipe fittings.

2.3 JOINING MATERIALS

A. Refer to individual Division 23 piping Sections for special joining materials not listed below.

B. 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-iron and cast-bronze flanges. b. Narrow-Face Type: For raised-face, Class 250, cast-iron and steel flanges.

2. AWWA C110, rubber, flat face, 1/8 inch (3.2 mm) thick, unless otherwise indicated; and full-face or ring type, unless otherwise indicated.

C. Flange Bolts and Nuts: ASME B18.2.1, carbon steel, unless otherwise indicated.

D. Plastic, Pipe-Flange Gasket, Bolts, and Nuts: Type and material recommended by piping system manufacturer, unless otherwise indicated.

E. Solder Filler Metals: ASTM B 32, lead-free alloys. Include water-flushable flux according to ASTM B 813.

F. Brazing Filler Metals: AWS A5.8, BCuP Series, copper-phosphorus alloys for general-duty brazing, unless otherwise indicated; and AWS A5.8, BAg1, silver alloy for refrigerant piping, unless otherwise indicated.



G. Welding Filler Metals: Comply with AWS D10.12 for welding materials appropriate for wall thickness and chemical analysis of steel pipe being welded.

H. Solvent Cements for Joining Plastic Piping:

1. CPVC Piping: ASTM F 493. 2. PVC Piping: ASTM D 2564. Include primer according to ASTM F 656.

I. Fiberglass Pipe Adhesive: As furnished or recommended by pipe manufacturer.

2.4 TRANSITION FITTINGS

A. Plastic-to-Metal Transition Fittings: CPVC and PVC one-piece fitting with manufacturer's Schedule 80 equivalent dimensions; one end with threaded brass insert, and one solvent-cement-joint end.

1. Manufacturers:

a. Eslon Thermoplastics.

B. Plastic-to-Metal Transition Adaptors: One-piece fitting with manufacturer's SDR 11 equivalent dimensions; one end with threaded brass insert, and one solvent-cement-joint end.

1. Manufacturers:

a. Thompson Plastics, Inc.

C. Plastic-to-Metal Transition Unions: MSS SP-107, CPVC and PVC four-part union. Include brass end, solvent-cement-joint end, rubber O-ring, and union nut.

1. Manufacturers:

a. NIBCO INC. b. NIBCO, Inc.; Chemtrol Div.

2.5 DIELECTRIC FITTINGS

A. Description: Combination fitting of copper alloy and ferrous materials with threaded, solder-joint, plain, or weld-neck end connections that match piping system materials.

B. Insulating Material: Suitable for system fluid, pressure, and temperature.

C. Dielectric Unions: Factory-fabricated, union assembly, for 250-psig minimum working pressure at 180 deg F.

D. Dielectric Flanges: Factory-fabricated, companion-flange assembly, for 150- or 300-psig minimum working pressure as required to suit system pressures.



E. Dielectric-Flange Kits: Companion-flange assembly for field assembly. Include flanges, full-face- or ring-type neoprene or phenolic gasket, phenolic or polyethylene bolt sleeves, phenolic washers, and steel backing washers.

1. Separate companion flanges and steel bolts and nuts shall have 150- or 300-psig minimum working pressure where required to suit system pressures.

F. Dielectric Couplings: Galvanized-steel coupling with inert and noncorrosive, thermoplastic lining; threaded ends; and 300-psig minimum working pressure at 225 deg F.

G. Dielectric Nipples: Electroplated steel nipple with inert and noncorrosive, thermoplastic lining; plain, threaded, or grooved ends; and 300-psig minimum working pressure at 225 deg F.

2.6 GROUT

A. Description: ASTM C 1107, Grade B, nonshrink and nonmetallic, dry hydraulic-cement grout.

1. Characteristics: Post-hardening, volume-adjusting, nonstaining, noncorrosive, nongaseous, and recommended for interior and exterior applications.

2. Design Mix: 5000-psi, 28-day compressive strength. 3. Packaging: Premixed and factory packaged.

PART 3 - EXECUTION

3.1 PIPING SYSTEMS - COMMON REQUIREMENTS

A. Install piping according to the following requirements and Division 23 Sections specifying piping systems.

B. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems. Indicated locations and arrangements 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.

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

D. 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.

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

F. Install piping to permit valve servicing.

G. Install piping at indicated slopes.

H. Install piping free of sags and bends.



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

J. Install piping to allow application of insulation.

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

L. Verify final equipment locations for roughing-in.

M. Refer to equipment specifications in other Sections of these Specifications for roughing-in requirements.

3.2 PIPING JOINT CONSTRUCTION

A. Join pipe and fittings according to the following requirements and Division 23 Sections specifying piping systems.

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. Soldered Joints: Apply ASTM B 813, water-flushable flux, unless otherwise indicated, to tube end. Construct joints according to ASTM B 828 or CDA's "Copper Tube Handbook," using lead-free solder alloy complying with ASTM B 32.

E. 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.

F. 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.

G. Welded Joints: Construct joints according to AWS D10.12, using qualified processes and welding operators according to Part 1 "Quality Assurance" Article.

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

I. Plastic Piping Solvent-Cement Joints: Clean and dry joining surfaces. Join pipe and fittings according to the following:

1. Comply with ASTM F 402 for safe-handling practice of cleaners, primers, and solvent cements.

2. CPVC Piping: Join according to ASTM D 2846/D 2846M Appendix.



3. PVC Pressure Piping: Join schedule number ASTM D 1785, PVC pipe and PVC socket fittings according to ASTM D 2672. Join other-than-schedule-number PVC pipe and socket fittings according to ASTM D 2855.

4. PVC Nonpressure Piping: Join according to ASTM D 2855.

J. Plastic Pressure Piping Gasketed Joints: Join according to ASTM D 3139.

K. Plastic Nonpressure Piping Gasketed Joints: Join according to ASTM D 3212.

L. PE Piping Heat-Fusion Joints: Clean and dry joining surfaces by wiping with clean cloth or paper towels. Join according to ASTM D 2657.

1. Plain-End Pipe and Fittings: Use butt fusion. 2. Plain-End Pipe and Socket Fittings: Use socket fusion.

M. Fiberglass Bonded Joints: Prepare pipe ends and fittings, apply adhesive, and join according to pipe manufacturer's written instructions.

3.3 PIPING CONNECTIONS

A. Make connections according to the following, unless otherwise indicated:

1. Install unions, in piping NPS 2 and smaller, adjacent to each valve and at final connection to each piece of equipment.

2. Install flanges, in piping NPS 2-1/2 and larger, adjacent to flanged valves and at final connection to each piece of equipment.

3. Dry Piping Systems: Install dielectric unions and flanges to connect piping materials of dissimilar metals.

4. Wet Piping Systems: Install dielectric coupling and nipple fittings to connect piping materials of dissimilar metals.

3.4 EQUIPMENT INSTALLATION - COMMON REQUIREMENTS

A. Install equipment to allow maximum possible headroom unless specific mounting heights are not indicated.

B. Install equipment level and plumb, parallel and perpendicular to other building systems and components in exposed interior spaces, unless otherwise indicated.

C. Install HVAC equipment to facilitate service, maintenance, and repair or replacement of components. Connect equipment for ease of disconnecting, with minimum interference to other installations. Extend grease fittings to accessible locations.

D. Install equipment to allow right of way for piping installed at required slope.

3.5 PAINTING

A. Painting of HVAC systems, equipment, and components is specified in Division 09 Sections "Interior Painting" and "Exterior Painting."



B. Damage and Touchup: Repair marred and damaged factory-painted finishes with materials and procedures to match original factory finish.

3.6 ERECTION OF METAL SUPPORTS AND ANCHORAGES

A. Refer to Division 05 Section "Metal Fabrications" for structural steel.

B. Cut, fit, and place miscellaneous metal supports accurately in location, alignment, and elevation to support and anchor HVAC materials and equipment.

C. Field Welding: Comply with AWS D1.1.

3.7 GROUTING

A. Mix and install grout for HVAC equipment base bearing surfaces, pump and other equipment base plates, and anchors.

B. Clean surfaces that will come into contact with grout.

C. Provide forms as required for placement of grout.

D. Avoid air entrapment during placement of grout.

E. Place grout, completely filling equipment bases.

F. Place grout on concrete bases and provide smooth bearing surface for equipment.

G. Place grout around anchors.

H. Cure placed grout.

END OF SECTION 230500


COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT 230513 - 1

SECTION 230513 - COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT

PART 1 - GENERAL



1.2 SUMMARY

A. Section includes general requirements for single-phase and polyphase, general-purpose, horizontal, small and medium, squirrel-cage induction motors for use on ac power systems up to 600 V and installed at equipment manufacturer's factory or shipped separately by equipment manufacturer for field installation.

1.3 COORDINATION

A. Coordinate features of motors, installed units, and accessory devices to be compatible with the following:

1. Motor controllers. 2. Torque, speed, and horsepower requirements of the load. 3. Ratings and characteristics of supply circuit and required control sequence. 4. Ambient and environmental conditions of installation location.

PART 2 - PRODUCTS

2.1 GENERAL MOTOR REQUIREMENTS

A. Comply with requirements in this Section except when stricter requirements are specified in HVAC equipment schedules or Sections.

B. Comply with NEMA MG 1 unless otherwise indicated.

2.2 MOTOR CHARACTERISTICS

A. Duty: Continuous duty at ambient temperature of 40 deg C and at altitude of 4500 feet above sea level.

B. Capacity and Torque Characteristics: Sufficient to start, accelerate, and operate connected loads at designated speeds, at installed altitude and environment, with indicated operating sequence, and without exceeding nameplate ratings or considering service factor.


COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT 230513 - 2

2.3 POLYPHASE MOTORS

A. Description: NEMA MG 1, Design B, medium induction motor.

B. Efficiency: Energy efficient, as defined in NEMA MG 1.

C. Service Factor: 1.15.

D. Rotor: Random-wound, squirrel cage.

E. Bearings: Regreasable, shielded, antifriction ball bearings suitable for radial and thrust loading.

F. Temperature Rise: Match insulation rating.

G. Insulation: Class F.

H. Code Letter Designation:

1. Motors Smaller than 15 HP: Manufacturer's standard starting characteristic.

I. Enclosure Material: Cast iron for motor frame sizes 324T and larger; rolled steel for motor frame sizes smaller than 324T.

2.4 SINGLE-PHASE MOTORS

A. Motors larger than 1/20 hp shall be one of the following, to suit starting torque and requirements of specific motor application:

1. Permanent-split capacitor. 2. Split phase. 3. Capacitor start, inductor run. 4. Capacitor start, capacitor run.

B. Multispeed Motors: Variable-torque, permanent-split-capacitor type.

C. Bearings: Prelubricated, antifriction ball bearings or sleeve bearings suitable for radial and thrust loading.

D. Motors 1/20 HP and Smaller: Shaded-pole type.

E. Thermal Protection: Internal protection to automatically open power supply circuit to motor when winding temperature exceeds a safe value calibrated to temperature rating of motor insulation. Thermal-protection device shall automatically reset when motor temperature returns to normal range.

PART 3 - EXECUTION (Not Applicable)



METERS AND GAGES FOR HVAC PIPING 230519 - 1

SECTION 230519 - METERS AND GAGES FOR HVAC PIPING

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes: 1. Liquid-in-glass thermometers. 2. Thermowells. 3. Dial-type pressure gages. 4. Gage attachments. 5. Test plugs. 6. Orifice flowmeters.

B. Related Sections:

1. Division 23 Section "Facility Natural-Gas Piping" for gas meters.

1.3 ACTION SUBMITTALS

A. Product Data: For each type of product indicated.

B. Wiring Diagrams: For power, signal, and control wiring.

1.4 INFORMATIONAL SUBMITTALS

A. Product Certificates: For each type of meter and gage, from manufacturer.

1.5 CLOSEOUT SUBMITTALS

A. Operation and Maintenance Data: For meters and gages to include in operation and maintenance manuals.



PART 2 - PRODUCTS

2.1 LIQUID-IN-GLASS THERMOMETERS

A. Metal-Case, Industrial-Style, Liquid-in-Glass Thermometers:

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

a. Flo Fab Inc. b. Miljoco Corporation. c. Palmer Wahl Instrumentation Group. d. Tel-Tru Manufacturing Company. e. Trerice, H. O. Co. f. Weiss Instruments, Inc. g. Winters Instruments - U.S.

2. Standard: ASME B40.200. 3. Case: Cast aluminum; 9-inch (229-mm) nominal size unless otherwise indicated. 4. Case Form: Adjustable angle unless otherwise indicated. 5. Tube: Glass with magnifying lens and blue or red organic liquid. 6. Tube Background: Nonreflective aluminum with permanently etched scale markings

graduated in deg F (deg C). 7. Window: Glass. 8. Stem: Aluminum and of length to suit installation.

a. Design for Air-Duct Installation: With ventilated shroud. b. Design for Thermowell Installation: Bare stem.

9. Connector: 1-1/4 inches (32 mm), with ASME B1.1 screw threads. 10. Accuracy: Plus or minus 1 percent of scale range or one scale division, to a maximum of

1.5 percent of scale range.

2.2 THERMOWELLS

A. Thermowells:

1. Standard: ASME B40.200. 2. Description: Pressure-tight, socket-type fitting made for insertion into piping tee fitting. 3. Material for Use with Copper Tubing: CNR or CUNI. 4. Material for Use with Steel Piping: CRES. 5. Type: Stepped shank unless straight or tapered shank is indicated. 6. External Threads: NPS 1/2, NPS 3/4, or NPS 1, (DN 15, DN 20, or NPS 25,)

ASME B1.20.1 pipe threads. 7. Internal Threads: 1/2, 3/4, and 1 inch (13, 19, and 25 mm), with ASME B1.1 screw

threads. 8. Bore: Diameter required to match thermometer bulb or stem. 9. Insertion Length: Length required to match thermometer bulb or stem. 10. Lagging Extension: Include on thermowells for insulated piping and tubing.



11. Bushings: For converting size of thermowell's internal screw thread to size of thermometer connection.

B. Heat-Transfer Medium: Mixture of graphite and glycerin.

2.3 PRESSURE GAGES

A. Direct-Mounted, Metal-Case, Dial-Type Pressure Gages:


a. AMETEK, Inc.; U.S. Gauge. b. Ashcroft Inc. c. Ernst Flow Industries. d. Flo Fab Inc. e. Marsh Bellofram. f. Miljoco Corporation. g. Noshok. h. Palmer Wahl Instrumentation Group. i. REOTEMP Instrument Corporation. j. Tel-Tru Manufacturing Company. k. Trerice, H. O. Co. l. Watts Regulator Co.; a div. of Watts Water Technologies, Inc. m. Weiss Instruments, Inc. n. WIKA Instrument Corporation - USA. o. Winters Instruments - U.S.

2. Standard: ASME B40.100. 3. Case: Liquid-filled Sealed type(s); cast aluminum or drawn steel; 6-inch (152-mm)

nominal diameter. 4. Pressure-Element Assembly: Bourdon tube unless otherwise indicated. 5. Pressure Connection: Brass, with NPS 1/4 or NPS 1/2 (DN 8 or DN 15), ASME B1.20.1

pipe threads and bottom-outlet type unless back-outlet type is indicated. 6. Movement: Mechanical, with link to pressure element and connection to pointer. 7. Dial: Nonreflective aluminum with permanently etched scale markings graduated in psi

(kPa). 8. Pointer: Dark-colored metal. 9. Window: Glass. 10. Ring: Metal. 11. Accuracy: Grade A, plus or minus 1 percent of middle half of scale range.

2.4 GAGE ATTACHMENTS

A. Snubbers: ASME B40.100, brass; with NPS 1/4 or NPS 1/2 (DN 8 or DN 15), ASME B1.20.1 pipe threads and porous-metal-type surge-dampening device. Include extension for use on insulated piping.

B. Siphons: Loop-shaped section of brass pipe with NPS 1/4 or NPS 1/2 (DN 8 or DN 15) pipe threads.



C. Valves: Brass or stainless-steel needle, with NPS 1/4 or NPS 1/2 (DN 8 or DN 15), ASME B1.20.1 pipe threads.

2.5 TEST PLUGS

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

1. Flow Design, Inc. 2. Miljoco Corporation. 3. National Meter, Inc. 4. Peterson Equipment Co., Inc. 5. Sisco Manufacturing Company, Inc. 6. Trerice, H. O. Co. 7. Watts Regulator Co.; a div. of Watts Water Technologies, Inc. 8. Weiss Instruments, Inc.

B. Description: Test-station fitting made for insertion into piping tee fitting.

C. Body: Brass or stainless steel with core inserts and gasketed and threaded cap. Include extended stem on units to be installed in insulated piping.

D. Thread Size: NPS 1/4 (DN 8) or NPS 1/2 (DN 15), ASME B1.20.1 pipe thread.

E. Minimum Pressure and Temperature Rating: 500 psig at 200 deg F (3450 kPa at 93 deg C).

F. Core Inserts: Chlorosulfonated polyethylene synthetic and EPDM self-sealing rubber.

2.6 TEST-PLUG KITS


1. Flow Design, Inc. 2. Miljoco Corporation. 3. National Meter, Inc. 4. Peterson Equipment Co., Inc. 5. Sisco Manufacturing Company, Inc. 6. Trerice, H. O. Co. 7. Watts Regulator Co.; a div. of Watts Water Technologies, Inc. 8. Weiss Instruments, Inc.

B. Furnish one test-plug kit(s) containing one thermometer(s), one pressure gage and adapter, and carrying case. Thermometer sensing elements, pressure gage, and adapter probes shall be of diameter to fit test plugs and of length to project into piping.

C. Low-Range Thermometer: Small, bimetallic insertion type with 1- to 2-inch- (25- to 51-mm-) diameter dial and tapered-end sensing element. Dial range shall be at least 25 to 125 deg F (minus 4 to plus 52 deg C).



D. High-Range Thermometer: Small, bimetallic insertion type with 1- to 2-inch- (25- to 51-mm-) diameter dial and tapered-end sensing element. Dial range shall be at least 0 to 220 deg F (minus 18 to plus 104 deg C).

E. Pressure Gage: Small, Bourdon-tube insertion type with 2- to 3-inch- (51- to 76-mm-) diameter dial and probe. Dial range shall be at least 0 to 200 psig (0 to 1380 kPa).

F. Carrying Case: Metal or plastic, with formed instrument padding.

2.7 FLOWMETERS

A. Orifice Flowmeters:


a. ABB; Instrumentation and Analytical. b. Bell & Gossett; ITT Industries. c. Meriam Process Technologies. d. Preso Meters; a division of Racine Federated Inc. e. S. A. Armstrong Limited; Armstrong Pumps Inc.

2. Description: Flowmeter with sensor, hoses or tubing, fittings, valves, indicator, and conversion chart.

3. Flow Range: Sensor and indicator shall cover operating range of equipment or system served.

4. Sensor: Wafer-orifice-type, calibrated, flow-measuring element; for installation between pipe flanges.

a. Design: Differential-pressure-type measurement for water. b. Construction: Cast-iron body, brass valves with integral check valves and caps,

and calibrated nameplate. c. Minimum Pressure Rating: 300 psig (2070 kPa). d. Minimum Temperature Rating: 250 deg F (121 deg C).

5. Permanent Indicators: Meter suitable for wall or bracket mounting, calibrated for connected sensor and having 6-inch- (152-mm-) diameter, or equivalent, dial with fittings and copper tubing for connecting to sensor.

a. Scale: Gallons per minute (Liters per second). b. Accuracy: Plus or minus 1 percent between 20 and 80 percent of scale range.

6. Display: Shows rate of flow, with register to indicate total volume in gallons (liters). 7. Conversion Chart: Flow rate data compatible with sensor and indicator. 8. Operating Instructions: Include complete instructions with each flowmeter.

B. Venturi Flowmeters:




a. ABB; Instrumentation and Analytical. b. Gerand Engineering Co. c. Hyspan Precision Products, Inc. d. Preso Meters; a division of Racine Federated Inc. e. S. A. Armstrong Limited; Armstrong Pumps Inc. f. Victaulic Company.

2. Description: Flowmeter with calibrated flow-measuring element, hoses or tubing, fittings, valves, indicator, and conversion chart.

3. Flow Range: Sensor and indicator shall cover operating range of equipment or system served.

4. Sensor: Venturi-type, calibrated, flow-measuring element; for installation in piping.

a. Design: Differential-pressure-type measurement for water. b. Construction: Bronze, brass, or factory-primed steel, with brass fittings and

attached tag with flow conversion data. c. Minimum Pressure Rating: 250 psig (1725 kPa). d. Minimum Temperature Rating: 250 deg F (121 deg C). e. End Connections for NPS 2 (DN 50) and Smaller: Threaded. f. End Connections for NPS 2-1/2 (DN 65) and Larger: Flanged or welded. g. Flow Range: Flow-measuring element and flowmeter shall cover operating range

of equipment or system served.

5. Permanent Indicators: Meter suitable for wall or bracket mounting, calibrated for connected flowmeter element, and having 6-inch- (152-mm-) diameter, or equivalent, dial with fittings and copper tubing for connecting to flowmeter element.


6. Portable Indicators: Hand-held, differential-pressure type, calibrated for connected flowmeter element and having two 12-foot (3.7-m) hoses, with carrying case.


7. Display: Shows rate of flow, with register to indicate total volume in gallons (liters). 8. Conversion Chart: Flow rate data compatible with sensor. 9. Operating Instructions: Include complete instructions with each flowmeter.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install thermowells with socket extending one-third of pipe diameter and in vertical position in piping tees.

B. Install thermowells of sizes required to match thermometer connectors. Include bushings if required to match sizes.



C. Install thermowells with extension on insulated piping.

D. Fill thermowells with heat-transfer medium.

E. Install direct-mounted thermometers in thermowells and adjust vertical and tilted positions.

F. Install remote-mounted thermometer bulbs in thermowells and install cases on panels; connect cases with tubing and support tubing to prevent kinks. Use minimum tubing length.

G. Install direct-mounted pressure gages in piping tees with pressure gage located on pipe at the most readable position.

H. Install remote-mounted pressure gages on panel.

I. Install valve and snubber in piping for each pressure gage for fluids (except steam).

J. Install valve and syphon fitting in piping for each pressure gage for steam.

K. Install test plugs in piping tees.

L. Install flow indicators in piping systems in accessible positions for easy viewing.

M. Assemble and install connections, tubing, and accessories between flow-measuring elements and flowmeters according to manufacturer's written instructions.

N. Install flowmeter elements in accessible positions in piping systems.

O. Install wafer-orifice flowmeter elements between pipe flanges.

P. Install differential-pressure-type flowmeter elements, with at least minimum straight lengths of pipe, upstream and downstream from element according to manufacturer's written instructions.

Q. Install permanent indicators on walls or brackets in accessible and readable positions.

R. Install connection fittings in accessible locations for attachment to portable indicators.

S. Mount thermal-energy meters on wall if accessible; if not, provide brackets to support meters.

T. Install thermometers in the following locations:

1. Inlet and outlet of each hydronic zone. 2. Inlet and outlet of each hydronic boiler. 3. Two inlets and two outlets of each chiller. 4. Inlet and outlet of each hydronic coil in air-handling units. 5. Two inlets and two outlets of each hydronic heat exchanger. 6. Inlet and outlet of each thermal-storage tank.

U. Install pressure gages in the following locations:

1. Discharge of each pressure-reducing valve. 2. Inlet and outlet of each chiller chilled-water and condenser-water connection. 3. Suction and discharge of each pump.



3.2 CONNECTIONS

A. Install meters and gages adjacent to machines and equipment to allow service and maintenance of meters, gages, machines, and equipment.

B. Connect flowmeter-system elements to meters.

C. Connect flowmeter transmitters to meters.

D. Connect thermal-energy meter transmitters to meters.

3.3 ADJUSTING

A. After installation, calibrate meters according to manufacturer's written instructions.

B. Adjust faces of meters and gages to proper angle for best visibility.

3.4 THERMOMETER SCALE-RANGE SCHEDULE

A. Scale Range for Chilled-Water Piping: 0 to 100 deg F (Minus 20 to plus 50 deg C).

B. Scale Range for Condenser-Water Piping: 0 to 160 deg F (Minus 20 to plus 70 deg C).

C. Scale Range for Heating, Hot-Water Piping: 30 to 240 deg F (0 to plus 115 deg C).

D. Scale Range for Steam and Steam-Condensate Piping: 30 to 240 deg F (0 to plus 115 deg C).

3.5 PRESSURE-GAGE SCALE-RANGE SCHEDULE

A. Scale Range for Chilled-Water Piping: 0 to two times the operating pressure psi (kPa).

B. Scale Range for Condenser-Water Piping: 0 to two times the operating pressure psi (kPa).

C. Scale Range for Heating, Hot-Water Piping: 0 to two times the operating pressure psi (kPa).

D. Scale Range for Steam Piping: 0 to two times the operating pressure psi (kPa).



GENERAL-DUTY VALVES FOR HVAC PIPING 230523 - 1

SECTION 230523 - GENERAL-DUTY VALVES FOR HVAC PIPING

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes: 1. Bronze ball valves. 2. Iron, single-flange butterfly valves. 3. High-performance butterfly valves. 4. Bronze swing check valves. 5. Iron swing check valves. 6. Iron swing check valves with closure control. 7. Bronze globe valves. 8. Iron globe valves.


1. Division 23 HVAC piping Sections for specialty valves applicable to those Sections only. 2. Division 23 Section "Identification for HVAC Piping and Equipment" for valve tags and

schedules.


A. Product Data: For each type of valve indicated.


A. Source Limitations for Valves: Obtain each type of valve from single source from single manufacturer.

B. ASME Compliance: ASME B16.10 and ASME B16.34 for ferrous valve dimensions and design criteria.

PART 2 - PRODUCTS

2.1 GENERAL REQUIREMENTS FOR VALVES

A. Refer to HVAC valve schedule articles for applications of valves.

B. Valve Pressure and Temperature Ratings: Not less than indicated and as required for system pressures and temperatures.

C. Valve Sizes: Same as upstream piping unless otherwise indicated.



D. Valve Actuator Types:

1. Gear Actuator: For quarter-turn valves NPS 8 (DN 200) and larger. 2. Handwheel: For valves other than quarter-turn types. 3. Handlever: For quarter-turn valves NPS 6 (DN 150) and smaller except plug valves.

E. Valves in Insulated Piping: With 2-inch (50-mm) stem extensions and the following features: 1. Ball Valves: With extended operating handle of non-thermal-conductive material, and

protective sleeve that allows operation of valve without breaking the vapor seal or disturbing insulation.

2. Butterfly Valves: With extended neck.

F. Valve-End Connections:

1. Flanged: With flanges according to ASME B16.1 for iron valves. 2. Solder Joint: With sockets according to ASME B16.18. 3. Threaded: With threads according to ASME B1.20.1.

2.2 BRONZE BALL VALVES

A. Two-Piece, Full-Port, Bronze Ball Valves with Bronze Trim:


a. American Valve, Inc. b. Conbraco Industries, Inc.; Apollo Valves. c. Crane Co.; Crane Valve Group; Crane Valves. d. Hammond Valve. e. Lance Valves; a division of Advanced Thermal Systems, Inc. f. Legend Valve. g. Milwaukee Valve Company. h. NIBCO INC. i. Red-White Valve Corporation. j. Watts Regulator Co.; a division of Watts Water Technologies, Inc.

2. Description:

a. Standard: MSS SP-110. b. SWP Rating: 150 psig (1035 kPa). c. CWP Rating: 600 psig (4140 kPa). d. Body Design: Two piece. e. Body Material: Bronze. f. Ends: Threaded. g. Seats: PTFE or TFE. h. Stem: Bronze. i. Ball: Chrome-plated brass. j. Port: Full.



2.3 IRON, SINGLE-FLANGE BUTTERFLY VALVES

A. 200 CWP, Iron, Single-Flange Butterfly Valves with EPDM Seat and Aluminum-Bronze Disc:


a. ABZ Valve and Controls; a division of ABZ Manufacturing, Inc. b. Conbraco Industries, Inc.; Apollo Valves. c. Cooper Cameron Valves; a division of Cooper Cameron Corp. d. Crane Co.; Crane Valve Group; Jenkins Valves. e. Crane Co.; Crane Valve Group; Stockham Division. f. DeZurik Water Controls. g. Flo Fab Inc. h. Hammond Valve. i. Kitz Corporation. j. Legend Valve. k. Milwaukee Valve Company. l. NIBCO INC. m. Norriseal; a Dover Corporation company. n. Red-White Valve Corporation. o. Spence Strainers International; a division of CIRCOR International. p. Watts Regulator Co.; a division of Watts Water Technologies, Inc.

2. Description:

a. Standard: MSS SP-67, Type I. b. CWP Rating: 200 psig (1380 kPa). c. Body Design: Lug type; suitable for bidirectional dead-end service at rated

pressure without use of downstream flange. d. Body Material: ASTM A 126, cast iron or ASTM A 536, ductile iron. e. Seat: EPDM. f. Stem: One- or two-piece stainless steel. g. Disc: Aluminum bronze.

B. 200 CWP, Iron, Single-Flange Butterfly Valves with EPDM Seat and Stainless-Steel Disc:


a. ABZ Valve and Controls; a division of ABZ Manufacturing, Inc. b. American Valve, Inc. c. Conbraco Industries, Inc.; Apollo Valves. d. Cooper Cameron Valves; a division of Cooper Cameron Corp. e. Crane Co.; Crane Valve Group; Jenkins Valves. f. Crane Co.; Crane Valve Group; Stockham Division. g. DeZurik Water Controls. h. Flo Fab Inc. i. Hammond Valve. j. Kitz Corporation. k. Legend Valve. l. Milwaukee Valve Company.



m. Mueller Steam Specialty; a division of SPX Corporation. n. NIBCO INC. o. Norriseal; a Dover Corporation company. p. Red-White Valve Corporation. q. Spence Strainers International; a division of CIRCOR International. r. Sure Flow Equipment Inc. s. Watts Regulator Co.; a division of Watts Water Technologies, Inc.

2. Description:

a. Standard: MSS SP-67, Type I. b. CWP Rating: 200 psig (1380 kPa). c. Body Design: Lug type; suitable for bidirectional dead-end service at rated

pressure without use of downstream flange. d. Body Material: ASTM A 126, cast iron or ASTM A 536, ductile iron. e. Seat: EPDM. f. Stem: One- or two-piece stainless steel. g. Disc: Stainless steel.

2.4 HIGH-PERFORMANCE BUTTERFLY VALVES

A. Class 300, Single-Flange, High-Performance Butterfly Valves:


a. ABZ Valve and Controls; a division of ABZ Manufacturing, Inc. b. Bray Controls; a division of Bray International. c. Cooper Cameron Valves; a division of Cooper Cameron Corp. d. Crane Co.; Crane Valve Group; Flowseal. e. Crane Co.; Crane Valve Group; Stockham Division. f. DeZurik Water Controls. g. Hammond Valve. h. Jamesbury; a subsidiary of Metso Automation. i. Milwaukee Valve Company. j. NIBCO INC. k. Process Development & Control, Inc. l. Tyco Valves & Controls; a unit of Tyco Flow Control. m. Xomox Corporation.

2. Description:

a. Standard: MSS SP-68. b. CWP Rating: 720 psig (4965 kPa) at 100 deg F (38 deg C). c. Body Design: Lug type; suitable for bidirectional dead-end service at rated

pressure without use of downstream flange. d. Body Material: Carbon steel, cast iron, or ductile iron. e. Seat: Reinforced PTFE or metal. f. Stem: Stainless steel; offset from seat plane. g. Disc: Carbon steel. h. Service: Bidirectional.



2.5 BRONZE SWING CHECK VALVES

A. Class 150, Bronze Swing Check Valves with Bronze Disc:


a. American Valve, Inc. b. Crane Co.; Crane Valve Group; Crane Valves. c. Crane Co.; Crane Valve Group; Jenkins Valves. d. Crane Co.; Crane Valve Group; Stockham Division. e. Kitz Corporation. f. Milwaukee Valve Company. g. NIBCO INC. h. Red-White Valve Corporation. i. Zy-Tech Global Industries, Inc.

2. Description:

a. Standard: MSS SP-80, Type 3. b. CWP Rating: 300 psig (2070 kPa). c. Body Design: Horizontal flow. d. Body Material: ASTM B 62, bronze. e. Ends: Threaded. f. Disc: Bronze.

2.6 IRON SWING CHECK VALVES

A. Class 125, Iron Swing Check Valves with Metal Seats:


a. Crane Co.; Crane Valve Group; Crane Valves. b. Crane Co.; Crane Valve Group; Jenkins Valves. c. Crane Co.; Crane Valve Group; Stockham Division. d. Hammond Valve. e. Kitz Corporation. f. Legend Valve. g. Milwaukee Valve Company. h. NIBCO INC. i. Powell Valves. j. Red-White Valve Corporation. k. Sure Flow Equipment Inc. l. Watts Regulator Co.; a division of Watts Water Technologies, Inc. m. Zy-Tech Global Industries, Inc.

2. Description:

a. Standard: MSS SP-71, Type I. b. NPS 2-1/2 to NPS 12 (DN 65 to DN 300), CWP Rating: 200 psig (1380 kPa).



c. NPS 14 to NPS 24 (DN 350 to DN 600), CWP Rating: 150 psig (1035 kPa). d. Body Design: Clear or full waterway. e. Body Material: ASTM A 126, gray iron with bolted bonnet. f. Ends: Flanged. g. Trim: Bronze. h. Gasket: Asbestos free.

2.7 IRON SWING CHECK VALVES WITH CLOSURE CONTROL

A. Class 125, Iron Swing Check Valves with Lever- and Spring-Closure Control:


a. NIBCO INC.

2. Description:

a. Standard: MSS SP-71, Type I. b. NPS 2-1/2 to NPS 12 (DN 65 to DN 300), CWP Rating: 200 psig (1380 kPa). c. NPS 14 to NPS 24 (DN 350 to DN 600), CWP Rating: 150 psig (1035 kPa). d. Body Design: Clear or full waterway. e. Body Material: ASTM A 126, gray iron with bolted bonnet. f. Ends: Flanged. g. Trim: Bronze. h. Gasket: Asbestos free. i. Closure Control: Factory-installed, exterior lever and spring.

2.8 BRONZE GLOBE VALVES

A. Class 150, Bronze Globe Valves with Nonmetallic Disc:


a. Crane Co.; Crane Valve Group; Crane Valves. b. Hammond Valve. c. Kitz Corporation. d. Milwaukee Valve Company. e. NIBCO INC. f. Powell Valves. g. Red-White Valve Corporation. h. Watts Regulator Co.; a division of Watts Water Technologies, Inc. i. Zy-Tech Global Industries, Inc.

2. Description:

a. Standard: MSS SP-80, Type 2. b. CWP Rating: 300 psig (2070 kPa). c. Body Material: ASTM B 62, bronze with integral seat and union-ring bonnet.



d. Ends: Threaded. e. Stem: Bronze. f. Disc: PTFE or TFE. g. Packing: Asbestos free. h. Handwheel: Malleable iron, bronze, or aluminum.

2.9 IRON GLOBE VALVES

A. Class 125, Iron Globe Valves:


a. Crane Co.; Crane Valve Group; Crane Valves. b. Crane Co.; Crane Valve Group; Jenkins Valves. c. Crane Co.; Crane Valve Group; Stockham Division. d. Hammond Valve. e. Kitz Corporation. f. Milwaukee Valve Company. g. NIBCO INC. h. Powell Valves. i. Red-White Valve Corporation. j. Watts Regulator Co.; a division of Watts Water Technologies, Inc. k. Zy-Tech Global Industries, Inc.

2. Description:

a. Standard: MSS SP-85, Type I. b. CWP Rating: 200 psig (1380 kPa). c. Body Material: ASTM A 126, gray iron with bolted bonnet. d. Ends: Flanged. e. Trim: Bronze. f. Packing and Gasket: Asbestos free.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine valve interior for cleanliness, freedom from foreign matter, and corrosion. Remove special packing materials, such as blocks, used to prevent disc movement during shipping and handling.

B. Operate valves in positions from fully open to fully closed. Examine guides and seats made accessible by such operations.

C. Examine threads on valve and mating pipe for form and cleanliness.



D. Examine mating flange faces for conditions that might cause leakage. Check bolting for proper size, length, and material. Verify that gasket is of proper size, that its material composition is suitable for service, and that it is free from defects and damage.

E. Do not attempt to repair defective valves; replace with new valves.

3.2 VALVE INSTALLATION

A. Install valves with unions or flanges at each piece of equipment arranged to allow service, maintenance, and equipment removal without system shutdown.

B. Locate valves for easy access and provide separate support where necessary.

C. Install valves in horizontal piping with stem at or above center of pipe.

D. Install valves in position to allow full stem movement.

E. Install swing check valves for proper direction of flow and in horizontal position with hinge pin level.

3.3 ADJUSTING

A. Adjust or replace valve packing after piping systems have been tested and put into service but before final adjusting and balancing. Replace valves if persistent leaking occurs.

3.4 GENERAL REQUIREMENTS FOR VALVE APPLICATIONS

A. If valve applications are not indicated, use the following:

1. Shutoff Service: Ball, butterfly valves. 2. Throttling Service, Except Steam: Globe , ball, or butterfly valves. 3. Pump-Discharge Check Valves:

a. NPS 2 (DN 50) and Smaller: Bronze swing check valves with bronze disc. b. NPS 2-1/2 (DN 65) and Larger: Iron swing check valves with lever and weight or

with spring.

B. If valves with specified SWP classes or CWP ratings are not available, the same types of valves with higher SWP classes or CWP ratings may be substituted.

C. Select valves, except wafer types, with the following end connections:

1. For Copper Tubing, NPS 2 (DN 50) and Smaller: Threaded ends except where solder-joint valve-end option is indicated in valve schedules below.

2. For Copper Tubing, NPS 2-1/2 to NPS 4 (DN 65 to DN 100): Flanged ends except where threaded valve-end option is indicated in valve schedules below.

3. For Copper Tubing, NPS 5 (DN 125) and Larger: Flanged ends. 4. For Steel Piping, NPS 2 (DN 50) and Smaller: Threaded ends.



5. For Steel Piping, NPS 2-1/2 to NPS 4 (DN 65 to DN 100): Flanged ends except where threaded valve-end option is indicated in valve schedules below.

6. For Steel Piping, NPS 5 (DN 125) and Larger: Flanged ends.

3.5 CHILLED-WATER VALVE SCHEDULE

A. Pipe NPS 4 (DN 100) and Smaller:

1. Bronze Valves: May be provided with solder-joint ends instead of threaded ends. 2. Ball Valves: Two piece, full port, bronze with bronze trim.

3.6 HEATING-WATER VALVE SCHEDULE

A. Pipe NPS 4 (DN 100) and Smaller:

1. Bronze Valves: May be provided with solder-joint ends instead of threaded ends. 2. Ball Valves: Two piece, full port, bronze with bronze trim.



HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT 230529 - 1

SECTION 230529 - HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes:

1. Metal pipe hangers and supports. 2. Trapeze pipe hangers. 3. Fastener systems.


1. Division 23 Section(s) "Metal Ducts" for duct hangers and supports.

1.3 DEFINITIONS

A. MSS: Manufacturers Standardization Society of The Valve and Fittings Industry Inc.

1.4 PERFORMANCE REQUIREMENTS

A. Delegated Design: Design trapeze pipe hangers and equipment supports, including comprehensive engineering analysis by a qualified professional engineer, using performance requirements and design criteria indicated.

B. Structural Performance: Hangers and supports for HVAC piping and equipment shall withstand the effects of gravity loads and stresses within limits and under conditions indicated according to the 2006 International Building Code.

1. Design supports for multiple pipes, including pipe stands, capable of supporting combined weight of supported systems, system contents, and test water.

2. Design equipment supports capable of supporting combined operating weight of supported equipment and connected systems and components.

3. Design seismic-restraint hangers and supports for piping and equipment and obtain approval from authorities having jurisdiction.

1.5 SUBMITTALS




B. Shop Drawings: Signed and sealed by a qualified professional engineer. Show fabrication and installation details and include calculations for the following; include Product Data for components:

1. Trapeze pipe hangers. 2. Metal framing systems. 3. Equipment supports.

C. Welding certificates.


A. Structural Steel Welding Qualifications: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel."

B. Pipe Welding Qualifications: Qualify procedures and operators according to ASME Boiler and Pressure Vessel Code.

PART 2 - PRODUCTS

2.1 METAL PIPE HANGERS AND SUPPORTS

A. Carbon-Steel Pipe Hangers and Supports:

1. Description: MSS SP-58, Types 1 through 58, factory-fabricated components. 2. Galvanized Metallic Coatings: Pregalvanized or hot dipped. 3. Nonmetallic Coatings: Plastic coating, jacket, or liner. 4. Padded Hangers: Hanger with fiberglass or other pipe insulation pad or cushion to

support bearing surface of piping. 5. Hanger Rods: Continuous-thread rod, nuts, and washer made of carbon steel.

2.2 TRAPEZE PIPE HANGERS

A. Description: MSS SP-69, Type 59, shop- or field-fabricated pipe-support assembly made from structural carbon-steel shapes with MSS SP-58 carbon-steel hanger rods, nuts, saddles, and U-bolts.

2.3 FASTENER SYSTEMS

A. Powder-Actuated Fasteners: Threaded-steel stud, for use in hardened portland cement concrete with pull-out, tension, and shear capacities appropriate for supported loads and building materials where used.

B. Mechanical-Expansion Anchors: Insert-wedge-type, zinc-coated steel anchors, for use in hardened portland cement concrete; with pull-out, tension, and shear capacities appropriate for supported loads and building materials where used.



2.4 MISCELLANEOUS MATERIALS

A. Structural Steel: ASTM A 36/A 36M, carbon-steel plates, shapes, and bars; black and galvanized.

B. Grout: ASTM C 1107, factory-mixed and -packaged, dry, hydraulic-cement, nonshrink and nonmetallic grout; suitable for interior and exterior applications.

1. Properties: Nonstaining, noncorrosive, and nongaseous. 2. Design Mix: 5000-psi, 28-day compressive strength.

PART 3 - EXECUTION

3.1 HANGER AND SUPPORT INSTALLATION

A. Metal Pipe-Hanger Installation: Comply with MSS SP-69 and MSS SP-89. Install hangers, supports, clamps, and attachments as required to properly support piping from the building structure.

B. Metal Trapeze Pipe-Hanger Installation: Comply with MSS SP-69 and MSS SP-89. Arrange for grouping of parallel runs of horizontal piping, and support together on field-fabricated trapeze pipe hangers.

1. Pipes of Various Sizes: Support together and space trapezes for smallest pipe size or install intermediate supports for smaller diameter pipes as specified for individual pipe hangers.

2. Field fabricate from ASTM A 36/A 36M, carbon-steel shapes selected for loads being supported. Weld steel according to AWS D1.1/D1.1M.

C. Fastener System Installation:

1. Install powder-actuated fasteners for use in lightweight concrete or concrete slabs less than 4 inches thick in concrete after concrete is placed and completely cured. Use operators that are licensed by powder-actuated tool manufacturer. Install fasteners according to powder-actuated tool manufacturer's operating manual.

2. Install mechanical-expansion anchors in concrete after concrete is placed and completely cured. Install fasteners according to manufacturer's written instructions.

D. Install hangers and supports complete with necessary attachments, inserts, bolts, rods, nuts, washers, and other accessories.

E. Equipment Support Installation: Fabricate from welded-structural-steel shapes.

F. Install hangers and supports to allow controlled thermal and seismic movement of piping systems, to permit freedom of movement between pipe anchors, and to facilitate action of expansion joints, expansion loops, expansion bends, and similar units.

G. Install lateral bracing with pipe hangers and supports to prevent swaying.



H. Install building attachments within concrete slabs or attach to structural steel. Install additional attachments at concentrated loads, including valves, flanges, and strainers, NPS 2-1/2 and larger and at changes in direction of piping. Install concrete inserts before concrete is placed; fasten inserts to forms and install reinforcing bars through openings at top of inserts.

I. Load Distribution: Install hangers and supports so that piping live and dead loads and stresses from movement will not be transmitted to connected equipment.

J. Pipe Slopes: Install hangers and supports to provide indicated pipe slopes and to not exceed maximum pipe deflections allowed by ASME B31.9 for building services piping.

3.2 METAL FABRICATIONS

A. Cut, drill, and fit miscellaneous metal fabrications for trapeze pipe hangers and equipment supports.

B. Fit exposed connections together to form hairline joints. Field weld connections that cannot be shop welded because of shipping size limitations.

C. Field Welding: Comply with AWS D1.1/D1.1M procedures for shielded, metal arc welding; appearance and quality of welds; and methods used in correcting welding work; and with the following:

1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.

2. Obtain fusion without undercut or overlap. 3. Remove welding flux immediately. 4. Finish welds at exposed connections so no roughness shows after finishing and so

contours of welded surfaces match adjacent contours.

3.3 ADJUSTING

A. Hanger Adjustments: Adjust hangers to distribute loads equally on attachments and to achieve indicated slope of pipe.

B. Trim excess length of continuous-thread hanger and support rods to 1-1/2 inches.

3.4 PAINTING

A. Touchup: Clean field welds and abraded areas of shop paint. Paint exposed areas immediately after erecting hangers and supports. Use same materials as used for shop painting. Comply with SSPC-PA 1 requirements for touching up field-painted surfaces.

1. Apply paint by brush or spray to provide a minimum dry film thickness of 2.0 mils.

B. Touchup: Cleaning and touchup painting of field welds, bolted connections, and abraded areas of shop paint on miscellaneous metal are specified in Division 09 painting Sections.



C. Galvanized Surfaces: Clean welds, bolted connections, and abraded areas and apply galvanizing-repair paint to comply with ASTM A 780.

3.5 HANGER AND SUPPORT SCHEDULE

A. Specific hanger and support requirements are in Sections specifying piping systems and equipment.

B. Comply with MSS SP-69 for pipe-hanger selections and applications that are not specified in piping system Sections.

C. Use hangers and supports with galvanized metallic coatings for piping and equipment that will not have field-applied finish.

D. Use nonmetallic coatings on attachments for electrolytic protection where attachments are in direct contact with copper tubing.

E. Use carbon-steel pipe hangers and supports metal trapeze pipe hangers and metal framing systems and attachments for general service applications.

F. Use stainless-steel pipe hangers and stainless-steel or corrosion-resistant attachments for hostile environment applications.

G. Use padded hangers for piping that is subject to scratching.

H. Use thermal-hanger shield inserts for insulated piping and tubing.

I. Horizontal-Piping Hangers and Supports: Unless otherwise indicated and except as specified in piping system Sections, install the following types:

1. Adjustable, Steel Clevis Hangers (MSS Type 1): For suspension of noninsulated or insulated, stationary pipes NPS 1/2 to NPS 30.

2. Pipe Hangers (MSS Type 5): For suspension of pipes NPS 1/2 to NPS 4, to allow off-center closure for hanger installation before pipe erection.

3. Adjustable, Swivel Split- or Solid-Ring Hangers (MSS Type 6): For suspension of noninsulated, stationary pipes NPS 3/4 to NPS 8.

4. Adjustable, Steel Band Hangers (MSS Type 7): For suspension of noninsulated, stationary pipes NPS 1/2 to NPS 8.

5. Adjustable Band Hangers (MSS Type 9): For suspension of noninsulated, stationary pipes NPS 1/2 to NPS 8.

6. Adjustable, Swivel-Ring Band Hangers (MSS Type 10): For suspension of noninsulated, stationary pipes NPS 1/2 to NPS 8.

7. Split Pipe Ring with or without Turnbuckle Hangers (MSS Type 11): For suspension of noninsulated, stationary pipes NPS 3/8 to NPS 8.

8. Extension Hinged or Two-Bolt Split Pipe Clamps (MSS Type 12): For suspension of noninsulated, stationary pipes NPS 3/8 to NPS 3.

9. U-Bolts (MSS Type 24): For support of heavy pipes NPS 1/2 to NPS 30.

J. Vertical-Piping Clamps: Unless otherwise indicated and except as specified in piping system Sections, install the following types:



1. Extension Pipe or Riser Clamps (MSS Type 8): For support of pipe risers NPS 3/4 to NPS 24.

2. Carbon- or Alloy-Steel Riser Clamps (MSS Type 42): For support of pipe risers NPS 3/4 to NPS 24 if longer ends are required for riser clamps.

K. Hanger-Rod Attachments: Unless otherwise indicated and except as specified in piping system Sections, install the following types:

1. Steel Turnbuckles (MSS Type 13): For adjustment up to 6 inches for heavy loads. 2. Steel Clevises (MSS Type 14): For 120 to 450 deg F piping installations. 3. Swivel Turnbuckles (MSS Type 15): For use with MSS Type 11, split pipe rings. 4. Malleable-Iron Sockets (MSS Type 16): For attaching hanger rods to various types of

building attachments. 5. Steel Weldless Eye Nuts (MSS Type 17): For 120 to 450 deg F piping installations.

L. Building Attachments: Unless otherwise indicated and except as specified in piping system Sections, install the following types:

1. Steel or Malleable Concrete Inserts (MSS Type 18): For upper attachment to suspend pipe hangers from concrete ceiling.

2. Top-Beam C-Clamps (MSS Type 19): For use under roof installations with bar-joist construction, to attach to top flange of structural shape.

3. Side-Beam or Channel Clamps (MSS Type 20): For attaching to bottom flange of beams, channels, or angles.

4. Center-Beam Clamps (MSS Type 21): For attaching to center of bottom flange of beams. 5. Welded Beam Attachments (MSS Type 22): For attaching to bottom of beams if loads

are considerable and rod sizes are large. 6. C-Clamps (MSS Type 23): For structural shapes. 7. Top-Beam Clamps (MSS Type 25): For top of beams if hanger rod is required tangent to

flange edge. 8. Side-Beam Clamps (MSS Type 27): For bottom of steel I-beams. 9. Steel-Beam Clamps with Eye Nuts (MSS Type 28): For attaching to bottom of steel I-

beams for heavy loads. 10. Linked-Steel Clamps with Eye Nuts (MSS Type 29): For attaching to bottom of steel I-

beams for heavy loads, with link extensions. 11. Malleable-Beam Clamps with Extension Pieces (MSS Type 30): For attaching to

structural steel. 12. Welded-Steel Brackets: For support of pipes from below or for suspending from above

by using clip and rod. Use one of the following for indicated loads:

a. Light (MSS Type 31): 750 lb. b. Medium (MSS Type 32): 1500 lb. c. Heavy (MSS Type 33): 3000 lb.

13. Side-Beam Brackets (MSS Type 34): For sides of steel or wooden beams. 14. Plate Lugs (MSS Type 57): For attaching to steel beams if flexibility at beam is required. 15. Horizontal Travelers (MSS Type 58): For supporting piping systems subject to linear

horizontal movement where headroom is limited.

M. Spring Hangers and Supports: Unless otherwise indicated and except as specified in piping system Sections, install the following types:

1. Restraint-Control Devices (MSS Type 47): Where indicated to control piping movement.



2. Spring Cushions (MSS Type 48): For light loads if vertical movement does not exceed 1-1/4 inches.

3. Spring-Cushion Roll Hangers (MSS Type 49): For equipping Type 41, roll hanger with springs.

4. Spring Sway Braces (MSS Type 50): To retard sway, shock, vibration, or thermal expansion in piping systems.

5. Variable-Spring Hangers (MSS Type 51): Preset to indicated load and limit variability factor to 25 percent to allow expansion and contraction of piping system from hanger.

6. Variable-Spring Base Supports (MSS Type 52): Preset to indicated load and limit variability factor to 25 percent to allow expansion and contraction of piping system from base support.

7. Variable-Spring Trapeze Hangers (MSS Type 53): Preset to indicated load and limit variability factor to 25 percent to allow expansion and contraction of piping system from trapeze support.

8. Constant Supports: For critical piping stress and if necessary to avoid transfer of stress from one support to another support, critical terminal, or connected equipment. Include auxiliary stops for erection, hydrostatic test, and load-adjustment capability. These supports include the following types:

a. Horizontal (MSS Type 54): Mounted horizontally. b. Vertical (MSS Type 55): Mounted vertically. c. Trapeze (MSS Type 56): Two vertical-type supports and one trapeze member.

N. Comply with MSS SP-69 for trapeze pipe-hanger selections and applications that are not specified in piping system Sections.

O. Comply with MFMA-103 for metal framing system selections and applications that are not specified in piping system Sections.

P. Use powder-actuated fasteners or mechanical-expansion anchors instead of building attachments where required in concrete construction.



VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT 230548 - 1

SECTION 230548 - VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT

PART 1 - GENERAL


A. Drawings and general provisions of Contract, including General and Supplementary Conditions and Division-1 Specification sections, apply to work of this section.

B. This section is part of each Division-15 section making reference to seismic and vibration control products specified herein.

1.2 SEISMIC AND VIBRATION CONTROL

A. General: Division 15 shall be responsible for purchasing and installing vibration isolators, flexible connections, rigid steel frames, concrete inertia bases, anchors, inserts, hangers and attachments and seismic bracing and snubbers as required for seismic control and prevention of the transmission of vibration for both isolated and non-isolated systems.

B. All mechanical equipment shall be designed for the site specific Seismic Zone as per the International Building Code.

C. Reference Standards: The work shall comply to the following standards: 1. International Building Code, current edition 2. NFPA Bulletin 90A, current edition 3. Bridge Bearing Specifications

D. Design Parameters: Refer to Section 1621 of the 2006 International Building Code and ASCE 7-02.

E. Approved Manufacturers: 1. In order to insure that the requirements of the project are achieved, the

Contractor must secure the services of a manufacturer or supplier who has proven capabilities of dealing effectively with vibration characteristics, effects and criteria and can provide facilities and capabilities for measuring, evaluating and designing for seismic disturbances.

2. Manufacturers approved for use are: a. Mason Industries, Inc. b. Amber/Booth Company. c. Vibration Eliminator Co. d. Kinetics Noise Control.

3. The Manufacturer's responsibilities shall include designing and providing all vibration isolators and seismic restraints. He shall also be responsible for the proper installation of these components. Periodic inspections to the job site will be made as required. He shall make a final inspection and submit a report to the Architect certifying compliance to these specifications, drawings and related standards. Provide submittals as specified.

4. The Manufacturer's responsibilities shall include designing and providing all vibration isolators and seismic restraints. He shall also be responsible for the



proper installation of these components. Periodic inspections to the job site will be made as required. The professional engineer who performs the calculations shall make a final inspection and submit a report to the Architect certifying compliance to these specifications, drawings and related standards. The Owner shall be notified in advance when the seismic engineer will be performing final certification inspection. The Owner may wish to be present for this inspection. Provide submittals as specified.

F. Submittals: Submittal data prior to fabrication, shall include but not be limited to the following: 1. Complete engineering calculations and shop drawings for all vibration and

seismic requirements for all equipment, piping and ductwork. 2. The Utah State professional stamp of the Engineer who is responsible for the

design and operation of the Vibration and Seismic System. 3. The type, size, and deflection of each isolator proposed for items in this

specification and on the drawings. 4. Details for all the isolators and seismic bracing with snubbers proposed for items

in this specification and on the drawings. 5. Details for steel frames and concrete inertia bases to be used in conjunction with

the isolation and seismic restraint of the items in this specification and drawings. 6. Clearly outlined procedures for installing and adjusting the isolators, seismic

bracing and snubber. 7. The size, loading and location of pipe and duct supports with an as-built plan or

complete description of the system.

G. Vibration Isolation: 1. All mechanical equipment 1 HP, and over unless otherwise noted, shall be

isolated from the structure by means of resilient vibration and noise isolators designed and supplied by the Seismic and Vibration Control Manufacturer. Piping and ductwork connected to vibrating equipment shall be isolated from the structure as required to prevent vibration transmission. Isolation equipment, hangers, connections, and other isolating devices shall be designed and installed to prevent transmission of vibration to the structure from the mechanical equipment or any of the associated piping and ductwork.

2. All vibration isolated equipment shall be mounted on rigid steel frames or concrete bases unless the equipment manufacturer certified direct attachment capability. The steel frames and bases on isolated equipment shall be provided by the Seismic and Vibration Control Manufacturer.

H. Vibration isolators shall be provided as follows and as otherwise indicated: 1. The Automatic Temperature Control air compressors shall be mounted on Type

P neoprene pads. 2. Floor mounted pumps shall be mounted on Type P neoprene pads. 3. Suspended exhaust fans and air handling units shall be suspended on Type D

spring hangers with neoprene element. 4. Floor mounted air handlers without internal vibration isolation shall be mounted

on type B springs with type H base or housed type spring isolator with integral seismic restraint.

5. Centrifugal supply fans shall be mounted on Type G structural steel base with Type B springs.

6. Centrifugal relief/exhaust fans shall be mounted on Type J concrete inertia base with Type B springs.



7. Boilers on grade support in Type P Neoprene Isolators. Boilers on suspended slabs support from Type C spring mounting.

8. Vertical pipe risers shall be supported with Type E precompressed spring hangers with neoprene element to allow for thermal expansion.

9. Roof mounted and floor mounted utility exhaust fans shall be mounted on housed type spring isolators with integral seismic restraint.

10. Isolate all water, steam and refrigerant piping 1-1/2" and larger within each mechanical equipment room which contains vibration isolated equipment. Isolators shall be Type D spring hangers with neoprene elements.

11. Isolate all water, steam and refrigerant piping that is connected to vibration isolated equipment, for a distance of at least 50 feet from the equipment. Isolators shall be Type D spring hangers.

12. Isolate all ductwork within the mechanical equipment rooms which contain vibration isolated equipment. Isolators shall be Type D spring isolators with neoprene elements.

13. Isolate all ductwork that is connected to vibration isolated equipment, for a distance of at least 50 feet from the equipment. Isolators shall be Type D spring hangers with neoprene elements.

14. Isolate all piping in chiller room. Isolators shall be Type D spring hangers.

I. Vibration isolators shall be as follows: 1. Type B Spring Mounting: Spring type isolators shall be free standing and

laterally stable without any housing and complete with 1/4" neoprene acoustical friction pads between the baseplate and the support. All mountings shall have leveling bolts that must be rigidly bolted to the equipment. Spring diameters shall be no less than 0.8 of the compressed height of the spring at rated load. Springs shall have a minimum additional travel to solid equal to 50% of the rated deflection. Submittals shall include spring diameters, deflections, compressed spring height and solid spring height. Mountings shall be type SLF as manufactured by Mason Industries, Inc. or equal by Amber-Booth.

2. Type C Spring Mounting: Equipment with operating weight different from the installed weight, such as chillers, boilers, etc. and equipment exposed to the wind, such as cooling towers, shall be mounted on spring mountings Type B, but a housing shall be used that includes vertical limit stops to prevent spring extension when weight is removed. All restraining bolts shall have large rubber grommets to provide cushioning in the vertical and horizontal directions. The housing shall serve as blocking during erection and cooling tower mounts shall be located between the supporting steel and roof or the grillage and dunnage as shown on the drawings. The installed and operating heights shall be the same. A minimum clearance of 3/8" shall be maintained around restraining bolts and between the housing and the spring so as not to interfere with the spring action. Limit stops shall be out of contact during normal operations. Mounting used out of doors shall be hot dipped galvanized. Mountings shall be SLR as manufactured by Mason Industries, Inc. or equal by Amber-Booth.

3. Type D Spring Hangers: Vibration hangers shall contain a steel spring and 0.3" deflection neoprene element in series. The neoprene element shall be molded with a rod isolation bushing that passes through the hanger box. Spring diameters and hanger box lower hole sizes shall be large enough to permit the hanger rod to swing through a 30 degree arc before contacting the hole and short circuiting the spring. Springs shall have a minimum additional travel to solid equal to 50% of the rated deflection. Hangers shall be type 30N as manufactured by Mason Industries, Inc. or equal by Amber-Booth.



4. Type E Spring Hangers: Vibration hangers shall be Type D, but they shall be precompressed to the rated deflection so as to keep the piping or equipment at a fixed elevation during installation. The hangers shall be designed with a release mechanism to free the spring after the installation is complete and the hanger is subjected to it's full load. Deflection shall be clearly indicated by means of a scale. Hangers shall be type PC30N as manufactured by Mason Industries, Inc. or equal by Amber-Booth.

5. Type F Spring Hangers: Vibration hangers shall contain a steel spring located in a neoprene cup manufactured with a grommet to prevent short circuiting of the hanger rod. The cup shall contain a steel washer designed to properly distribute the load on the neoprene and prevent its extrusion. Spring diameters and hanger box lower hole sizes shall be large enough to permit the hanger rod to swing through a 30 degree arc before contacting the hole and short circuiting the spring. Springs shall have a minimum additional travel to solid equal to 50% of the rated deflection. Hangers shall be provided with an eye bolt on the spring end and provision to attach the housing to the flat iron duct straps. Submittals shall include a scale drawing of the hanger showing the 30 degree capability. Hangers shall be type W30 as manufactured by Mason Industries, Inc. or equal by Amber-Booth.

6. Type G Steel Bases: vibration isolator manufacturer shall furnish integral structural steel bases. Bases shall be rectangular in shape for all equipment other than centrifugal refrigeration machines and pump bases which may be 'T' or 'L' shaped. Pump bases for split case pumps shall include supports for suction and discharge base ells. All perimeter members shall be beams with a minimum depth equal to 1/10th of the longest dimension of the base. Beam depth need not exceed 14" provided that the deflection and misalignment is kept within acceptable limits as determined by the manufacturer. Height saving brackets shall be employed in all mounting locations to provide a base clearance of one inch. Bases shall be type WF as manufactured by Mason Industries, Inc. Mount on Mason SSFLH spring isolators with integral seismic restraints.

7. Type H Steel Bases: Vibration isolator manufacturer shall provide steel members welded to height saving brackets to cradle machines having legs or bases that do not require a compete supplementary base. Members shall be sufficiently rigid to prevent strains in the equipment. Inverted saddles shall be Type ICS as manufactured by Mason Industries, Inc., or equal by Amber-Booth.

8. Type J Concrete Inertia Bases: Vibration isolator manufacturer shall furnish rectangular structural beam or channel concrete forms for floating foundations. Bases for split case pumps shall be large enough to provide support for suction and discharge base ells. The base depth need not exceed 12" unless specifically recommended by the base manufacturer for mass or rigidity. In general, bases shall be a minimum of 1/12th of the longest dimension of the base, but not less than 6". Forms shall include minimum concrete reinforcement consisting of half-inch bars or angles welded in place on 6" centers running both ways in a layer 1-1/2" above the bottom, or additional steel as is required by the structural conditions. Forms shall be furnished with steel members to hold anchor-bolt sleeves when the anchor bolts fall in concrete locations. Height saving brackets shall be employed in all mounting locations to maintain a 1" clearance below the base. Bases shall be Type K as manufactured by Mason Industries, Inc.

9. Type P Neoprene Pad: A pad type mounting consisting of two layers of 3/8" thick ribbed or waffled bridge bearing neoprene pads bonded to a 16 gage galvanized steel separator plate. Anchor bolt with neoprene washer and sleeve.



J. Seismic Restraints: 1. General: The intent of the seismic restraints is to restrain the mechanical

equipment, pipes and ducts during an earthquake for life safety purposes; to prevent equipment from overturning; to prevent suspended equipment, pipes and ducts from swaying or falling and creating a potential life safety hazard. For "Essential" and "Hazardous" facilities (as defined in the International Building Code), the intent of the seismic restraint system also includes keeping the mechanical systems operational during and following an earthquake. See Section 05500 "Metal Fabrication" for standards for miscellaneous metal fabrication.

2. The following mechanical items shall be seismically braced as specified, detailed on the drawings, or as recommended by the Seismic and Vibration Control manufacturer: a. Paint Booth - anchor bolts b. Foundry Hood - anchor bolts c. Heat Transfer Package - anchor bolts d. Roof Hoods - anchor bolts e. Packaged Rooftop Air Handlers - anchor bolts f. Hot Water Unit Heaters - cables g. Evaporative Cooler - anchor bolts h. Water Storage Tanks - anchor bolts and cables i. Cooling Tower - anchor bolts j. Vaneaxial Supply Fans - seismic snubbers or restrained isolators k. Chillers - anchor bolts l. ATC Air Compressor - anchor bolts (seismic snubbers or restrained

isolators) m. Heat Exchangers - anchor bolts and cables n. Air Handler - anchor bolts o. Base Mounted Pumps - anchor bolts p. Water Softeners and Brine Tanks - anchor bolts or cables q. Expansion Tanks - cables or anchor bolts r. Relief Fans - angle iron or cables s. Boiler - anchor bolts t. Water Heater - anchor bolts u. Inline Exhaust Fans - cables v. Suspended Air Handlers - cables w. Roof Exhaust Fans - anchor bolts x. Water Treatment Station - anchor bolts y. All duct work and piping shall be provided with seismic restraints in

accordance with the current edition of the International Building Code. Insulated piping longitudinal restraints shall be attached directly to piping.

3. Connections of the seismic bracing to the structure shall be coordinated with the General Contractor and acceptable to the Structural Engineers. In general, connect to beams, concrete slabs, or to the top member of the joists at the panel points. Division 15 shall provide spanner beams where required for seismic bracing. Seismic anchorage shall extend through concrete house keeping pads and anchor to the building floor slabs.

4. The Seismic and Vibration Control manufacturer shall determine the number, size, and type of anchor bolts, cable restraints, seismic snubbers, etc., for each piece of equipment and groups of pipes and ducts. Individual pipes and ducts shall be braced as per the SMACNA details and approved and verified by the Seismic and Vibration Control manufacturer.



K. Seismic Snubbers: 1. All vibration isolated equipment shall be mounted on rigid steel frames or

concrete bases as described in the vibration control specifications unless the equipment manufacturer certifies direct attachment capability. Each spring mounted base shall have a minimum of four all-directional seismic snubbers that are double acting and located as close to the vibration isolators as possible to facilitate attachment both to the base and the structure. The snubbers shall consist of interlocking steel members restrained by shock absorbent rubber materials compounded to bridge bearing specifications. Elastomeric materials shall be replaceable and a minimum of 3/4" thick. Snubbers shall be manufactured with an air gap between hard and resilient material of not less than 1/8" nor more than 1/4". Snubbers shall be installed with factory set clearances.

2. The capacity of the seismic snubber at 3/8" deflection shall be 3 to 4 times the load assigned to the mount grouping in its immediate area. Submittals shall include load deflection curves up to 1/2" deflection in the y and z planes. Test shall be conducted in an independent laboratory or under the signed supervision of an independent registered engineer. The snubber assemblies shall be bolted to the test machine as the snubber is normally installed. Test reports shall certify that neither the neoprene elements nor the snubber body sustained any obvious deformation after release of load. Snubbers shall be series Z-1011 as manufactured by Mason Industries, Inc. or equal by Amber-Booth.



OPERATION AND MAINTENANCE MANUALS 230550 - 1

SECTION 230550 – OPERATION AND MAINTENANCE MANUALS

PART 1 - GENERAL


A. All pertinent sections of Division 22 and 23 Mechanical General requirements, are part of the work of this Section. Division 1 is part of this and all other Sections of these specifications.

1. Testing and Balancing is specified in section 230594.

1.2 SCOPE OF WORK

A. Submission of Operating and Maintenance Manuals complete with Balancing reports (Coordinate with Division 1).

B. Provide a hard copy and an electronic copy of the O and M Manual.

1.3 SUBMITTALS

A. Submit product data in accordance with Division 1. Submit the following:

1. Sample of O and M Manual outline.


PART 2 - PRODUCTS

2.1 O & M MANUALS

A. The operating and maintenance manuals shall be as follows:

1. Binders shall be red buckram with easy-view metal for size 8-1/2 x 11-inch sheets, with capacity expandable from 2 inches to 3-1/2 inches as required for the project. Construction shall be rivet-through with library corners. No. 12 backbone and lining shall be the same material as the cover. The front cover and backbone shall be foil-stamped in white as follows:

OPERATING AND MAINTENANCE

MANUAL

FOR THE

(INSERT NAME OF PROJECT)



2010

VOLUME No. ( )

(INSERT NAME OF MECHANICAL ENGINEERING FIRM)

MECHANICAL ENGINEER

(INSERT ARCHITECTURAL FIRM)

Binders shall be manufactured by Hiller Bookbinding

PART 3 - EXECUTION

3.1 OPERATING AND MAINTENANCE MANUALS:

A. Work under this section shall be performed in concert with the contractor performing the system testing and balancing. Two (2) copies of the manuals shall be furnished to the Architect for distribution to the owner.

B. The “Start-Up and Operation” section is one of the most important in the manual. Information in this section shall be complete and accurately written and shall be verified with the actual equipment on the job, such as switches, starters, relays, automatic controls, etc. A step-by-step start-up procedure shall be described.

C. The manuals shall include air and water-balancing reports, system commission procedures, start-up tests and reports, equipment and system performance test reports, warranties, and certificates of training given to the owner’s representatives.

D. An index sheet typed on AICO Gold-line indexes shall be provided in the front of the binder. The manual shall be include the fallowing.

SYSTEM DESCRIPTIONS

START-UP PROCEDURE AND OPERATION OF SYSTEM

MAINTENANCE AND LUBRICATION TABLE

OPERATION AND MAINTENANCE BULLETINS

AUTOMATIC TEMPERATURE CONTROL DESCRIPTION OF OPERATION, INTERLOCK AND CONTROL DIAGRAMS, AND CONTROL PANELS.

AIR AND WATER SYSTEM BALANCING REPORTS

EQUIPMENT WARRANTIES AND TRAINING CERTIFICATES

SYSTEM COMMISSIONING REPORTS



EQUIPMENT START-UP REPORTS



IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT 230553 - 1

SECTION 230553 - IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT

PART 1 - GENERAL



1.2 SUMMARY


1. Equipment labels. 2. Warning signs and labels. 3. Pipe labels. 4. Duct labels. 5. Valve tags. 6. Warning tags.

1.3 SUBMITTALS


B. Samples: For color, letter style, and graphic representation required for each identification material and device.

C. Equipment Label Schedule: Include a listing of all equipment to be labeled with the proposed content for each label.

1.4 COORDINATION

A. Coordinate installation of identifying devices with completion of covering and painting of surfaces where devices are to be applied.

B. Coordinate installation of identifying devices with locations of access panels and doors.

C. Install identifying devices before installing acoustical ceilings and similar concealment.

PART 2 - PRODUCTS

2.1 EQUIPMENT LABELS

A. Plastic Labels for Equipment:



1. Material and Thickness: Multilayer, multicolor, plastic labels for mechanical engraving, 1/16 inch thick, and having predrilled holes for attachment hardware.

2. Letter Color: White. 3. Background Color: Blue. 4. Maximum Temperature: Able to withstand temperatures up to 160 deg F. 5. Minimum Label Size: Length and width vary for required label content, but not less than

2-1/2 by 3/4 inch. 6. Minimum Letter Size: 1/4 inch for name of units if viewing distance is less than 24

inches, 1/2 inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two-thirds to three-fourths the size of principal lettering.

7. Fasteners: Stainless-steel rivets or self-tapping screws. 8. Adhesive: Contact-type permanent adhesive, compatible with label and with substrate.

B. Label Content: Include equipment's Drawing designation or unique equipment number, Drawing numbers where equipment is indicated (plans, details, and schedules), plus the Specification Section number and title where equipment is specified.

C. Equipment Label Schedule: For each item of equipment to be labeled, on 8-1/2-by-11-inch bond paper. Tabulate equipment identification number and identify Drawing numbers where equipment is indicated (plans, details, and schedules), plus the Specification Section number and title where equipment is specified. Equipment schedule shall be included in operation and maintenance data.

2.2 WARNING SIGNS AND LABELS

A. Material and Thickness: Multilayer, multicolor, plastic labels for mechanical engraving, 1/16 inch thick, and having predrilled holes for attachment hardware.

B. Letter Color: Black.

C. Background Color: Yellow.

D. Maximum Temperature: Able to withstand temperatures up to 160 deg F.

E. Minimum Label Size: Length and width vary for required label content, but not less than 2-1/2 by 3/4 inch.

F. Minimum Letter Size: 1/4 inch for name of units if viewing distance is less than 24 inches, 1/2 inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two-thirds to three-fourths the size of principal lettering.

G. Fasteners: Stainless-steel rivets or self-tapping screws.

H. Adhesive: Contact-type permanent adhesive, compatible with label and with substrate.

I. Label Content: Include caution and warning information, plus emergency notification instructions.



2.3 PIPE LABELS

A. General Requirements for Manufactured Pipe Labels: Preprinted, color-coded, with lettering indicating service, and showing flow direction.

B. Pretensioned Pipe Labels: Precoiled, semirigid plastic formed to cover full circumference of pipe and to attach to pipe without fasteners or adhesive.

C. Self-Adhesive Pipe Labels: Printed plastic with contact-type, permanent-adhesive backing.

D. Pipe Label Contents: Include identification of piping service using same designations or abbreviations as used on Drawings, pipe size, and an arrow indicating flow direction.

1. Flow-Direction Arrows: Integral with piping system service lettering to accommodate both directions, or as separate unit on each pipe label to indicate flow direction.

2. Lettering Size: At least 1-1/2 inches high.

2.4 DUCT LABELS

A. Material and Thickness: Multilayer, multicolor, plastic labels for mechanical engraving, 1/16 inch thick, and having predrilled holes for attachment hardware.

B. Letter Color: Black.

C. Background Color: Blue Yellow Green.

D. Maximum Temperature: Able to withstand temperatures up to 160 deg F.

E. Minimum Label Size: Length and width vary for required label content, but not less than 2-1/2 by 3/4 inch.

F. Minimum Letter Size: 1/4 inch for name of units if viewing distance is less than 24 inches, 1/2 inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two-thirds to three-fourths the size of principal lettering.

G. Fasteners: Stainless-steel rivets or self-tapping screws.

H. Adhesive: Contact-type permanent adhesive, compatible with label and with substrate.

I. Duct Label Contents: Include identification of duct service using same designations or abbreviations as used on Drawings, duct size, and an arrow indicating flow direction.

1. Flow-Direction Arrows: Integral with duct system service lettering to accommodate both directions, or as separate unit on each duct label to indicate flow direction.

2. Lettering Size: At least 1-1/2 inches high.



2.5 VALVE TAGS

A. Valve Tags: Stamped or engraved with 1/4-inch letters for piping system abbreviation and 1/2-inch numbers.

1. Tag Material: Brass, 0.032-inch minimum thickness, and having predrilled or stamped holes for attachment hardware.

2. Fasteners: Brass wire-link or beaded chain; or S-hook.

B. Valve Schedules: For each piping system, on 8-1/2-by-11-inch bond paper. Tabulate valve number, piping system, system abbreviation (as shown on valve tag), location of valve (room or space), normal-operating position (open, closed, or modulating), and variations for identification. Mark valves for emergency shutoff and similar special uses.

1. Valve-tag schedule shall be included in operation and maintenance data.

2.6 WARNING TAGS

A. Warning Tags: Preprinted or partially preprinted, accident-prevention tags, of plasticized card stock with matte finish suitable for writing.

1. Size: 3 by 5-1/4 inches minimum. 2. Fasteners: Brass grommet and wire Reinforced grommet and wire or string. 3. Nomenclature: Large-size primary caption such as "DANGER," "CAUTION," or "DO NOT

OPERATE." 4. Color: Yellow background with black lettering.

PART 3 - EXECUTION

3.1 PREPARATION

A. Clean piping and equipment surfaces of substances that could impair bond of identification devices, including dirt, oil, grease, release agents, and incompatible primers, paints, and encapsulants.

3.2 EQUIPMENT LABEL INSTALLATION

A. Install or permanently fasten labels on each major item of mechanical equipment.

B. Locate equipment labels where accessible and visible.

3.3 PIPE LABEL INSTALLATION

A. Piping Color-Coding: Painting of piping is specified in Division 09 Section "Interior Painting [High-Performance Coatings]."



B. Locate pipe labels where piping is exposed or above accessible ceilings in finished spaces; machine rooms; accessible maintenance spaces such as shafts, tunnels, and plenums; and exterior exposed locations as follows:

1. Near each valve and control device. 2. Near each branch connection, excluding short takeoffs for fixtures and terminal units.

Where flow pattern is not obvious, mark each pipe at branch. 3. Near penetrations through walls, floors, ceilings, and inaccessible enclosures. 4. At access doors, manholes, and similar access points that permit view of concealed

piping. 5. Near major equipment items and other points of origination and termination. 6. Spaced at maximum intervals of 50 feet (15 m) along each run. Reduce intervals to 25

feet (7.6 m) in areas of congested piping and equipment. 7. On piping above removable acoustical ceilings. Omit intermediately spaced labels.

C. Pipe Label Color Schedule:

1. Chilled-Water Piping:

a. Background Color: Green. b. Letter Color: Black.

2. Condenser-Water Piping:

a. Background Color: Green. b. Letter Color: Black.

3. Heating Water Piping:

a. Background Color: Yellow. b. Letter Color: Black.

4. Refrigerant Piping:


5. Low-Pressure Steam Piping:


6. High-Pressure Steam Piping:


7. Steam Condensate Piping:




3.4 DUCT LABEL INSTALLATION

A. Install plastic-laminated or self-adhesive duct labels with permanent adhesive on air ducts in the following color codes:

1. Blue: For cold-air supply ducts. 2. Yellow: For hot-air supply ducts. 3. Green: For exhaust-, outside-, relief-, return-, and mixed-air ducts. 4. ASME A13.1 Colors and Designs: For hazardous material exhaust.

B. Locate labels near points where ducts enter into concealed spaces and at maximum intervals of 50 feet in each space where ducts are exposed or concealed by removable ceiling system.

3.5 VALVE-TAG INSTALLATION

A. Install tags on valves and control devices in piping systems, except check valves; valves within factory-fabricated equipment units; shutoff valves; faucets; convenience and lawn-watering hose connections; and HVAC terminal devices and similar roughing-in connections of end-use fixtures and units. List tagged valves in a valve schedule.

B. Valve-Tag Application Schedule: Tag valves according to size, shape, and color scheme and with captions similar to those indicated in the following subparagraphs:

1. Valve-Tag Size and Shape:

a. Gas: 1-1/2 inches, round.

b. Chilled Water: 1-1/2 inches (38 mm), round. c. Condenser Water: 1-1/2 inches (38 mm), round. d. Refrigerant: 1-1/2 inches (38 mm), round. e. Hot Water: 1-1/2 inches (38 mm), round. f. Gas: 1-1/2 inches (38 mm), round. g. Low-Pressure Steam: 1-1/2 inches (38 mm), round. h. High-Pressure Steam: 1-1/2 inches (38 mm), round. i. Steam Condensate: 1-1/2 inches (38 mm), round .

2. Valve-Tag Color:

a. Chilled Water: Natural. b. Condenser Water: Natural. c. Refrigerant: Natural. d. Hot Water: Natural. e. Gas: Natural. f. Low-Pressure Steam: Natural. g. High-Pressure Steam: Natural. h. Steam Condensate: Natural.

3. Letter Color:



a. Chilled Water: Black. b. Condenser Water: Black. c. Refrigerant: Black. d. Hot Water: Black. e. Gas: Black. f. Low-Pressure Steam: Black. g. High-Pressure Steam: Black. h. Steam Condensate: Black.

3.6 WARNING-TAG INSTALLATION

A. Write required message on, and attach warning tags to, equipment and other items where required.



TESTING, ADJUSTING, AND BALANCING FOR HVAC 230593 - 1

SECTION 230593 - TESTING, ADJUSTING, AND BALANCING FOR HVAC

PART 1 - GENERAL



1.2 SUMMARY


1. Balancing Air Systems:

a. Constant-volume air systems. b. Variable-air-volume systems.

2. Balancing Hydronic Piping Systems:

a. Constant-flow hydronic systems. b. Variable-flow hydronic systems. c. Primary-secondary hydronic systems.

1.3 DEFINITIONS

A. AABC: Associated Air Balance Council.

B. NEBB: National Environmental Balancing Bureau.

C. TAB: Testing, adjusting, and balancing.

D. TABB: Testing, Adjusting, and Balancing Bureau.

E. TAB Specialist: An entity engaged to perform TAB Work.

1.4 SUBMITTALS

A. Qualification Data: Within 15 days of Contractor's Notice to Proceed, submit documentation that the TAB contractor and this Project's TAB team members meet the qualifications specified in "Quality Assurance" Article.

B. Certified TAB reports.

C. Sample report forms.



D. Instrument calibration reports, to include the following:

1. Instrument type and make. 2. Serial number. 3. Application. 4. Dates of use. 5. Dates of calibration.


A. TAB Contractor Qualifications: Engage a TAB entity certified by AABC NEBB or TABB.

1. TAB Field Supervisor: Employee of the TAB contractor and certified by AABC NEBB or TABB.

B. TAB Report Forms: Use standard TAB contractor's forms approved by Design Engineer.

C. Instrumentation Type, Quantity, Accuracy, and Calibration: As described in ASHRAE 111, Section 5, "Instrumentation."

D. ASHRAE Compliance: Applicable requirements in ASHRAE 62.1, Section 7.2.2 - "Air Balancing."

E. ASHRAE/IESNA Compliance: Applicable requirements in ASHRAE/IESNA 90.1, Section 6.7.2.3 - "System Balancing."

1.6 PROJECT CONDITIONS

A. Full Owner Occupancy: Owner will occupy the site and existing building during entire TAB period. Cooperate with Owner during TAB operations to minimize conflicts with Owner's operations.

1.7 COORDINATION

A. Notice: Provide seven days' advance notice for each test. Include scheduled test dates and times.

B. Perform TAB after leakage and pressure tests on air and water distribution systems have been satisfactorily completed.



PART 2 - PRODUCTS (Not Applicable)

PART 3 - EXECUTION

3.1 TAB SPECIALISTS

A. Subject to compliance with requirements, engage one of the following:

1. BTC Sevices, Inc. 2. Certified Test & Balance. 3. QT&B Inc.

3.2 EXAMINATION

A. Examine the Contract Documents to become familiar with Project requirements and to discover conditions in systems' designs that may preclude proper TAB of systems and equipment.

B. Examine systems for installed balancing devices, such as test ports, gage cocks, thermometer wells, flow-control devices, balancing valves and fittings, and manual volume dampers. Verify that locations of these balancing devices are accessible.

C. Examine the approved submittals for HVAC systems and equipment.

D. Examine design data including HVAC system descriptions, statements of design assumptions for environmental conditions and systems' output, and statements of philosophies and assumptions about HVAC system and equipment controls.

E. Examine ceiling plenums and underfloor air plenums used for supply, return, or relief air to verify that they meet the leakage class of connected ducts as specified in Division 23 Section "Metal Ducts" and are properly separated from adjacent areas. Verify that penetrations in plenum walls are sealed and fire-stopped if required.

F. Examine equipment performance data including fan and pump curves.

1. Relate performance data to Project conditions and requirements, including system effects that can create undesired or unpredicted conditions that cause reduced capacities in all or part of a system.

2. Calculate system-effect factors to reduce performance ratings of HVAC equipment when installed under conditions different from the conditions used to rate equipment performance. To calculate system effects for air systems, use tables and charts found in AMCA 201, "Fans and Systems," or in SMACNA's "HVAC Systems - Duct Design." Compare results with the design data and installed conditions.

G. Examine system and equipment installations and verify that field quality-control testing, cleaning, and adjusting specified in individual Sections have been performed.

H. Examine test reports specified in individual system and equipment Sections.



I. Examine HVAC equipment and filters and verify that bearings are greased, belts are aligned and tight, and equipment with functioning controls is ready for operation.

J. Examine terminal units, such as variable-air-volume boxes, and verify that they are accessible and their controls are connected and functioning.

K. Examine strainers. Verify that startup screens are replaced by permanent screens with indicated perforations.

L. Examine three-way valves for proper installation for their intended function of diverting or mixing fluid flows.

M. Examine heat-transfer coils for correct piping connections and for clean and straight fins.

N. Examine system pumps to ensure absence of entrained air in the suction piping.

O. Examine operating safety interlocks and controls on HVAC equipment.

P. Report deficiencies discovered before and during performance of TAB procedures. Observe and record system reactions to changes in conditions. Record default set points if different from indicated values

3.3 PREPARATION

A. Prepare a TAB plan that includes strategies and step-by-step procedures.

B. Complete system-readiness checks and prepare reports. Verify the following:

1. Permanent electrical-power wiring is complete. 2. Hydronic systems are filled, clean, and free of air. 3. Automatic temperature-control systems are operational. 4. Equipment and duct access doors are securely closed. 5. Balance, smoke, and fire dampers are open. 6. Isolating and balancing valves are open and control valves are operational. 7. Ceilings are installed in critical areas where air-pattern adjustments are required and

access to balancing devices is provided. 8. Windows and doors can be closed so indicated conditions for system operations can be

met.

3.4 GENERAL PROCEDURES FOR TESTING AND BALANCING

A. Perform testing and balancing procedures on each system according to the procedures contained in AABC's "National Standards for Total System Balance" or NEBB's "Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems" and in this Section.

1. Comply with requirements in ASHRAE 62.1-2004, Section 7.2.2, "Air Balancing."

B. Cut insulation, ducts, pipes, and equipment cabinets for installation of test probes to the minimum extent necessary for TAB procedures.



1. After testing and balancing, patch probe holes in ducts with same material and thickness as used to construct ducts.

2. After testing and balancing, install test ports and duct access doors that comply with requirements in Division 23 Section "Air Duct Accessories."

3. Install and join new insulation that matches removed materials. Restore insulation, coverings, vapor barrier, and finish according to Division 23 Section "HVAC Insulation."

C. Mark equipment and balancing devices, including damper-control positions, valve position indicators, fan-speed-control levers, and similar controls and devices, with paint or other suitable, permanent identification material to show final settings.

D. Take and report testing and balancing measurements in inch-pound (IP) units.

3.5 GENERAL PROCEDURES FOR BALANCING AIR SYSTEMS

A. Prepare test reports for both fans and outlets. Obtain manufacturer's outlet factors and recommended testing procedures. Crosscheck the summation of required outlet volumes with required fan volumes.

B. Prepare schematic diagrams of systems' "as-built" duct layouts.

C. For variable-air-volume systems, develop a plan to simulate diversity.

D. Determine the best locations in main and branch ducts for accurate duct-airflow measurements.

E. Check airflow patterns from the outdoor-air louvers and dampers and the return- and exhaust-air dampers through the supply-fan discharge and mixing dampers.

F. Locate start-stop and disconnect switches, electrical interlocks, and motor starters.

G. Verify that motor starters are equipped with properly sized thermal protection.

H. Check dampers for proper position to achieve desired airflow path.

I. Check for airflow blockages.

J. Check condensate drains for proper connections and functioning.

K. Check for proper sealing of air-handling-unit components.

L. Verify that air duct system is sealed as specified in Division 23 Section "Metal Ducts."

3.6 PROCEDURES FOR CONSTANT-VOLUME AIR SYSTEMS

A. Adjust fans to deliver total indicated airflows within the maximum allowable fan speed listed by fan manufacturer.

1. Measure total airflow.



a. Where sufficient space in ducts is unavailable for Pitot-tube traverse measurements, measure airflow at terminal outlets and inlets and calculate the total airflow.

2. Measure fan static pressures as follows to determine actual static pressure:

a. Measure outlet static pressure as far downstream from the fan as practical and upstream from restrictions in ducts such as elbows and transitions.

b. Measure static pressure directly at the fan outlet or through the flexible connection. c. Measure inlet static pressure of single-inlet fans in the inlet duct as near the fan as

possible, upstream from the flexible connection, and downstream from duct restrictions.

d. Measure inlet static pressure of double-inlet fans through the wall of the plenum that houses the fan.

3. Measure static pressure across each component that makes up an air-handling unit, rooftop unit, and other air-handling and -treating equipment.

a. Report the cleanliness status of filters and the time static pressures are measured.

4. Measure static pressures entering and leaving other devices, such as sound traps, heat-recovery equipment, and air washers, under final balanced conditions.

5. Review Record Documents to determine variations in design static pressures versus actual static pressures. Calculate actual system-effect factors. Recommend adjustments to accommodate actual conditions.

6. Obtain approval from Design Engineer for adjustment of fan speed higher or lower than indicated speed. Comply with requirements in Division 23 Sections for air-handling units for adjustment of fans, belts, and pulley sizes to achieve indicated air-handling-unit performance.

7. Do not make fan-speed adjustments that result in motor overload. Consult equipment manufacturers about fan-speed safety factors. Modulate dampers and measure fan-motor amperage to ensure that no overload will occur. Measure amperage in full-cooling, full-heating, economizer, and any other operating mode to determine the maximum required brake horsepower.

B. Adjust volume dampers for main duct, submain ducts, and major branch ducts to indicated airflows within specified tolerances.

1. Measure airflow of submain and branch ducts.

a. Where sufficient space in submain and branch ducts is unavailable for Pitot-tube traverse measurements, measure airflow at terminal outlets and inlets and calculate the total airflow for that zone.

2. Measure static pressure at a point downstream from the balancing damper, and adjust volume dampers until the proper static pressure is achieved.

3. Remeasure each submain and branch duct after all have been adjusted. Continue to adjust submain and branch ducts to indicated airflows within specified tolerances.

C. Measure air outlets and inlets without making adjustments.



1. Measure terminal outlets using a direct-reading hood or outlet manufacturer's written instructions and calculating factors.

D. Adjust air outlets and inlets for each space to indicated airflows within specified tolerances of indicated values. Make adjustments using branch volume dampers rather than extractors and the dampers at air terminals.

1. Adjust each outlet in same room or space to within specified tolerances of indicated quantities without generating noise levels above the limitations prescribed by the Contract Documents.

2. Adjust patterns of adjustable outlets for proper distribution without drafts.

3.7 PROCEDURES FOR VARIABLE-AIR-VOLUME SYSTEMS

A. Compensating for Diversity: When the total airflow of all terminal units is more than the indicated airflow of the fan, place a selected number of terminal units at a minimum set-point airflow with the remainder at maximum-airflow condition until the total airflow of the terminal units equals the indicated airflow of the fan. Select the reduced-airflow terminal units so they are distributed evenly among the branch ducts.

B. Pressure-Independent, Variable-Air-Volume Systems: After the fan systems have been adjusted, adjust the variable-air-volume systems as follows:

1. Set outdoor-air dampers at minimum, and set return- and exhaust-air dampers at a position that simulates full-cooling load.

2. Select the terminal unit that is most critical to the supply-fan airflow and static pressure. Measure static pressure. Adjust system static pressure so the entering static pressure for the critical terminal unit is not less than the sum of the terminal-unit manufacturer's recommended minimum inlet static pressure plus the static pressure needed to overcome terminal-unit discharge system losses.

3. Measure total system airflow. Adjust to within indicated airflow. 4. Set terminal units at maximum airflow and adjust controller or regulator to deliver the

designed maximum airflow. Use terminal-unit manufacturer's written instructions to make this adjustment. When total airflow is correct, balance the air outlets downstream from terminal units the same as described for constant-volume air systems.

5. Set terminal units at minimum airflow and adjust controller or regulator to deliver the designed minimum airflow. Check air outlets for a proportional reduction in airflow the same as described for constant-volume air systems.

a. If air outlets are out of balance at minimum airflow, report the condition but leave outlets balanced for maximum airflow.

6. Remeasure the return airflow to the fan while operating at maximum return airflow and minimum outdoor airflow.

a. Adjust the fan and balance the return-air ducts and inlets the same as described for constant-volume air systems.

7. Measure static pressure at the most critical terminal unit and adjust the static-pressure controller at the main supply-air sensing station to ensure that adequate static pressure is maintained at the most critical unit.



8. Record final fan-performance data.

3.8 GENERAL PROCEDURES FOR HYDRONIC SYSTEMS

A. Prepare test reports with pertinent design data, and number in sequence starting at pump to end of system. Check the sum of branch-circuit flows against the approved pump flow rate. Correct variations that exceed plus or minus 5 percent.

B. Prepare schematic diagrams of systems' "as-built" piping layouts.

C. Prepare hydronic systems for testing and balancing according to the following, in addition to the general preparation procedures specified above:

1. Open all manual valves for maximum flow. 2. Check liquid level in expansion tank. 3. Check makeup water-station pressure gage for adequate pressure for highest vent. 4. Check flow-control valves for specified sequence of operation, and set at indicated flow. 5. Set differential-pressure control valves at the specified differential pressure. Do not set at

fully closed position when pump is positive-displacement type unless several terminal valves are kept open.

6. Set system controls so automatic valves are wide open to heat exchangers. 7. Check pump-motor load. If motor is overloaded, throttle main flow-balancing device so

motor nameplate rating is not exceeded. 8. Check air vents for a forceful liquid flow exiting from vents when manually operated.

3.9 PROCEDURES FOR CONSTANT-FLOW HYDRONIC SYSTEMS

A. Measure water flow at pumps. Use the following procedures except for positive-displacement pumps:

1. Verify impeller size by operating the pump with the discharge valve closed. Read pressure differential across the pump. Convert pressure to head and correct for differences in gage heights. Note the point on manufacturer's pump curve at zero flow and verify that the pump has the intended impeller size.

a. If impeller sizes must be adjusted to achieve pump performance, obtain approval from Architect and comply with requirements in Division 23 Section "Hydronic Pumps."

2. Check system resistance. With all valves open, read pressure differential across the pump and mark pump manufacturer's head-capacity curve. Adjust pump discharge valve until indicated water flow is achieved.

a. Monitor motor performance during procedures and do not operate motors in overload conditions.

3. Verify pump-motor brake horsepower. Calculate the intended brake horsepower for the system based on pump manufacturer's performance data. Compare calculated brake horsepower with nameplate data on the pump motor. Report conditions where actual amperage exceeds motor nameplate amperage.



4. Report flow rates that are not within plus or minus 10 percent of design.

B. Measure flow at all automatic flow control valves to verify that valves are functioning as designed.

C. Measure flow at all pressure-independent characterized control valves, with valves in fully open position, to verify that valves are functioning as designed.

D. Set calibrated balancing valves, if installed, at calculated presettings.

E. Measure flow at all stations and adjust, where necessary, to obtain first balance.

1. System components that have Cv rating or an accurately cataloged flow-pressure-drop relationship may be used as a flow-indicating device.

F. Measure flow at main balancing station and set main balancing device to achieve flow that is 5 percent greater than indicated flow.

G. Adjust balancing stations to within specified tolerances of indicated flow rate as follows:

1. Determine the balancing station with the highest percentage over indicated flow. 2. Adjust each station in turn, beginning with the station with the highest percentage over

indicated flow and proceeding to the station with the lowest percentage over indicated flow.

3. Record settings and mark balancing devices.

H. Measure pump flow rate and make final measurements of pump amperage, voltage, rpm, pump heads, and systems' pressures and temperatures including outdoor-air temperature.

I. Measure the differential-pressure-control-valve settings existing at the conclusion of balancing.

J. Check settings and operation of each safety valve. Record settings.

3.10 PROCEDURES FOR VARIABLE-FLOW HYDRONIC SYSTEMS

A. Balance systems with automatic two- and three-way control valves by setting systems at maximum flow through heat-exchange terminals and proceed as specified above for hydronic systems.

3.11 PROCEDURES FOR PRIMARY-SECONDARY HYDRONIC SYSTEMS

A. Balance the primary circuit flow first and then balance the secondary circuits.

3.12 PROCEDURES FOR HEAT EXCHANGERS

A. Measure water flow through all circuits.

B. Adjust water flow to within specified tolerances.



C. Measure inlet and outlet water temperatures.

D. Measure inlet steam pressure.

E. Check settings and operation of safety and relief valves. Record settings.

3.13 PROCEDURES FOR MOTORS

A. Motors, 1/2 HP and Larger: Test at final balanced conditions and record the following data:

1. Manufacturer's name, model number, and serial number. 2. Motor horsepower rating. 3. Motor rpm. 4. Efficiency rating. 5. Nameplate and measured voltage, each phase. 6. Nameplate and measured amperage, each phase. 7. Starter thermal-protection-element rating.

B. Motors Driven by Variable-Frequency Controllers: Test for proper operation at speeds varying from minimum to maximum. Test the manual bypass of the controller to prove proper operation. Record observations including name of controller manufacturer, model number, serial number, and nameplate data.

3.14 PROCEDURES FOR CHILLERS

A. Balance water flow through each evaporator and condenser to within specified tolerances of indicated flow with all pumps operating. With only one chiller operating in a multiple chiller installation, do not exceed the flow for the maximum tube velocity recommended by the chiller manufacturer. Measure and record the following data with each chiller operating at design conditions:

1. Evaporator-water entering and leaving temperatures, pressure drop, and water flow. 2. For water-cooled chillers, condenser-water entering and leaving temperatures, pressure

drop, and water flow. 3. Evaporator and condenser refrigerant temperatures and pressures, using instruments

furnished by chiller manufacturer. 4. Power factor if factory-installed instrumentation is furnished for measuring kilowatts. 5. Kilowatt input if factory-installed instrumentation is furnished for measuring kilowatts. 6. Capacity: Calculate in tons of cooling. 7. For air-cooled chillers, verify condenser-fan rotation and record fan and motor data

including number of fans and entering- and leaving-air temperatures.

3.15 PROCEDURES FOR BOILERS

A. Hydronic Boilers: Measure and record entering- and leaving-water temperatures and water flow.



3.16 PROCEDURES FOR HEAT-TRANSFER COILS

A. Measure, adjust, and record the following data for each water coil:

1. Entering- and leaving-water temperature. 2. Water flow rate. 3. Water pressure drop. 4. Dry-bulb temperature of entering and leaving air. 5. Wet-bulb temperature of entering and leaving air for cooling coils. 6. Airflow. 7. Air pressure drop.

3.17 TOLERANCES

A. Set HVAC system's air flow rates and water flow rates within the following tolerances:

1. Supply, Return, and Exhaust Fans and Equipment with Fans: Plus or minus 10 percent. 2. Air Outlets and Inlets: Plus or minus 10 percent. 3. Heating-Water Flow Rate: Plus or minus 10 percent. 4. Cooling-Water Flow Rate: Plus or minus 10 percent.

3.18 REPORTING

A. Initial Construction-Phase Report: Based on examination of the Contract Documents as specified in "Examination" Article, prepare a report on the adequacy of design for systems' balancing devices. Recommend changes and additions to systems' balancing devices to facilitate proper performance measuring and balancing. Recommend changes and additions to HVAC systems and general construction to allow access for performance measuring and balancing devices.

B. Status Reports: Prepare progress reports to describe completed procedures, procedures in progress, and scheduled procedures. Include a list of deficiencies and problems found in systems being tested and balanced. Prepare a separate report for each system and each building floor for systems serving multiple floors.

3.19 FINAL REPORT

A. General: Prepare a certified written report; tabulate and divide the report into separate sections for tested systems and balanced systems.

1. Include a certification sheet at the front of the report's binder, signed and sealed by the certified testing and balancing engineer.

2. Include a list of instruments used for procedures, along with proof of calibration.

B. Final Report Contents: In addition to certified field-report data, include the following:

1. Pump curves. 2. Fan curves. 3. Manufacturers' test data.



4. Field test reports prepared by system and equipment installers. 5. Other information relative to equipment performance; do not include Shop Drawings and

product data.

C. General Report Data: In addition to form titles and entries, include the following data:

1. Title page. 2. Name and address of the TAB contractor. 3. Project name. 4. Project location. 5. Architect's name and address. 6. Engineer's name and address. 7. Contractor's name and address. 8. Report date. 9. Signature of TAB supervisor who certifies the report. 10. Table of Contents with the total number of pages defined for each section of the report.

Number each page in the report. 11. Summary of contents including the following:

a. Indicated versus final performance. b. Notable characteristics of systems. c. Description of system operation sequence if it varies from the Contract

Documents.

12. Nomenclature sheets for each item of equipment. 13. Data for terminal units, including manufacturer's name, type, size, and fittings. 14. Notes to explain why certain final data in the body of reports vary from indicated values. 15. Test conditions for fans and pump performance forms including the following:

a. Settings for outdoor-, return-, and exhaust-air dampers. b. Conditions of filters. c. Cooling coil, wet- and dry-bulb conditions. d. Face and bypass damper settings at coils. e. Fan drive settings including settings and percentage of maximum pitch diameter. f. Inlet vane settings for variable-air-volume systems. g. Settings for supply-air, static-pressure controller. h. Other system operating conditions that affect performance.

D. System Diagrams: Include schematic layouts of air and hydronic distribution systems. Present each system with single-line diagram and include the following:

1. Quantities of outdoor, supply, return, and exhaust airflows. 2. Water and steam flow rates. 3. Duct, outlet, and inlet sizes. 4. Pipe and valve sizes and locations. 5. Terminal units. 6. Balancing stations. 7. Position of balancing devices.

E. Air-Handling-Unit Test Reports: For air-handling units with coils, include the following:

1. Unit Data:



a. Unit identification. b. Location. c. Make and type. d. Model number and unit size. e. Manufacturer's serial number. f. Unit arrangement and class. g. Discharge arrangement. h. Sheave make, size in inches, and bore. i. Center-to-center dimensions of sheave, and amount of adjustments in inches. j. Number, make, and size of belts. k. Number, type, and size of filters.

2. Motor Data:

a. Motor make, and frame type and size. b. Horsepower and rpm. c. Volts, phase, and hertz. d. Full-load amperage and service factor. e. Sheave make, size in inches, and bore. f. Center-to-center dimensions of sheave, and amount of adjustments in inches.

3. Test Data (Indicated and Actual Values):

a. Total air flow rate in cfm. b. Total system static pressure in inches wg. c. Fan rpm. d. Discharge static pressure in inches wg. e. Filter static-pressure differential in inches wg. f. Preheat-coil static-pressure differential in inches wg. g. Cooling-coil static-pressure differential in inches wg. h. Heating-coil static-pressure differential in inches wg. i. Outdoor airflow in cfm. j. Return airflow in cfm. k. Outdoor-air damper position. l. Return-air damper position. m. Vortex damper position.

F. Apparatus-Coil Test Reports:

1. Coil Data:

a. System identification. b. Location. c. Coil type. d. Number of rows. e. Fin spacing in fins per inch (mm) o.c. f. Make and model number. g. Face area in sq. ft. (sq. m). h. Tube size in NPS (DN). i. Tube and fin materials. j. Circuiting arrangement.




a. Air flow rate in cfm (L/s). b. Average face velocity in fpm (m/s). c. Air pressure drop in inches wg (Pa). d. Outdoor-air, wet- and dry-bulb temperatures in deg F (deg C). e. Return-air, wet- and dry-bulb temperatures in deg F (deg C). f. Entering-air, wet- and dry-bulb temperatures in deg F (deg C). g. Leaving-air, wet- and dry-bulb temperatures in deg F (deg C). h. Water flow rate in gpm (L/s). i. Water pressure differential in feet of head or psig (kPa). j. Entering-water temperature in deg F (deg C). k. Leaving-water temperature in deg F (deg C).

G. Fan Test Reports: For supply, return, and exhaust fans, include the following:

1. Fan Data:

a. System identification. b. Location. c. Make and type. d. Model number and size. e. Manufacturer's serial number. f. Arrangement and class. g. Sheave make, size in inches, and bore. h. Center-to-center dimensions of sheave, and amount of adjustments in inches.

2. Motor Data:

a. Motor make, and frame type and size. b. Horsepower and rpm. c. Volts, phase, and hertz. d. Full-load amperage and service factor. e. Sheave make, size in inches, and bore. f. Center-to-center dimensions of sheave, and amount of adjustments in inches. g. Number, make, and size of belts.


a. Total airflow rate in cfm. b. Total system static pressure in inches wg. c. Fan rpm. d. Discharge static pressure in inches wg. e. Suction static pressure in inches wg.

H. Round, Flat-Oval, and Rectangular Duct Traverse Reports: Include a diagram with a grid representing the duct cross-section and record the following:

1. Report Data:

a. System and air-handling-unit number. b. Location and zone. c. Traverse air temperature in deg F. d. Duct static pressure in inches wg.



e. Duct size in inches. f. Duct area in sq. ft.. g. Indicated air flow rate in cfm. h. Indicated velocity in fpm. i. Actual air flow rate in cfm. j. Actual average velocity in fpm. k. Barometric pressure in psig.

I. Air-Terminal-Device Reports:

1. Unit Data:

a. System and air-handling unit identification. b. Location and zone. c. Apparatus used for test. d. Area served. e. Make. f. Number from system diagram. g. Type and model number. h. Size. i. Effective area in sq. ft. (sq. m).


a. Air flow rate in cfm (L/s). b. Air velocity in fpm (m/s). c. Preliminary air flow rate as needed in cfm (L/s). d. Preliminary velocity as needed in fpm (m/s). e. Final air flow rate in cfm (L/s). f. Final velocity in fpm (m/s). g. Space temperature in deg F (deg C).

J. System-Coil Reports: For reheat coils and water coils of terminal units, include the following:

1. Unit Data:

a. System and air-handling-unit identification. b. Location and zone. c. Room or riser served. d. Coil make and size. e. Flowmeter type.


a. Air flow rate in cfm (L/s). b. Entering-water temperature in deg F (deg C). c. Leaving-water temperature in deg F (deg C). d. Water pressure drop in feet of head or psig (kPa). e. Entering-air temperature in deg F (deg C). f. Leaving-air temperature in deg F (deg C).



K. Pump Test Reports: Calculate impeller size by plotting the shutoff head on pump curves and include the following:

1. Unit Data:

a. Unit identification. b. Location. c. Service. d. Make and size. e. Model number and serial number. f. Water flow rate in gpm. g. Water pressure differential in feet of head or psig. h. Required net positive suction head in feet of head or psig. i. Pump rpm. j. Impeller diameter in inches. k. Motor make and frame size. l. Motor horsepower and rpm. m. Voltage at each connection. n. Amperage for each phase. o. Full-load amperage and service factor. p. Seal type.


a. Static head in feet of head or psig. b. Pump shutoff pressure in feet of head or psig. c. Actual impeller size in inches. d. Full-open flow rate in gpm. e. Full-open pressure in feet of head or psig. f. Final discharge pressure in feet of head or psig. g. Final suction pressure in feet of head or psig. h. Final total pressure in feet of head or psig. i. Final water flow rate in gpm. j. Voltage at each connection. k. Amperage for each phase.

L. Instrument Calibration Reports:

1. Report Data:

a. Instrument type and make. b. Serial number. c. Application. d. Dates of use. e. Dates of calibration.

3.20 INSPECTIONS

A. Initial Inspection:



1. After testing and balancing are complete, operate each system and randomly check measurements to verify that the system is operating according to the final test and balance readings documented in the final report.

2. Check the following for each system:

a. Measure airflow of at least 10 percent of air outlets. b. Measure room temperature at each thermostat/temperature sensor. Compare the

reading to the set point. c. Verify that balancing devices are marked with final balance position. d. Note deviations from the Contract Documents in the final report.

B. Final Inspection:

1. After initial inspection is complete and documentation by random checks verifies that testing and balancing are complete and accurately documented in the final report, request that a final inspection be made by Design Engineer.

2. The TAB contractor's test and balance engineer shall conduct the inspection in the presence of Design Engineer.

3. The Design Engineer shall randomly select measurements, documented in the final report, to be rechecked. Rechecking shall be limited to either 10 percent of the total measurements recorded or the extent of measurements that can be accomplished in a normal 8-hour business day.

4. If rechecks yield measurements that differ from the measurements documented in the final report by more than the tolerances allowed, the measurements shall be noted as "FAILED."

5. If the number of "FAILED" measurements is greater than 10 percent of the total measurements checked during the final inspection, the testing and balancing shall be considered incomplete and shall be rejected.

C. TAB Work will be considered defective if it does not pass final inspections. If TAB Work fails, proceed as follows:

1. Recheck all measurements and make adjustments. Revise the final report and balancing device settings to include all changes; resubmit the final report and request a second final inspection.

2. If the second final inspection also fails, Owner may contract the services of another TAB contractor to complete TAB Work according to the Contract Documents and deduct the cost of the services from the original TAB contractor's final payment.

D. Prepare test and inspection reports.

3.21 ADDITIONAL TESTS

A. Within 90 days of completing TAB, perform additional TAB to verify that balanced conditions are being maintained throughout and to correct unusual conditions.

B. Seasonal Periods: If initial TAB procedures were not performed during near-peak summer and winter conditions, perform additional TAB during near-peak summer and winter conditions.



HVAC PIPING INSULATION 230719 - 1

SECTION 230719 - HVAC PIPING INSULATION

PART 1 - GENERAL



1.2 SUMMARY

A. Section includes insulating the following HVAC piping systems:

1. Condensate drain piping, indoors. 2. Chilled-water and brine piping, indoors and outdoors. 3. Heating hot-water piping, indoors. 4. Refrigerant suction and hot-gas piping, indoors and outdoors.


A. Product Data: For each type of product indicated. Include thermal conductivity, water-vapor permeance thickness, and jackets (both factory and field applied if any).

B. Shop Drawings: Include plans, elevations, sections, details, and attachments to other work.

1. Detail application of protective shields, saddles, and inserts at hangers for each type of insulation and hanger.

2. Detail attachment and covering of heat tracing inside insulation. 3. Detail insulation application at pipe expansion joints for each type of insulation. 4. Detail insulation application at elbows, fittings, flanges, valves, and specialties for each

type of insulation. 5. Detail removable insulation at piping specialties. 6. Detail application of field-applied jackets. 7. Detail application at linkages of control devices.


A. Qualification Data: For qualified Installer.

B. Material Test Reports: From a qualified testing agency acceptable to authorities having jurisdiction indicating, interpreting, and certifying test results for compliance of insulation materials, sealers, attachments, cements, and jackets, with requirements indicated. Include dates of tests and test methods employed.

C. Field quality-control reports.




A. Installer Qualifications: Skilled mechanics who have successfully completed an apprenticeship program or another craft training program certified by the Department of Labor, Bureau of Apprenticeship and Training.

B. Surface-Burning Characteristics: For insulation and related materials, as determined by testing identical products according to ASTM E 84, by a testing and inspecting agency acceptable to authorities having jurisdiction. Factory label insulation and jacket materials and adhesive, mastic, tapes, and cement material containers, with appropriate markings of applicable testing agency.

1. Insulation Installed Indoors: Flame-spread index of 25 or less, and smoke-developed index of 50 or less.

2. Insulation Installed Outdoors: Flame-spread index of 75 or less, and smoke-developed index of 150 or less.


A. Packaging: Insulation material containers shall be marked by manufacturer with appropriate ASTM standard designation, type and grade, and maximum use temperature.

1.7 COORDINATION

A. Coordinate sizes and locations of supports, hangers, and insulation shields specified in Division 23 Section "Hangers and Supports for HVAC Piping and Equipment."

B. Coordinate clearance requirements with piping Installer for piping insulation application. Before preparing piping Shop Drawings, establish and maintain clearance requirements for installation of insulation and field-applied jackets and finishes and for space required for maintenance.

C. Coordinate installation and testing of heat tracing.

1.8 SCHEDULING

A. Schedule insulation application after pressure testing systems and, where required, after installing and testing heat tracing. Insulation application may begin on segments that have satisfactory test results.

B. Complete installation and concealment of plastic materials as rapidly as possible in each area of construction.



PART 2 - PRODUCTS

2.1 INSULATION MATERIALS

A. Comply with requirements in "Piping Insulation Schedule, General," "Indoor Piping Insulation Schedule," "Outdoor, Aboveground Piping Insulation Schedule," and "Outdoor, Underground Piping Insulation Schedule" articles for where insulating materials shall be applied.

B. Products shall not contain asbestos, lead, mercury, or mercury compounds.

C. Products that come in contact with stainless steel shall have a leachable chloride content of less than 50 ppm when tested according to ASTM C 871.

D. Insulation materials for use on austenitic stainless steel shall be qualified as acceptable according to ASTM C 795.

E. Foam insulation materials shall not use CFC or HCFC blowing agents in the manufacturing process.

F. Calcium Silicate:

1. Products: Subject to compliance with requirements, provide the following:

a. Industrial Insulation Group (IIG); Thermo-12 Gold.

2. Preformed Pipe Sections: Flat-, curved-, and grooved-block sections of noncombustible, inorganic, hydrous calcium silicate with a non-asbestos fibrous reinforcement. Comply with ASTM C 533, Type I.

3. Flat-, curved-, and grooved-block sections of noncombustible, inorganic, hydrous calcium silicate with a non-asbestos fibrous reinforcement. Comply with ASTM C 533, Type I.

4. Prefabricated Fitting Covers: Comply with ASTM C 450 and ASTM C 585 for dimensions used in preforming insulation to cover valves, elbows, tees, and flanges.

G. Mineral-Fiber, Preformed Pipe Insulation:


a. Fibrex Insulations Inc.; Coreplus 1200. b. Johns Manville; Micro-Lok. c. Knauf Insulation; 1000-Degree Pipe Insulation. d. Manson Insulation Inc.; Alley-K. e. Owens Corning; Fiberglas Pipe Insulation.

2. Type I, 850 deg F (454 deg C) Materials: Mineral or glass fibers bonded with a thermosetting resin. Comply with ASTM C 547, Type I, Grade A, with factory-applied ASJ. Factory-applied jacket requirements are specified in "Factory-Applied Jackets" Article.



2.2 INSULATING CEMENTS

A. Mineral-Fiber Insulating Cement: Comply with ASTM C 195.


a. Ramco Insulation, Inc.; Super-Stik.

2.3 ADHESIVES

A. Materials shall be compatible with insulation materials, jackets, and substrates and for bonding insulation to itself and to surfaces to be insulated unless otherwise indicated.

B. Calcium Silicate Adhesive: Fibrous, sodium-silicate-based adhesive with a service temperature range of 50 to 800 deg F (10 to 427 deg C).


a. Childers Brand, Specialty Construction Brands, Inc., a business of H. B. Fuller Company; CP-97.

b. Eagle Bridges - Marathon Industries; 290. c. Foster Brand, Specialty Construction Brands, Inc., a business of H. B. Fuller

Company; 81-27. d. Mon-Eco Industries, Inc.; 22-30. e. Vimasco Corporation; 760.

2. For indoor applications, adhesive shall have a VOC content of 80 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

3. Adhesive shall comply with the testing and product requirements of the California Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers."

C. Mineral-Fiber Adhesive: Comply with MIL-A-3316C, Class 2, Grade A.




Company; 85-60/85-70. d. Mon-Eco Industries, Inc.; 22-25.



D. PVC Jacket Adhesive: Compatible with PVC jacket.




a. Dow Corning Corporation; 739, Dow Silicone. b. Johns Manville; Zeston Perma-Weld, CEEL-TITE Solvent Welding Adhesive. c. P.I.C. Plastics, Inc.; Welding Adhesive. d. Speedline Corporation; Polyco VP Adhesive.



2.4 MASTICS

A. Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL-PRF-19565C, Type II.

1. For indoor applications, use mastics that have a VOC content of 50 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

B. Vapor-Barrier Mastic: Water based; suitable for indoor use on below-ambient services.


a. Foster Brand, Specialty Construction Brands, Inc., a business of H. B. Fuller Company; 30-80/30-90.

b. Vimasco Corporation; 749.

2. Water-Vapor Permeance: ASTM E 96/E 96M, Procedure B, 0.013 perm (0.009 metric perm) at 43-mil (1.09-mm) dry film thickness.

3. Service Temperature Range: Minus 20 to plus 180 deg F (Minus 29 to plus 82 deg C). 4. Solids Content: ASTM D 1644, 58 percent by volume and 70 percent by weight. 5. Color: White.

2.5 SEALANTS

A. Joint Sealants:

1. Materials shall be compatible with insulation materials, jackets, and substrates. 2. Permanently flexible, elastomeric sealant. 3. Service Temperature Range: Minus 100 to plus 300 deg F (Minus 73 to plus 149 deg C). 4. Color: White or gray. 5. For indoor applications, sealants shall have a VOC content of 420 g/L or less when

calculated according to 40 CFR 59, Subpart D (EPA Method 24). 6. Sealants shall comply with the testing and product requirements of the California

Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers."

B. FSK and Metal Jacket Flashing Sealants:






Company; 95-44. d. Mon-Eco Industries, Inc.; 44-05.

2. Materials shall be compatible with insulation materials, jackets, and substrates. 3. Fire- and water-resistant, flexible, elastomeric sealant. 4. Service Temperature Range: Minus 40 to plus 250 deg F (Minus 40 to plus 121 deg C). 5. Color: Aluminum. 6. For indoor applications, sealants shall have a VOC content of 420 g/L or less when



C. ASJ Flashing Sealants, and Vinyl, PVDC, and PVC Jacket Flashing Sealants:



2. Materials shall be compatible with insulation materials, jackets, and substrates. 3. Fire- and water-resistant, flexible, elastomeric sealant. 4. Service Temperature Range: Minus 40 to plus 250 deg F (Minus 40 to plus 121 deg C). 5. Color: White. 6. For indoor applications, sealants shall have a VOC content of 420 g/L or less when



2.6 FIELD-APPLIED JACKETS

A. Field-applied jackets shall comply with ASTM C 921, Type I, unless otherwise indicated.

B. PVC Jacket: High-impact-resistant, UV-resistant PVC complying with ASTM D 1784, Class 16354-C; thickness as scheduled; roll stock ready for shop or field cutting and forming. Thickness is indicated in field-applied jacket schedules.


a. Johns Manville; Zeston. b. P.I.C. Plastics, Inc.; FG Series. c. Proto Corporation; LoSmoke. d. Speedline Corporation; SmokeSafe.



2. Adhesive: As recommended by jacket material manufacturer. 3. Color: Color-code jackets based on system. Color as selected by Architect. 4. Factory-fabricated fitting covers to match jacket if available; otherwise, field fabricate.

a. Shapes: 45- and 90-degree, short- and long-radius elbows, tees, valves, flanges, unions, reducers, end caps, soil-pipe hubs, traps, mechanical joints, and P-trap and supply covers for lavatories.

2.7 TAPES

A. PVC Tape: White vapor-retarder tape matching field-applied PVC jacket with acrylic adhesive; suitable for indoor and outdoor applications.


a. ABI, Ideal Tape Division; 370 White PVC tape. b. Compac Corporation; 130. c. Venture Tape; 1506 CW NS.

2. Width: 2 inches (50 mm). 3. Thickness: 6 mils (0.15 mm). 4. Adhesion: 64 ounces force/inch (0.7 N/mm) in width. 5. Elongation: 500 percent. 6. Tensile Strength: 18 lbf/inch (3.3 N/mm) in width.

B. Aluminum-Foil Tape: Vapor-retarder tape with acrylic adhesive.


a. ABI, Ideal Tape Division; 488 AWF. b. Avery Dennison Corporation, Specialty Tapes Division; Fasson 0800. c. Compac Corporation; 120. d. Venture Tape; 3520 CW.

2. Width: 2 inches (50 mm). 3. Thickness: 3.7 mils (0.093 mm). 4. Adhesion: 100 ounces force/inch (1.1 N/mm) in width. 5. Elongation: 5 percent. 6. Tensile Strength: 34 lbf/inch (6.2 N/mm) in width.

2.8 SECUREMENTS

A. Bands:


a. ITW Insulation Systems; Gerrard Strapping and Seals. b. RPR Products, Inc.; Insul-Mate Strapping, Seals, and Springs.



2. Stainless Steel: ASTM A 167 or ASTM A 240/A 240M, Type 304 or Type 316; 0.015 inch (0.38 mm) thick, 1/2 inch (13 mm) wide with wing seal or closed seal.

3. Aluminum: ASTM B 209 (ASTM B 209M), Alloy 3003, 3005, 3105, or 5005; Temper H-14, 0.020 inch (0.51 mm) thick, 1/2 inch (13 mm) wide with wing seal or closed seal.

4. Springs: Twin spring set constructed of stainless steel with ends flat and slotted to accept metal bands. Spring size determined by manufacturer for application.

B. Staples: Outward-clinching insulation staples, nominal 3/4-inch- (19-mm-) wide, stainless steel or Monel.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine substrates and conditions for compliance with requirements for installation tolerances and other conditions affecting performance of insulation application.

1. Verify that systems to be insulated have been tested and are free of defects. 2. Verify that surfaces to be insulated are clean and dry. 3. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 PREPARATION

A. Surface Preparation: Clean and dry surfaces to receive insulation. Remove materials that will adversely affect insulation application.

B. Surface Preparation: Clean and prepare surfaces to be insulated. Before insulating, apply a corrosion coating to insulated surfaces as follows:

1. Stainless Steel: Coat 300 series stainless steel with an epoxy primer 5 mils (0.127 mm) thick and an epoxy finish 5 mils (0.127 mm) thick if operating in a temperature range between 140 and 300 deg F (60 and 149 deg C). Consult coating manufacturer for appropriate coating materials and application methods for operating temperature range.

2. Carbon Steel: Coat carbon steel operating at a service temperature between 32 and 300 deg F (0 and 149 deg C) with an epoxy coating. Consult coating manufacturer for appropriate coating materials and application methods for operating temperature range.

C. Coordinate insulation installation with the trade installing heat tracing. Comply with requirements for heat tracing that apply to insulation.

D. Mix insulating cements with clean potable water; if insulating cements are to be in contact with stainless-steel surfaces, use demineralized water.

3.3 GENERAL INSTALLATION REQUIREMENTS

A. Install insulation materials, accessories, and finishes with smooth, straight, and even surfaces; free of voids throughout the length of piping including fittings, valves, and specialties.



B. Install insulation materials, forms, vapor barriers or retarders, jackets, and thicknesses required for each item of pipe system as specified in insulation system schedules.

C. Install accessories compatible with insulation materials and suitable for the service. Install accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state.

D. Install insulation with longitudinal seams at top and bottom of horizontal runs.

E. Install multiple layers of insulation with longitudinal and end seams staggered.

F. Do not weld brackets, clips, or other attachment devices to piping, fittings, and specialties.

G. Keep insulation materials dry during application and finishing.

H. Install insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by insulation material manufacturer.

I. Install insulation with least number of joints practical.

J. Where vapor barrier is indicated, seal joints, seams, and penetrations in insulation at hangers, supports, anchors, and other projections with vapor-barrier mastic.

1. Install insulation continuously through hangers and around anchor attachments. 2. For insulation application where vapor barriers are indicated, extend insulation on anchor

legs from point of attachment to supported item to point of attachment to structure. Taper and seal ends at attachment to structure with vapor-barrier mastic.

3. Install insert materials and install insulation to tightly join the insert. Seal insulation to insulation inserts with adhesive or sealing compound recommended by insulation material manufacturer.

4. Cover inserts with jacket material matching adjacent pipe insulation. Install shields over jacket, arranged to protect jacket from tear or puncture by hanger, support, and shield.

K. Apply adhesives, mastics, and sealants at manufacturer's recommended coverage rate and wet and dry film thicknesses.

L. Install insulation with factory-applied jackets as follows:

1. Draw jacket tight and smooth. 2. Cover circumferential joints with 3-inch- (75-mm-) wide strips, of same material as

insulation jacket. Secure strips with adhesive and outward clinching staples along both edges of strip, spaced 4 inches (100 mm) o.c.

3. Overlap jacket longitudinal seams at least 1-1/2 inches (38 mm). Install insulation with longitudinal seams at bottom of pipe. Clean and dry surface to receive self-sealing lap. Staple laps with outward clinching staples along edge at 2 inches (50 mm) o.c.

a. For below-ambient services, apply vapor-barrier mastic over staples.

4. Cover joints and seams with tape, according to insulation material manufacturer's written instructions, to maintain vapor seal.

5. Where vapor barriers are indicated, apply vapor-barrier mastic on seams and joints and at ends adjacent to pipe flanges and fittings.



M. Cut insulation in a manner to avoid compressing insulation more than 75 percent of its nominal thickness.

N. Finish installation with systems at operating conditions. Repair joint separations and cracking due to thermal movement.

O. Repair damaged insulation facings by applying same facing material over damaged areas. Extend patches at least 4 inches (100 mm) beyond damaged areas. Adhere, staple, and seal patches similar to butt joints.

P. For above-ambient services, do not install insulation to the following:

1. Vibration-control devices. 2. Testing agency labels and stamps. 3. Nameplates and data plates. 4. Manholes. 5. Handholes. 6. Cleanouts.

3.4 PENETRATIONS

A. Insulation Installation at Interior Wall and Partition Penetrations (That Are Not Fire Rated): Install insulation continuously through walls and partitions.

3.5 GENERAL PIPE INSULATION INSTALLATION

A. Requirements in this article generally apply to all insulation materials except where more specific requirements are specified in various pipe insulation material installation articles.

B. Insulation Installation on Fittings, Valves, Strainers, Flanges, and Unions:

1. Install insulation over fittings, valves, strainers, flanges, unions, and other specialties with continuous thermal and vapor-retarder integrity unless otherwise indicated.

2. Insulate pipe elbows using preformed fitting insulation or mitered fittings made from same material and density as adjacent pipe insulation. Each piece shall be butted tightly against adjoining piece and bonded with adhesive. Fill joints, seams, voids, and irregular surfaces with insulating cement finished to a smooth, hard, and uniform contour that is uniform with adjoining pipe insulation.

3. Insulate tee fittings with preformed fitting insulation or sectional pipe insulation of same material and thickness as used for adjacent pipe. Cut sectional pipe insulation to fit. Butt each section closely to the next and hold in place with tie wire. Bond pieces with adhesive.

4. Insulate valves using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. For valves, insulate up to and including the bonnets, valve stuffing-box studs, bolts, and nuts. Fill joints, seams, and irregular surfaces with insulating cement.

5. Insulate strainers using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe



insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. Fill joints, seams, and irregular surfaces with insulating cement. Insulate strainers so strainer basket flange or plug can be easily removed and replaced without damaging the insulation and jacket. Provide a removable reusable insulation cover. For below-ambient services, provide a design that maintains vapor barrier.

6. Insulate flanges and unions using a section of oversized preformed pipe insulation. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker.

7. Cover segmented insulated surfaces with a layer of finishing cement and coat with a mastic. Install vapor-barrier mastic for below-ambient services and a breather mastic for above-ambient services. Reinforce the mastic with fabric-reinforcing mesh. Trowel the mastic to a smooth and well-shaped contour.

8. For services not specified to receive a field-applied jacket except for flexible elastomeric and polyolefin, install fitted PVC cover over elbows, tees, strainers, valves, flanges, and unions. Terminate ends with PVC end caps. Tape PVC covers to adjoining insulation facing using PVC tape.

9. Stencil or label the outside insulation jacket of each union with the word "union." Match size and color of pipe labels.

C. Insulate instrument connections for thermometers, pressure gages, pressure temperature taps, test connections, flow meters, sensors, switches, and transmitters on insulated pipes. Shape insulation at these connections by tapering it to and around the connection with insulating cement and finish with finishing cement, mastic, and flashing sealant.

D. Install removable insulation covers at locations indicated. Installation shall conform to the following:

1. Make removable flange and union insulation from sectional pipe insulation of same thickness as that on adjoining pipe. Install same insulation jacket as adjoining pipe insulation.

2. When flange and union covers are made from sectional pipe insulation, extend insulation from flanges or union long at least two times the insulation thickness over adjacent pipe insulation on each side of flange or union. Secure flange cover in place with stainless-steel or aluminum bands. Select band material compatible with insulation and jacket.

3. Construct removable valve insulation covers in same manner as for flanges, except divide the two-part section on the vertical center line of valve body.

4. When covers are made from block insulation, make two halves, each consisting of mitered blocks wired to stainless-steel fabric. Secure this wire frame, with its attached insulation, to flanges with tie wire. Extend insulation at least 2 inches (50 mm) over adjacent pipe insulation on each side of valve. Fill space between flange or union cover and pipe insulation with insulating cement. Finish cover assembly with insulating cement applied in two coats. After first coat is dry, apply and trowel second coat to a smooth finish.

5. Unless a PVC jacket is indicated in field-applied jacket schedules, finish exposed surfaces with a metal jacket.

3.6 INSTALLATION OF CALCIUM SILICATE INSULATION

A. Insulation Installation on Straight Pipes and Tubes:



1. Secure single-layer insulation with stainless-steel bands at 12-inch (300-mm) intervals and tighten bands without deforming insulation materials.

2. Install two-layer insulation with joints tightly butted and staggered at least 3 inches (75 mm). Secure inner layer with wire spaced at 12-inch (300-mm) intervals. Secure outer layer with stainless-steel bands at 12-inch (300-mm) intervals.

3. Apply a skim coat of mineral-fiber, hydraulic-setting cement to insulation surface. When cement is dry, apply flood coat of lagging adhesive and press on one layer of glass cloth or tape. Overlap edges at least 1 inch (25 mm). Apply finish coat of lagging adhesive over glass cloth or tape. Thin finish coat to achieve smooth, uniform finish.

B. Insulation Installation on Pipe Flanges:

1. Install preformed pipe insulation to outer diameter of pipe flange. 2. Make width of insulation section same as overall width of flange and bolts, plus twice the

thickness of pipe insulation. 3. Fill voids between inner circumference of flange insulation and outer circumference of

adjacent straight pipe segments with cut sections of block insulation of same material and thickness as pipe insulation.

4. Finish flange insulation same as pipe insulation.

C. Insulation Installation on Pipe Fittings and Elbows:

1. Install preformed sections of same material as straight segments of pipe insulation when available. Secure according to manufacturer's written instructions.

2. When preformed insulation sections of insulation are not available, install mitered sections of calcium silicate insulation. Secure insulation materials with wire or bands.

3. Finish fittings insulation same as pipe insulation.

D. Insulation Installation on Valves and Pipe Specialties:

1. Install mitered segments of calcium silicate insulation to valve body. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation.

2. Install insulation to flanges as specified for flange insulation application. 3. Finish valve and specialty insulation same as pipe insulation.

3.7 INSTALLATION OF MINERAL-FIBER INSULATION

A. Insulation Installation on Straight Pipes and Tubes:

1. Secure each layer of preformed pipe insulation to pipe with wire or bands and tighten bands without deforming insulation materials.

2. Where vapor barriers are indicated, seal longitudinal seams, end joints, and protrusions with vapor-barrier mastic and joint sealant.

3. For insulation with factory-applied jackets on above-ambient surfaces, secure laps with outward-clinched staples at 6 inches (150 mm) o.c.

4. For insulation with factory-applied jackets on below-ambient surfaces, do not staple longitudinal tabs. Instead, secure tabs with additional adhesive as recommended by insulation material manufacturer and seal with vapor-barrier mastic and flashing sealant.

B. Insulation Installation on Pipe Flanges:



1. Install preformed pipe insulation to outer diameter of pipe flange. 2. Make width of insulation section same as overall width of flange and bolts, plus twice the

thickness of pipe insulation. 3. Fill voids between inner circumference of flange insulation and outer circumference of

adjacent straight pipe segments with mineral-fiber blanket insulation. 4. Install jacket material with manufacturer's recommended adhesive, overlap seams at

least 1 inch (25 mm), and seal joints with flashing sealant.

C. Insulation Installation on Pipe Fittings and Elbows:

1. Install preformed sections of same material as straight segments of pipe insulation when available.

2. When preformed insulation elbows and fittings are not available, install mitered sections of pipe insulation, to a thickness equal to adjoining pipe insulation. Secure insulation materials with wire or bands.

D. Insulation Installation on Valves and Pipe Specialties:

1. Install preformed sections of same material as straight segments of pipe insulation when available.

2. When preformed sections are not available, install mitered sections of pipe insulation to valve body.

3. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation.

4. Install insulation to flanges as specified for flange insulation application.

3.8 FIELD-APPLIED JACKET INSTALLATION

A. Where PVC jackets are indicated, install with 1-inch (25-mm) overlap at longitudinal seams and end joints; for horizontal applications. Seal with manufacturer's recommended adhesive.

1. Apply two continuous beads of adhesive to seams and joints, one bead under lap and the finish bead along seam and joint edge.

3.9 FINISHES

A. Color: Final color as selected by Architect. Vary first and second coats to allow visual inspection of the completed Work.

3.10 PIPING INSULATION SCHEDULE, GENERAL

A. Acceptable preformed pipe and tubular insulation materials and thicknesses are identified for each piping system and pipe size range. If more than one material is listed for a piping system, selection from materials listed is Contractor's option.

B. Items Not Insulated: Unless otherwise indicated, do not install insulation on the following:

1. Drainage piping located in crawl spaces. 2. Underground piping.



3. Chrome-plated pipes and fittings unless there is a potential for personnel injury.

3.11 INDOOR PIPING INSULATION SCHEDULE

A. Condensate and Equipment Drain Water below 60 Deg F (16 Deg C):

1. All Pipe Sizes: Insulation shall be the following: a. Mineral-Fiber, Preformed Pipe Insulation, Type I: 1 inch (25 mm) thick.

B. Heating-Hot-Water Supply and Return, 200 Deg F (93 Deg C) and Below:

1. 1-1/2” inch and Smaller: Insulation shall be the following: a. Mineral-Fiber, Preformed Pipe, Type I: 1 inch (25 mm) thick.

2. 2” and Larger: Insulation shall be the following: a. Mineral-Fiber, Preformed Pipe, Type I: 2 inches (50 mm) thick.

3.12 INDOOR, FIELD-APPLIED JACKET SCHEDULE

A. Install jacket over insulation material. For insulation with factory-applied jacket, install the field-applied jacket over the factory-applied jacket.

B. If more than one material is listed, selection from materials listed is Contractor's option.

C. Piping, Concealed:

1. None.

D. Piping, Exposed: 1. PVC, Color-Coded by System: 30 mils (0.8 mm) thick.



DIRECT DIGITAL CONTROL SYSTEM 230900 - 1

SECTION 230900 – DIRECT DIGITAL CONTROL SYSTEM

PART 1 - CONTROL SPECIFICATION

1. Existing direct digital control system

A. The existing direct digital control system as installed by Box Elder School District shall remain in place and be modified as noted in this specification section.

B. Provide/modify boiler control panel connection to the control system head end automa-tion system.

C. Provide the following monitoring abilities from the automation system.

1) Start/Stop 2) Flame Failure 3) System Temperature 4) Alternate Boiler Operation 5) Isolation Valves (Future)

2. Boilers with ModSync boiler control panel (see specification 235218)

A. The ModSync will include control for the system pumps and VFDs.

B. The ModSync will include ModBus communications for system monitoring and operator control.

C. The ModSync will include an outside temperature sensor and a supply loop temperature sensor.

D. The ModSync will include the pressure sensors for differential pressure control with the VFDs.

E. The VFD's will include motor manual starters and and integral disconnect.


DIRECT DIGITAL CONTROL SYSTEM 230900 - 2

3. Installation by Others (Electrician):

A. Install and wire the outside temperature sensor and supply loop temperature sensor to the ModSync controller.

B. Install and wire the pressure sensors in the supply and return lines of the buildings to the ModSync controller.

C. 4-20mA control wiring from the ModSync controller to each VFD.

D. Enable/Disable (24VDC) control wiring from ModSync controller to each VFD.

E. 3-wire control wiring from ModSync controller to Boiler #1.

F. 3-wire control wiring from Boiler #1 to Boiler #2.

G. E-Stop switch and power relay provided by others and wired to each boiler.

H. Connect 120V/1ph power wiring to boilers and ModSync controller.

I. Connect 208V/3ph power wiring to VFDs and from VFDs to pump motors.



FACILITY NATURAL-GAS PIPING 231123 - 1

SECTION 231123 - FACILITY NATURAL-GAS PIPING

PART 1 - GENERAL



1.2 SUMMARY


1. Pipes, tubes, and fittings. 2. Piping specialties. 3. Piping and tubing joining materials. 4. Valves. 5. Pressure regulators.

1.3 DEFINITIONS

A. Finished Spaces: Spaces other than mechanical and electrical equipment rooms, furred spaces, pipe and duct shafts, unheated spaces immediately below roof, spaces above ceilings, unexcavated spaces, crawlspaces, and tunnels.

B. Exposed, Interior Installations: Exposed to view indoors. Examples include finished occupied spaces and mechanical equipment rooms.

C. Exposed, Exterior Installations: Exposed to view outdoors or subject to outdoor ambient temperatures and weather conditions. Examples include rooftop locations.


A. Natural-Gas System Pressures within Buildings: Two pressure ranges. Primary pressure is more than 0.5 psig but not more than 2 psig, and is reduced to secondary pressure of 0.5 psig or less.

1.5 SUBMITTALS

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

1. Piping specialties. 2. Valves. Include pressure rating, capacity, settings, and electrical connection data of

selected models. 3. Pressure regulators. Indicate pressure ratings and capacities.



4. Dielectric fittings.

B. Shop Drawings: For facility natural-gas piping layout. Include plans, piping layout and elevations, sections, and details for fabrication of pipe anchors, hangers, supports for multiple pipes, alignment guides, expansion joints and loops, and attachments of the same to building structure. Detail location of anchors, alignment guides, and expansion joints and loops.

1. Shop Drawing Scale: 1/4 inch per foot. 2. Detail mounting, supports, and valve arrangements for pressure regulator assembly.

C. Site Survey: Plans, drawn to scale, on which natural-gas piping is shown and coordinated with other services and utilities.

D. Qualification Data: For qualified professional engineer.

E. Welding certificates.

F. Field quality-control reports.

G. Operation and Maintenance Data: For pressure regulators to include in emergency, operation, and maintenance manuals.


A. Steel Support Welding Qualifications: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel."

B. Pipe Welding Qualifications: Qualify procedures and operators according to ASME Boiler and Pressure Vessel Code.

C. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.


A. Handling Flammable Liquids: Remove and dispose of liquids from existing natural-gas piping according to requirements of authorities having jurisdiction.

B. Deliver pipes and tubes with factory-applied end caps. Maintain end caps through shipping, storage, and handling to prevent pipe end damage and to prevent entrance of dirt, debris, and moisture.

C. Store and handle pipes and tubes having factory-applied protective coatings to avoid damaging coating, and protect from direct sunlight.

D. Protect stored PE pipes and valves from direct sunlight.



1.8 PROJECT CONDITIONS

A. Perform site survey, research public utility records, and verify existing utility locations. Contact utility-locating service for area where Project is located.

1.9 COORDINATION

A. Coordinate sizes and locations of concrete bases with actual equipment provided.

B. Coordinate requirements for access panels and doors for valves installed concealed behind finished surfaces. Comply with requirements in Division 08 Section "Access Doors and Frames."

PART 2 - PRODUCTS

2.1 PIPES, TUBES, AND FITTINGS

A. Steel Pipe: ASTM A 53/A 53M, black steel, Schedule 40, Type E or S, Grade B.

1. Malleable-Iron Threaded Fittings: ASME B16.3, Class 150, standard pattern. 2. Wrought-Steel Welding Fittings: ASTM A 234/A 234M for butt welding and socket

welding. 3. Unions: ASME B16.39, Class 150, malleable iron with brass-to-iron seat, ground joint,

and threaded ends.

2.2 PIPING SPECIALTIES

A. Appliance Flexible Connectors:

1. Indoor, Fixed-Appliance Flexible Connectors: Comply with ANSI Z21.24. 2. Indoor, Movable-Appliance Flexible Connectors: Comply with ANSI Z21.69. 3. Outdoor, Appliance Flexible Connectors: Comply with ANSI Z21.75. 4. Corrugated stainless-steel tubing with polymer coating. 5. Operating-Pressure Rating: 0.5 psig. 6. End Fittings: Zinc-coated steel. 7. Threaded Ends: Comply with ASME B1.20.1. 8. Maximum Length: 72 inches.

B. Quick-Disconnect Devices: Comply with ANSI Z21.41.

1. Copper-alloy convenience outlet and matching plug connector. 2. Nitrile seals. 3. Hand operated with automatic shutoff when disconnected. 4. For indoor or outdoor applications. 5. Adjustable, retractable restraining cable.

C. Y-Pattern Strainers:



1. Body: ASTM A 126, Class B, cast iron with bolted cover and bottom drain connection. 2. End Connections: Threaded ends for NPS 2 and smaller; flanged ends for NPS 2-1/2

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

percent free area. 4. CWP Rating: 125 psig.

D. Weatherproof Vent Cap: Cast- or malleable-iron increaser fitting with corrosion-resistant wire screen, with free area at least equal to cross-sectional area of connecting pipe and threaded-end connection.


A. Joint Compound and Tape: Suitable for natural gas.

B. Welding Filler Metals: Comply with AWS D10.12/D10.12M for welding materials appropriate for wall thickness and chemical analysis of steel pipe being welded.

2.4 MANUAL GAS SHUTOFF VALVES

A. See "Underground Manual Gas Shutoff Valve Schedule" and "Aboveground Manual Gas Shutoff Valve Schedule" Articles for where each valve type is applied in various services.

B. General Requirements for Metallic Valves, NPS 2 and Smaller: Comply with ASME B16.33.

1. CWP Rating: 125 psig. 2. Threaded Ends: Comply with ASME B1.20.1. 3. Dryseal Threads on Flare Ends: Comply with ASME B1.20.3. 4. Tamperproof Feature: Locking feature for valves indicated in "Underground Manual Gas

Shutoff Valve Schedule" and "Aboveground Manual Gas Shutoff Valve Schedule" Articles.

5. Listing: Listed and labeled by an NRTL acceptable to authorities having jurisdiction for valves 1 inch and smaller.

6. Service Mark: Valves 1-1/4 inches to NPS 2 shall have initials "WOG" permanently marked on valve body.

C. General Requirements for Metallic Valves, NPS 2-1/2 and Larger: Comply with ASME B16.38.

1. CWP Rating: 125 psig. 2. Flanged Ends: Comply with ASME B16.5 for steel flanges. 3. Tamperproof Feature: Locking feature for valves indicated in "Underground Manual Gas

Shutoff Valve Schedule" and "Aboveground Manual Gas Shutoff Valve Schedule" Articles.

4. Service Mark: Initials "WOG" shall be permanently marked on valve body.

D. One-Piece, Bronze Ball Valve with Bronze Trim: MSS SP-110.




a. BrassCraft Manufacturing Company; a Masco company. b. Conbraco Industries, Inc.; Apollo Div. c. McDonald, A. Y. Mfg. Co.

2. Body: Bronze, complying with ASTM B 584. 3. Ball: Chrome-plated brass. 4. Stem: Bronze; blowout proof. 5. Seats: Reinforced TFE; blowout proof. 6. Packing: Separate packnut with adjustable-stem packing threaded ends. 7. Ends: Threaded, flared, or socket as indicated in "Underground Manual Gas Shutoff

Valve Schedule" and "Aboveground Manual Gas Shutoff Valve Schedule" Articles. 8. CWP Rating: 600 psig. 9. Listing: Valves NPS 1 and smaller shall be listed and labeled by an NRTL acceptable to

authorities having jurisdiction. 10. Service: Suitable for natural-gas service with "WOG" indicated on valve body.

E. Two-Piece, Full-Port, Bronze Ball Valves with Bronze Trim: MSS SP-110.


a. Conbraco Industries, Inc.; Apollo Div. b. Lyall, R. W. & Company, Inc. c. McDonald, A. Y. Mfg. Co.

2. Body: Bronze, complying with ASTM B 584. 3. Ball: Chrome-plated bronze. 4. Stem: Bronze; blowout proof. 5. Seats: Reinforced TFE; blowout proof. 6. Packing: Threaded-body packnut design with adjustable-stem packing. 7. Ends: Threaded, flared, or socket as indicated in "Underground Manual Gas Shutoff



F. Two-Piece, Regular-Port Bronze Ball Valves with Bronze Trim: MSS SP-110.


a. BrassCraft Manufacturing Company; a Masco company. b. Conbraco Industries, Inc.; Apollo Div. c. Lyall, R. W. & Company, Inc. d. McDonald, A. Y. Mfg. Co. e. Perfection Corporation; a subsidiary of American Meter Company.

2. Body: Bronze, complying with ASTM B 584. 3. Ball: Chrome-plated bronze. 4. Stem: Bronze; blowout proof. 5. Seats: Reinforced TFE.



6. Packing: Threaded-body packnut design with adjustable-stem packing. 7. Ends: Threaded, flared, or socket as indicated in "Underground Manual Gas Shutoff



G. Bronze Plug Valves: MSS SP-78.


a. Lee Brass Company. b. McDonald, A. Y. Mfg. Co.

2. Body: Bronze, complying with ASTM B 584. 3. Plug: Bronze. 4. Ends: Threaded, socket, or flanged as indicated in "Underground Manual Gas Shutoff

Valve Schedule" and "Aboveground Manual Gas Shutoff Valve Schedule" Articles. 5. Operator: Square head or lug type with tamperproof feature where indicated. 6. Pressure Class: 125 psig. 7. Listing: Valves NPS 1 and smaller shall be listed and labeled by an NRTL acceptable to


H. Cast-Iron, Nonlubricated Plug Valves: MSS SP-78.


a. McDonald, A. Y. Mfg. Co. b. Mueller Co.; Gas Products Div. c. Xomox Corporation; a Crane company.

2. Body: Cast iron, complying with ASTM A 126, Class B. 3. Plug: Bronze or nickel-plated cast iron. 4. Seat: Coated with thermoplastic. 5. Stem Seal: Compatible with natural gas. 6. Ends: Threaded or flanged as indicated in "Underground Manual Gas Shutoff Valve

Schedule" and "Aboveground Manual Gas Shutoff Valve Schedule" Articles. 7. Operator: Square head or lug type with tamperproof feature where indicated. 8. Pressure Class: 125 psig. 9. Listing: Valves NPS 1 and smaller shall be listed and labeled by an NRTL acceptable to


I. Cast-Iron, Lubricated Plug Valves: MSS SP-78.




a. Flowserve. b. McDonald, A. Y. Mfg. Co. c. Mueller Co.; Gas Products Div.

2. Body: Cast iron, complying with ASTM A 126, Class B. 3. Plug: Bronze or nickel-plated cast iron. 4. Seat: Coated with thermoplastic. 5. Stem Seal: Compatible with natural gas. 6. Ends: Threaded or flanged as indicated in "Underground Manual Gas Shutoff Valve

Schedule" and "Aboveground Manual Gas Shutoff Valve Schedule" Articles. 7. Operator: Square head or lug type with tamperproof feature where indicated. 8. Pressure Class: 125 psig. 9. Listing: Valves NPS 1 and smaller shall be listed and labeled by an NRTL acceptable to


2.5 PRESSURE REGULATORS

A. General Requirements:

1. Single stage and suitable for natural gas. 2. Steel jacket and corrosion-resistant components. 3. Elevation compensator. 4. End Connections: Threaded for regulators NPS 2 and smaller; flanged for regulators

NPS 2-1/2 and larger.

B. Line Pressure Regulators: Comply with ANSI Z21.80.


a. American Meter Company. b. Eclipse Combustion, Inc. c. Fisher Control Valves and Regulators; Division of Emerson Process Management.

2. Body and Diaphragm Case: Cast iron or die-cast aluminum. 3. Springs: Zinc-plated steel; interchangeable. 4. Diaphragm Plate: Zinc-plated steel. 5. Seat Disc: Nitrile rubber resistant to gas impurities, abrasion, and deformation at the

valve port. 6. Orifice: Aluminum; interchangeable. 7. Seal Plug: Ultraviolet-stabilized, mineral-filled nylon. 8. Single-port, self-contained regulator with orifice no larger than required at maximum

pressure inlet, and no pressure sensing piping external to the regulator. 9. Pressure regulator shall maintain discharge pressure setting downstream, and not

exceed 150 percent of design discharge pressure at shutoff. 10. Overpressure Protection Device: Factory mounted on pressure regulator. 11. Atmospheric Vent: Factory- or field-installed, stainless-steel screen in opening if not

connected to vent piping. 12. Maximum Inlet Pressure: 5 psig.



C. Appliance Pressure Regulators: Comply with ANSI Z21.18.


a. Eaton Corporation; Controls Div. b. Maxitrol Company. c. SCP, Inc.

2. Body and Diaphragm Case: Die-cast aluminum. 3. Springs: Zinc-plated steel; interchangeable. 4. Diaphragm Plate: Zinc-plated steel. 5. Seat Disc: Nitrile rubber. 6. Seal Plug: Ultraviolet-stabilized, mineral-filled nylon. 7. Factory-Applied Finish: Minimum three-layer polyester and polyurethane paint finish. 8. Regulator may include vent limiting device, instead of vent connection, if approved by

authorities having jurisdiction. 9. Maximum Inlet Pressure: 2 psig.


A. General Requirements: Assembly of copper alloy and ferrous materials with separating nonconductive insulating material. Include end connections compatible with pipes to be joined.

B. Dielectric Unions:


a. Hart Industries International, Inc. b. McDonald, A. Y. Mfg. Co. c. Watts Regulator Co.; a division of Watts Water Technologies, Inc. d. Standard: ASSE 1079. e. Pressure Rating: 150 psig. f. End Connections: Solder-joint copper alloy and threaded ferrous.

C. Dielectric-Flange Insulating Kits:


a. Advance Products & Systems, Inc. b. Calpico, Inc. c. Pipeline Seal and Insulator, Inc.

2. Description:

a. Nonconducting materials for field assembly of companion flanges. b. Pressure Rating: 150 psig. c. Gasket: Neoprene or phenolic. d. Bolt Sleeves: Phenolic or polyethylene.



e. Washers: Phenolic with steel backing washers.

2.7 LABELING AND IDENTIFYING

A. Detectable Warning Tape: Acid- and alkali-resistant, PE film warning tape manufactured for marking and identifying underground utilities, a minimum of 6 inches wide and 4 mils thick, continuously inscribed with a description of utility, with metallic core encased in a protective jacket for corrosion protection, detectable by metal detector when tape is buried up to 30 inches deep; colored yellow.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine roughing-in for natural-gas piping system to verify actual locations of piping connections before equipment installation.

B. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 PREPARATION

A. Close equipment shutoff valves before turning off natural gas to premises or piping section.

B. Inspect natural-gas piping according to the International Fuel Gas Code to determine that natural-gas utilization devices are turned off in piping section affected.

C. Comply with the International Fuel Gas Code requirements for prevention of accidental ignition.

3.3 INDOOR PIPING INSTALLATION

A. Comply with the International Fuel Gas Code for installation and purging of natural-gas piping.

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

C. Arrange for pipe spaces, chases, slots, sleeves, and openings in building structure during progress of construction, to allow for mechanical installations.

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

E. 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.



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

G. Locate valves for easy access.

H. Install natural-gas piping at uniform grade of 2 percent down toward drip and sediment traps.

I. Install piping free of sags and bends.

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

K. Verify final equipment locations for roughing-in.

L. Comply with requirements in Sections specifying gas-fired appliances and equipment for roughing-in requirements.

M. Drips and Sediment Traps: Install drips at points where condensate may collect, including service-meter outlets. Locate where accessible to permit cleaning and emptying. Do not install where condensate is subject to freezing.

1. Construct drips and sediment traps using tee fitting with bottom outlet plugged or capped. Use nipple a minimum length of 3 pipe diameters, but not less than 3 inches long and same size as connected pipe. Install with space below bottom of drip to remove plug or cap.

N. Extend relief vent connections for service regulators, line regulators, and overpressure protection devices to outdoors and terminate with weatherproof vent cap.

O. Conceal pipe installations in walls, pipe spaces, utility spaces, above ceilings, below grade or floors, and in floor channels unless indicated to be exposed to view.

P. Concealed Location Installations: Except as specified below, install concealed natural-gas piping and piping installed under the building in containment conduit constructed of steel pipe with welded joints as described in Part 2. Install a vent pipe from containment conduit to outdoors and terminate with weatherproof vent cap.

1. Above Accessible Ceilings: Natural-gas piping, fittings, valves, and regulators may be installed in accessible spaces without containment conduit.

2. In Floors: Install natural-gas piping with welded or brazed joints and protective coating in cast-in-place concrete floors. Cover piping to be cast in concrete slabs with minimum of 1-1/2 inches of concrete. Piping may not be in physical contact with other metallic structures such as reinforcing rods or electrically neutral conductors. Do not embed piping in concrete slabs containing quick-set additives or cinder aggregate.

3. In Floor Channels: Install natural-gas piping in floor channels. Channels must have cover and be open to space above cover for ventilation.

4. In Walls or Partitions: Protect tubing installed inside partitions or hollow walls from physical damage using steel striker barriers at rigid supports.

a. Exception: Tubing passing through partitions or walls does not require striker barriers.

5. Prohibited Locations:



a. Do not install natural-gas piping in or through circulating air ducts, clothes or trash chutes, chimneys or gas vents (flues), ventilating ducts, or dumbwaiter or elevator shafts.

b. Do not install natural-gas piping in solid walls or partitions.

Q. Use eccentric reducer fittings to make reductions in pipe sizes. Install fittings with level side down.

R. Connect branch piping from top or side of horizontal piping.

S. Install unions in pipes NPS 2 and smaller, adjacent to each valve, at final connection to each piece of equipment. Unions are not required at flanged connections.

T. Do not use natural-gas piping as grounding electrode.

U. Install strainer on inlet of each line-pressure regulator and automatic or electrically operated valve.

V. Install pressure gage upstream and downstream from each line regulator. Pressure gages are specified in Division 23 Section "Meters and Gages for HVAC Piping."

W. Install sleeves for piping penetrations of walls, ceilings, and floors. Comply with requirements for sleeves specified in Division 23 Section "Sleeves and Sleeve Seals for HVAC Piping."

X. Install sleeve seals for piping penetrations of concrete walls and slabs. Comply with requirements for sleeve seals specified in Division 23 Section "Sleeves and Sleeve Seals for HVAC Piping."

Y. Install escutcheons for piping penetrations of walls, ceilings, and floors. Comply with requirements for escutcheons specified in Division 23 Section "Escutcheons for HVAC Piping."

3.4 VALVE INSTALLATION

A. Install manual gas shutoff valve for each gas appliance ahead of corrugated stainless-steel tubing, aluminum, or copper connector.

B. Install underground valves with valve boxes.

C. Install regulators and overpressure protection devices with maintenance access space adequate for servicing and testing.

D. Install earthquake valves aboveground outside buildings according to listing.

E. Install anode for metallic valves in underground PE piping.

3.5 PIPING JOINT CONSTRUCTION

A. Ream ends of pipes and tubes and remove burrs.



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

C. Threaded Joints:

1. Thread pipe with tapered pipe threads complying with ASME B1.20.1. 2. Cut threads full and clean using sharp dies. 3. Ream threaded pipe ends to remove burrs and restore full inside diameter of pipe. 4. Apply appropriate tape or thread compound to external pipe threads unless dryseal

threading is specified. 5. 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.

D. Welded Joints:

1. Construct joints according to AWS D10.12/D10.12M, using qualified processes and welding operators.

2. Bevel plain ends of steel pipe. 3. Patch factory-applied protective coating as recommended by manufacturer at field welds

and where damage to coating occurs during construction.

3.6 HANGER AND SUPPORT INSTALLATION

A. Install seismic restraints on piping. Comply with requirements for seismic-restraint devices specified in Division 23 Section "Vibration and Seismic Controls for HVAC Piping and Equipment."

B. Comply with requirements for pipe hangers and supports specified in Division 23 Section "Hangers and Supports for HVAC Piping and Equipment."

C. Install hangers for horizontal steel piping with the following maximum spacing and minimum rod sizes:

1. NPS 1 and Smaller: Maximum span, 96 inches; minimum rod size, 3/8 inch. 2. NPS 1-1/4: Maximum span, 108 inches; minimum rod size, 3/8 inch. 3. NPS 1-1/2 and NPS 2: Maximum span, 108 inches; minimum rod size, 3/8 inch. 4. NPS 2-1/2 to NPS 3-1/2: Maximum span, 10 feet; minimum rod size, 1/2 inch. 5. NPS 4 and Larger: Maximum span, 10 feet; minimum rod size, 5/8 inch.

3.7 CONNECTIONS

A. Connect to utility's gas main according to utility's procedures and requirements.

B. Install natural-gas piping electrically continuous, and bonded to gas appliance equipment grounding conductor of the circuit powering the appliance according to NFPA 70.

C. Install piping adjacent to appliances to allow service and maintenance of appliances.



D. Connect piping to appliances using manual gas shutoff valves and unions. Install valve within 72 inches of each gas-fired appliance and equipment. Install union between valve and appliances or equipment.

E. Sediment Traps: Install tee fitting with capped nipple in bottom to form drip, as close as practical to inlet of each appliance.

3.8 LABELING AND IDENTIFYING

A. Comply with requirements in Division 23 Section "Identification for HVAC Piping and Equipment" for piping and valve identification.

B. Install detectable warning tape directly above gas piping, 12 inches below finished grade, except 6 inches below subgrade under pavements and slabs.

3.9 PAINTING

A. Comply with requirements in Division 09 painting Sections for painting interior and exterior natural-gas piping.

B. Paint exposed, exterior metal piping, valves, service regulators, service meters and meter bars, earthquake valves, and piping specialties, except components, with factory-applied paint or protective coating.

1. Alkyd System: MPI EXT 5.1D.

a. Prime Coat: Alkyd anticorrosive metal primer. b. Intermediate Coat: Exterior alkyd enamel matching topcoat. c. Topcoat: Exterior alkyd enamel (semigloss). d. Color: Gray.

C. Paint exposed, interior metal piping, valves, service regulators, service meters and meter bars, earthquake valves, and piping specialties, except components, with factory-applied paint or protective coating.

1. Latex Over Alkyd Primer System: MPI INT 5.1Q.

a. Prime Coat: Quick-drying alkyd metal primer. b. Intermediate Coat: Interior latex matching topcoat. c. Topcoat: Interior latex (flat). d. Color: Gray.

2. Alkyd System: MPI INT 5.1E.

a. Prime Coat: Quick-drying alkyd metal primer. b. Intermediate Coat: Interior alkyd matching topcoat. c. Topcoat: Interior alkyd (flat). d. Color: Gray.



D. Damage and Touchup: Repair marred and damaged factory-applied finishes with materials and by procedures to match original factory finish.

3.10 FIELD QUALITY CONTROL

A. Perform tests and inspections.

B. Tests and Inspections:

1. Test, inspect, and purge natural gas according to the International Fuel Gas Code and authorities having jurisdiction.

C. Natural-gas piping will be considered defective if it does not pass tests and inspections.

D. Prepare test and inspection reports.

3.11 DEMONSTRATION

A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain earthquake valves.

3.12 INDOOR PIPING SCHEDULE FOR SYSTEM PRESSURES LESS THAN 0.5 PSIG

A. Aboveground, branch piping NPS 1 and smaller shall be the following:

1. Steel pipe with malleable-iron fittings and threaded joints.

B. Aboveground, distribution piping shall be one of the following:

1. Steel pipe with malleable-iron fittings and threaded joints. 2. Steel pipe with wrought-steel fittings and welded joints.

C. Underground, below building, piping shall be the following:

1. Steel pipe with wrought-steel fittings and welded joints.

D. Containment Conduit: Steel pipe with wrought-steel fittings and welded joints. Coat pipe and fittings with protective coating for steel piping.

E. Containment Conduit Vent Piping: Steel pipe with malleable-iron fittings and threaded or wrought-steel fittings with welded joints. Coat underground pipe and fittings with protective coating for steel piping.

3.13 INDOOR PIPING SCHEDULE FOR SYSTEM PRESSURES MORE THAN 0.5 PSIG AND LESS THAN 5 PSIG

A. Aboveground, branch piping NPS 1 and smaller shall be the following:



1. Steel pipe with malleable-iron fittings and threaded joints.

B. Aboveground, distribution piping shall be one of the following:

1. Steel pipe with malleable-iron fittings and threaded joints. 2. Steel pipe with steel welding fittings and welded joints.



HYDRONIC PIPING 232113 - 1

SECTION 232113 - HYDRONIC PIPING

PART 1 - GENERAL



1.2 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. Makeup-water piping. 3. Condensate-drain piping. 4. Blowdown-drain piping. 5. Air-vent piping. 6. Safety-valve-inlet and -outlet piping.

B. Related Sections include the following:

1. Division 23 Section "Hydronic Pumps" for pumps, motors, and accessories for hydronic piping.


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

1. Hot-Water Heating Piping: 125 psig at 200 deg F (93 deg C). 2. Makeup-Water Piping: 80 psig (552 kPa) at 150 deg F (66 deg C). 3. Condensate-Drain Piping: 150 deg F (66 deg C). 4. Blowdown-Drain Piping: 200 deg F (93 deg C). 5. Air-Vent Piping: 200 deg F (93 deg C). 6. Safety-Valve-Inlet and -Outlet Piping: Equal to the pressure of the piping system to

which it is attached.


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

1. Plastic pipe and fittings with solvent cement. 2. RTRP and RTRF with adhesive. 3. Pressure-seal fittings.



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

5. Air control devices. 6. Chemical treatment. 7. Hydronic specialties.

B. Shop Drawings: Detail, at 1/4 (1:50) scale, the piping layout, fabrication of pipe anchors, hangers, supports for multiple pipes, alignment guides, expansion joints and loops, and attachments of the same to the building structure. Detail location of anchors, alignment guides, and expansion joints and loops.


A. Qualification Data: For Installer.


C. Field quality-control test reports.

D. Water Analysis: Submit a copy of the water analysis to illustrate water quality available at Project site.


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

1.7 MAINTENANCE MATERIAL SUBMITTALS

A. Water-Treatment Chemicals: Furnish enough chemicals for initial system startup and for preventive maintenance for one year from date of Substantial Completion.

B. Differential Pressure Meter: For each type of balancing valve and automatic flow control valve, include flowmeter, probes, hoses, flow charts, and carrying case.


A. Installer Qualifications:

1. Installers of Pressure-Sealed Joints: Installers shall be certified by the pressure-seal joint manufacturer as having been trained and qualified to join piping with pressure-seal pipe couplings and fittings.

2. Fiberglass Pipe and Fitting Installers: Installers of RTRF and RTRP shall be certified by the manufacturer of pipes and fittings as having been trained and qualified to join fiberglass piping with manufacturer-recommended adhesive.

B. Steel Support Welding: Qualify processes and operators according to AWS D1.1/D1.1M, "Structural Welding Code - Steel."



C. Welding: Qualify processes and operators according to ASME Boiler and Pressure Vessel Code: Section IX.

1. Comply with provisions in ASME B31 Series, "Code for Pressure Piping." 2. Certify that each welder has passed AWS qualification tests for welding processes

involved and that certification is current.

D. ASME Compliance: Comply with ASME B31.9, "Building Services Piping," 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 01.

PART 2 - PRODUCTS

2.1 COPPER TUBE AND FITTINGS

A. Drawn-Temper Copper Tubing: ASTM B 88, Type L (ASTM B 88M, Type B).

B. Annealed-Temper Copper Tubing: ASTM B 88, Type K (ASTM B 88M, Type A).

C. DWV Copper Tubing: ASTM B 306, Type DWV.

D. 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.

2. Grooved-End Copper Fittings: ASTM B 75 (ASTM B 75M), copper tube or ASTM B 584, bronze casting.

3. Grooved-End-Tube Couplings: Rigid pattern, unless otherwise indicated; gasketed fitting. Ductile-iron housing with keys matching pipe and fitting grooves, prelubricated EPDM gasket rated for minimum 230 deg F (110 deg C) for use with housing, and steel bolts and nuts.

E. Copper or Bronze Pressure-Seal Fittings: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the

following:

a. Stadler-Viega.

2. Housing: Copper. 3. O-Rings and Pipe Stops: EPDM. 4. Tools: Manufacturer's special tools. 5. Minimum 200-psig (1379-kPa) working-pressure rating at 250 deg F (121 deg C).

F. 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:



a. T-DRILL Industries Inc.

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

2.2 STEEL PIPE AND FITTINGS

A. Steel Pipe: ASTM A 53/A 53M, black steel with plain ends; type, grade, and wall thickness as indicated in Part 3 "Piping Applications" Article.

B. Cast-Iron Threaded Fittings: ASME B16.4; Classes 125 and 250 as indicated in Part 3 "Piping Applications" Article.

C. Malleable-Iron Threaded Fittings: ASME B16.3, Classes 150 and 300 as indicated in Part 3 "Piping Applications" Article.

D. Malleable-Iron Unions: ASME B16.39; Classes 150, 250, and 300 as indicated in Part 3 "Piping Applications" Article.

E. Cast-Iron Pipe Flanges and Flanged Fittings: ASME B16.1, Classes 25, 125, and 250; raised ground face, and bolt holes spot faced as indicated in Part 3 "Piping Applications" Article.

F. Wrought-Steel Fittings: ASTM A 234/A 234M, wall thickness to match adjoining pipe.

G. Wrought Cast- and Forged-Steel Flanges and Flanged Fittings: ASME B16.5, including bolts, nuts, and gaskets of the following material group, end connections, and facings:

1. Material Group: 1.1. 2. End Connections: Butt welding. 3. Facings: Raised face.

H. Grooved Mechanical-Joint Fittings and Couplings: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the

following:

a. Anvil International, Inc. b. Central Sprinkler Company; a division of Tyco Fire & Building Products. c. National Fittings, Inc. d. S. P. Fittings; a division of Star Pipe Products. e. Victaulic Company.

2. Joint Fittings: ASTM A 536, Grade 65-45-12 ductile iron; ASTM A 47/A 47M, Grade 32510 malleable iron; ASTM A 53/A 53M, Type F, E, or S, Grade B fabricated steel; or ASTM A 106, Grade B steel fittings with grooves or shoulders constructed to accept grooved-end couplings; with nuts, bolts, locking pin, locking toggle, or lugs to secure grooved pipe and fittings.

3. Couplings: Ductile- or malleable-iron housing and synthetic rubber gasket of central cavity pressure-responsive design; with nuts, bolts, locking pin, locking toggle, or lugs to secure grooved pipe and fittings.

I. Steel Pipe Nipples: ASTM A 733, made of same materials and wall thicknesses as pipe in which they are installed.



2.3 PLASTIC PIPE AND FITTINGS

A. CPVC Plastic Pipe: ASTM F 441/F 441M, Schedules 40 and 80, plain ends as indicated in Part 3 "Piping Applications" Article.

B. CPVC Plastic Pipe Fittings: Socket-type pipe fittings, ASTM F 438 for Schedule 40 pipe; ASTM F 439 for Schedule 80 pipe.

C. PVC Plastic Pipe: ASTM D 1785, Schedules 40 and 80, plain ends as indicated in Part 3 "Piping Applications" Article.

D. PVC Plastic Pipe Fittings: Socket-type pipe fittings, ASTM D 2466 for Schedule 40 pipe; ASTM D 2467 for Schedule 80 pipe.


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-iron and cast-bronze flanges. b. Narrow-Face Type: For raised-face, Class 250, cast-iron and steel flanges.

B. Flange Bolts and Nuts: ASME B18.2.1, carbon steel, unless otherwise indicated.

C. Plastic, Pipe-Flange Gasket, Bolts, and Nuts: Type and material recommended by piping system manufacturer, unless otherwise indicated.

D. Solder Filler Metals: ASTM B 32, lead-free alloys. Include water-flushable flux according to ASTM B 813.

E. 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.

F. Welding Filler Metals: Comply with AWS D10.12/D10.12M for welding materials appropriate for wall thickness and chemical analysis of steel pipe being welded.

G. Solvent Cements for Joining Plastic Piping:

1. CPVC Piping: ASTM F 493.

a. CPVC solvent cement shall have a VOC content of 490 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

b. Adhesive primer shall have a VOC content of 550 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

c. Solvent cement and adhesive primer shall comply with the testing and product requirements of the California Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers."



2. PVC Piping: ASTM D 2564. Include primer according to ASTM F 656.

a. PVC solvent cement shall have a VOC content of 510 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

b. Adhesive primer shall have a VOC content of 550 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

c. Solvent cement and adhesive primer shall comply with the testing and product requirements of the California Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers."

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

2.5 TRANSITION FITTINGS

A. Plastic-to-Metal Transition Fittings: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the

following:

a. Charlotte Pipe and Foundry Company. b. IPEX Inc. c. KBi.

2. CPVC and PVC one-piece fitting with one threaded brass or copper insert and one Schedule 80 solvent-cement-joint end.

B. Plastic-to-Metal Transition Unions: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the

following:

a. Charlotte Pipe and Foundry Company. b. IPEX Inc. c. KBi. d. NIBCO INC.

2. MSS SP-107, CPVC and PVC union. Include brass or copper end, Schedule 80 solvent-cement-joint end, rubber gasket, and threaded union.


A. General Requirements: Assembly of copper alloy and ferrous materials with separating nonconductive insulating material. Include end connections compatible with pipes to be joined.

B. Dielectric Unions:


a. Capitol Manufacturing Company. b. Central Plastics Company.



c. Hart Industries International, Inc. d. Jomar International Ltd. e. Matco-Norca, Inc. f. McDonald, A. Y. Mfg. Co. g. Watts Regulator Co.; a division of Watts Water Technologies, Inc. h. Wilkins; a Zurn company.

2. Description:

a. Standard: ASSE 1079. b. Pressure Rating: 150 psig (1035 kPa). c. End Connections: Solder-joint copper alloy and threaded ferrous.

C. Dielectric Flanges:


a. Capitol Manufacturing Company. b. Central Plastics Company. c. Matco-Norca, Inc. d. Watts Regulator Co.; a division of Watts Water Technologies, Inc. e. Wilkins; a Zurn company.

2. Description:

a. Standard: ASSE 1079. b. Factory-fabricated, bolted, companion-flange assembly. c. Pressure Rating: 150 psig (1035 kPa). d. End Connections: Solder-joint copper alloy and threaded ferrous; threaded solder-

joint copper alloy and threaded ferrous.

D. Dielectric-Flange Insulating Kits:


a. Advance Products & Systems, Inc. b. Calpico, Inc. c. Central Plastics Company. d. Pipeline Seal and Insulator, Inc.

2. Description:

a. Nonconducting materials for field assembly of companion flanges. b. Pressure Rating: 150 psig (1035 kPa). c. Gasket: Neoprene or phenolic. d. Bolt Sleeves: Phenolic or polyethylene. e. Washers: Phenolic with steel backing washers.

E. Dielectric Nipples:




a. Elster Perfection. b. Grinnell Mechanical Products. c. Matco-Norca, Inc. d. Precision Plumbing Products, Inc. e. Victaulic Company.

2. Description:

a. Standard: IAPMO PS 66 b. Electroplated steel nipple. complying with ASTM F 1545. c. Pressure Rating: 300 psig (2070 kPa) at 225 deg F (107 deg C). d. End Connections: Male threaded or grooved. e. Lining: Inert and noncorrosive, propylene.

2.7 VALVES

A. Gate, Globe, Check, Ball, and Butterfly Valves: Comply with requirements specified in Division 23 Section "General-Duty Valves for HVAC Piping."

B. Automatic Temperature-Control Valves, Actuators, and Sensors: Comply with requirements specified in Division 23 Section "Instrumentation and Control for HVAC."

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. Flow Design Inc. d. Gerand Engineering Co. e. Griswold Controls. f. Nexus. g. 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: 250 deg F (121 deg C).

D. Cast-Iron or Steel, 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. Flow Design Inc. d. Gerand Engineering Co. e. Griswold Controls. f. Nexus. g. Taco. h. Tour & Andersson; available through Victaulic Company.

2. Body: Cast-iron or steel body, ball, plug, or globe pattern with calibrated orifice or venturi.

3. Ball: Brass or stainless steel. 4. Stem Seals: EPDM O-rings. 5. Disc: Glass and carbon-filled PTFE. 6. Seat: PTFE. 7. End Connections: Flanged or grooved. 8. Pressure Gage Connections: Integral seals for portable differential pressure meter. 9. Handle Style: Lever, with memory stop to retain set position. 10. CWP Rating: Minimum 125 psig (860 kPa). 11. Maximum Operating Temperature: 250 deg F (121 deg C).

E. Diaphragm-Operated, Pressure-Reducing Valves: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the

following:

a. Amtrol, Inc. b. Armstrong Pumps, Inc. c. Bell & Gossett Domestic Pump; a division of ITT Industries. d. Conbraco Industries, Inc. e. Spence Engineering Company, Inc. f. 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. Low inlet-pressure check valve. 8. Inlet Strainer: stainless steel, removable without system shutdown. 9. Valve Seat and Stem: Noncorrosive. 10. Valve Size, Capacity, and Operating Pressure: Selected to suit system in which installed,

with operating pressure and capacity factory set and field adjustable.

F. Diaphragm-Operated Safety Valves: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the

following:

a. Amtrol, Inc. b. Armstrong Pumps, Inc. c. Bell & Gossett Domestic Pump; a division of ITT Industries. d. Conbraco Industries, Inc. e. Spence Engineering Company, Inc. f. 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. 8. Inlet Strainer: stainless steel, 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.

G. 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. c. Nexus.

2. Body: Brass or ferrous metal. 3. Piston and Spring Assembly: Stainless steel 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: 200 deg F (93 deg C).

2.8 AIR CONTROL DEVICES


1. Amtrol, Inc. 2. Armstrong Pumps, Inc. 3. Bell & Gossett Domestic Pump; a division of ITT Industries. 4. Patterson Pumps. 5. 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: 225 deg F (107 deg C).



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: 240 deg F (116 deg C).

D. Bladder-Type Expansion Tanks:

1. Tank: Welded steel, rated for 125-psig (860-kPa) working pressure and 375 deg F (191 deg C) maximum operating temperature. Factory test with taps fabricated and supports installed and labeled according to ASME Boiler and Pressure Vessel Code: Section VIII, Division 1.

2. Bladder: Securely sealed into tank to separate air charge from system water to maintain required expansion capacity.

3. Air-Charge Fittings: Schrader valve, stainless steel with EPDM seats.

E. In-Line Air Separators:

1. Tank: One-piece cast iron with an integral weir constructed to decelerate system flow to maximize air separation.

2. Maximum Working Pressure: Up to 175 psig (1207 kPa). 3. Maximum Operating Temperature: Up to 300 deg F (149 deg C).

2.9 CHEMICAL TREATMENT

A. Bypass Chemical Feeder: Welded steel construction; 125-psig (860-kPa) working pressure; 5-gal. (19-L) capacity; with fill funnel and inlet, outlet, and drain valves.

1. Chemicals: Specially formulated, based on analysis of makeup water, to prevent accumulation of scale and corrosion in piping and connected equipment.

2.10 HYDRONIC PIPING SPECIALTIES

A. Y-Pattern Strainers:

1. Body: ASTM A 126, Class B, cast iron with bolted cover and bottom drain connection. 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: 60-mesh startup strainer, and perforated stainless-steel basket with 50

percent free area. 4. CWP Rating: 125 psig (860 kPa).

B. Basket Strainers:

1. Body: ASTM A 126, Class B, high-tensile cast iron with bolted cover and bottom drain connection.



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: 60-mesh startup strainer, and perforated stainless-steel basket with 50 percent free area.

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

C. Spherical, Rubber, Flexible Connectors:

1. Body: Fiber-reinforced rubber body. 2. End Connections: Steel flanges drilled to align with Classes 150 and 300 steel flanges. 3. Performance: Capable of misalignment. 4. CWP Rating: 150 psig (1035 kPa). 5. Maximum Operating Temperature: 250 deg F (121 deg C).

D. Expansion fittings are specified in Division 23 Section "Expansion Fittings and Loops for HVAC Piping."

PART 3 - EXECUTION

3.1 PIPING APPLICATIONS

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

1. Type L (B), drawn-temper copper tubing, wrought-copper fittings, and soldered joints. 2. Schedule 40 steel pipe; Class 150, malleable-iron fittings; cast-iron flanges and flange

fittings; and threaded joints.

B. Hot-water heating piping, aboveground, NPS 2-1/2 (DN 65) and larger, shall be any of the following: 1. Schedule 40 steel pipe, wrought-steel fittings and wrought-cast or forged-steel flanges

and flange fittings, and welded and flanged joints. 2. Schedule 40 steel pipe; grooved, mechanical joint coupling and fittings; and grooved,

mechanical joints.

C. Hot-water heating piping installed belowground and within slabs shall be the following:

1. Type K (A), annealed-temper copper tubing, wrought-copper fittings, and soldered joints. Use the fewest possible joints.

D. Makeup-water piping installed aboveground shall be the following:

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

E. Makeup-Water Piping Installed Belowground and within Slabs: Type K (A), annealed-temper copper tubing, wrought-copper fittings, and soldered joints. Use the fewest possible joints.

F. Condensate-Drain Piping: Type M (C), drawn-temper copper tubing, wrought-copper fittings, and soldered joints.



G. Blowdown-Drain Piping: Same materials and joining methods as for piping specified for the service in which blowdown drain is installed.

H. 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.

I. Safety-Valve-Inlet and -Outlet Piping for Hot-Water Piping: Same materials and joining methods as for piping specified for the service in which safety valve is installed with metal-to-plastic transition fittings for plastic piping systems according to the piping manufacturer's written instructions.

3.2 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 check valves at each pump discharge and elsewhere as required to control flow direction.

E. 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.

F. Install pressure-reducing valves at makeup-water connection to regulate system fill pressure.

3.3 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.

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 mechanically formed 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 23 Section "General-Duty Valves for HVAC Piping."

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. Install expansion loops, expansion joints, anchors, and pipe alignment guides as specified in Division 23 Section "Expansion Fittings and Loops for HVAC Piping."

U. Identify piping as specified in Division 23 Section "Identification for HVAC Piping and Equipment."

V. Install sleeves for piping penetrations of walls, ceilings, and floors. Comply with requirements for sleeves specified in Division 23 Section "Sleeves and Sleeve Seals for HVAC Piping."

W. Install sleeve seals for piping penetrations of concrete walls and slabs. Comply with requirements for sleeve seals specified in Division 23 Section "Sleeves and Sleeve Seals for HVAC Piping."

X. Install escutcheons for piping penetrations of walls, ceilings, and floors. Comply with requirements for escutcheons specified in Division 23 Section "Escutcheons for HVAC Piping."



3.4 HANGERS AND SUPPORTS

A. Hanger, support, and anchor devices are specified in Division 23 Section "Hangers and Supports for HVAC Piping and Equipment." Comply with the following requirements for maximum spacing of supports.

B. Seismic restraints are specified in Division 23 Section "Vibration and Seismic Controls for HVAC Piping and Equipment."

C. 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. 6. On plastic pipe, install pads or cushions on bearing surfaces to prevent hanger from

scratching pipe.

D. Install hangers for steel piping with the following maximum spacing and minimum rod sizes:

1. NPS 3/4 (DN 20): Maximum span, 7 feet (2.1 m); minimum rod size, 1/4 inch (6.4 mm). 2. NPS 1 (DN 25): Maximum span, 7 feet (2.1 m); minimum rod size, 1/4 inch (6.4 mm). 3. NPS 1-1/2 (DN 40): Maximum span, 9 feet (2.7 m); minimum rod size, 3/8 inch (10 mm). 4. NPS 2 (DN 50): Maximum span, 10 feet (3 m); minimum rod size, 3/8 inch (10 mm). 5. NPS 2-1/2 (DN 65): Maximum span, 11 feet (3.4 m); minimum rod size, 3/8 inch (10

mm). 6. NPS 3 (DN 80): Maximum span, 12 feet (3.7 m); minimum rod size, 3/8 inch (10 mm). 7. NPS 4 (DN 100): Maximum span, 14 feet (4.3 m); minimum rod size, 1/2 inch (13 mm). 8. NPS 6 (DN 150): Maximum span, 17 feet (5.2 m); minimum rod size, 1/2 inch (13 mm).

E. 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). 6. NPS 3 (DN 80): Maximum span, 10 feet (3 m); minimum rod size, 3/8 inch (10 mm).

F. Plastic Piping Hanger Spacing: Space hangers according to pipe manufacturer's written instructions for service conditions. Avoid point loading. Space and install hangers with the fewest practical rigid anchor points.

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



3.5 PIPE JOINT CONSTRUCTION

A. Join pipe and fittings according to the following requirements and Division 23 Sections specifying piping systems.

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. Soldered Joints: Apply ASTM B 813, water-flushable flux, unless otherwise indicated, to tube end. Construct joints according to ASTM B 828 or CDA's "Copper Tube Handbook," using lead-free solder alloy complying with ASTM B 32.

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. Welded Joints: Construct joints according to AWS D10.12/D10.12M, using qualified processes and welding operators according to Part 1 "Quality Assurance" Article.

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

H. Plastic Piping Solvent-Cemented Joints: Clean and dry joining surfaces. Join pipe and fittings according to the following:

1. Comply with ASTM F 402 for safe-handling practice of cleaners, primers, and solvent cements.

2. CPVC Piping: Join according to ASTM D 2846/D 2846M Appendix. 3. PVC Pressure Piping: Join ASTM D 1785 schedule number, PVC pipe and PVC socket

fittings according to ASTM D 2672. Join other-than-schedule number PVC pipe and socket fittings according to ASTM D 2855.

I. Grooved Joints: Assemble joints with coupling and gasket, lubricant, and bolts. Cut or roll grooves in ends of pipe based on pipe and coupling manufacturer's written instructions for pipe wall thickness. Use grooved-end fittings and rigid, grooved-end-pipe couplings.

J. Mechanically Formed, Copper-Tube-Outlet Joints: Use manufacturer-recommended tool and procedure, and brazed joints.

K. Pressure-Sealed Joints: Use manufacturer-recommended tool and procedure. Leave insertion marks on pipe after assembly.



3.6 HYDRONIC SPECIALTIES INSTALLATION

A. Install manual air vents at high points in piping, at heat-transfer coils, and elsewhere as required for system air venting.

B. 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.

C. Install in-line air separators in pump suction. Install drain valve on air separators NPS 2 (DN 50) and larger.

D. Install bypass chemical feeders in each hydronic system where indicated, in upright position with top of funnel not more than 48 inches (1200 mm) above the floor. Install feeder in minimum NPS 3/4 (DN 20) bypass line, from main with full-size, full-port, ball valve in the main between bypass connections. Install NPS 3/4 (DN 20) pipe from chemical feeder drain, to nearest equipment drain and include a full-size, full-port, ball valve.

E. Install expansion tanks on the floor. Vent and purge air from hydronic system, and ensure tank is properly charged with air to suit system Project requirements.

3.7 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 gages and thermometers at coil inlet and outlet connections according to Division 23 Section "Meters and Gages for HVAC Piping."

3.8 CHEMICAL TREATMENT

A. Perform an analysis of makeup water to determine type and quantities of chemical treatment needed to keep system free of scale, corrosion, and fouling, and to sustain the following water characteristics:

1. pH: 9.0 to 10.5. 2. "P" Alkalinity: 100 to 500 ppm. 3. Boron: 100 to 200 ppm. 4. Chemical Oxygen Demand: Maximum 100 ppm. Modify this value if closed system

contains glycol. 5. Corrosion Inhibitor:

a. Sodium Nitrate: 1000 to 1500 ppm. b. Molybdate: 200 to 300 ppm. c. Chromate: 200 to 300 ppm. d. Sodium Nitrate Plus Molybdate: 100 to 200 ppm each. e. Chromate Plus Molybdate: 50 to 100 ppm each.



6. Soluble Copper: Maximum 0.20 ppm. 7. Tolyiriazole Copper and Yellow Metal Corrosion Inhibitor: Minimum 10 ppm. 8. Total Suspended Solids: Maximum 10 ppm. 9. Ammonia: Maximum 20 ppm. 10. Free Caustic Alkalinity: Maximum 20 ppm. 11. Microbiological Limits:

a. Total Aerobic Plate Count: Maximum 1000 organisms/ml. b. Total Anaerobic Plate Count: Maximum 100 organisms/ml. c. Nitrate Reducers: 100 organisms/ml. d. Sulfate Reducers: Maximum 0 organisms/ml. e. Iron Bacteria: Maximum 0 organisms/ml.

B. Fill system with fresh water and add liquid alkaline compound with emulsifying agents and detergents to remove grease and petroleum products from piping. Circulate solution for a minimum of 24 hours, drain, clean strainer screens, and refill with fresh water.

C. Add initial chemical treatment and maintain water quality in ranges noted above for the first year of operation.

3.9 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. 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, "Building Services Piping."

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 pumps for proper rotation. 3. Set makeup pressure-reducing valves for required system pressure. 4. 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). 5. Set temperature controls so all coils are calling for full flow. 6. Inspect and set operating temperatures of hydronic equipment, such as boilers, chillers,

cooling towers, to specified values. 7. Verify lubrication of motors and bearings.



VARIABLE-FREQUENCY MOTOR CONTROLLERS 239000 - 1

SECTION 239000 – VARIABLE FREQUENCY DRIVES

PART 1-GENERAL

1.01 SECTION INCLUDES

A. Variable Frequency Drive(VFD)

1.02 REFERENCES

A. NEMA250 B. EN 50178 (LVD) C. EN 61800-3, EN 61000-4-2(-3,-4,-5-6)/A2, EN 61000-2-1, EN 60146-1-1/A1 D. IEEE 519 E. UL 508C (Power Conversion)

1.03 SUBMITTALS

A. Shop drawing shall include: Wiring diagrams, electrical schematics, front and side views of enclosures, overall dimensions, conduit entrance locations and requirements, name-plate legends, physical layout and enclosure details.

B. Product Data: Provide data sheets showing; voltage, ratings of customer use of switching and over-current protective devices, short circuit rating, and weights.

C. Manufacturer’s Installation Instructions and Technical Manuals: Indicate application con-ditions and limitations of use stipulated by product testing agency specified under regula-tory requirements. Include instructions for storage, handling, protection, examination, preparation, installation, and starting of Adjustable Frequency Drive. Document the se-quence of operation, cautions and warnings, trouble shooting procedures, spare parts lists and guidance.

1.04 QUALIFICATIONS

A. Manufacturer must have minimum of 20 years of documented experience, specializing in variable frequency drives.

B. UL and ULc approval on all VFDs specified


A. Accept VFD on site in original packing. Inspect for damage. B. Store in a clean, dry space. Maintain factory wrapping, or provide additional heavy can-

vas, or heavy plastic cover, to protect units from dirt, water, construction debris, and traf-fic.

C. Handle carefully, in accordance of manufacturer’s written instruction, to avoid damage to components, enclosure, and finish.



1.06 WARRANTY

A. Provide VFD warranty, for 5 years from date of start up – P Drives for variable torque ap-plications. Warranty shall include parts, and labor at factory for repair. Servicing techni-cian on VFD does not need factory certification to preserve warranty.

PART 2 – PRODUCTS

2.01 MANUFACTURERS

A. VFD shall be manufactured by Cerus Industrial.

2.02 RATINGS:

A. Input 380/415/440/460 VAC +/- 10%, 3 phase, 48-63 Hz or input 200/208/220/230 VAC +/- 10%, 3 phase, 48-63 Hz.

B. Output Frequency 0 to 120 Hz

C. Environmental operating conditions: -10 to 40°C, 0 to 3300 feet above sea level, less than 95% humidity, non-condensing.

D. Enclosure shall be UL Type 1, unless otherwise noted. E. Starting Torque: 175% starting torque shall be available from .5 Hz to 60 Hz. F. Minimum operating efficiency greater than 96% G. Input Power Factor is greater than 95% from no load to full load. H. Must meet RFI requirements as specified by IEC STD EN 61000-2(-4)(2001) for variable

frequency drives.

2.03 DESIGN

A. All VFD must be solid state, utilizing Space Vector PWM control for lower motor operat-ing temperature and lower THD on the output. The VFD package as specified herein shall be enclosed in a UL Type 1 enclosure, completely assembled and tested by the manufacturer.

B. All VFD shall include a digital display, and keypad, regardless of horsepower rating. The keypad is to be used for local control, for setting all parameters, and for stepping through the displays and menus. The keypad shall be removable, capable of remote mounting, and shall have its own non-volatile memory. The keypad shall allow for uploading and downloading of parameter settings as an aid for start-up of multiple VFDs. 1. The keypad shall display motor speed (in Hz or RPM, selectable), current amps and

start/stop and speed control settings. 2. The keypad shall display VFD status (run, power, fault) and all available fault condi-

tions. C. All VFD must have adjustable carrier frequency and up to 4 programmable V/Hz points. D. All VFD must have BAS (Building Automation System) protocols such as Johnson Meta-

sys N2, Modbus, and RS485 as standard and LonWorks, Profibus or BACnet as an op-tion.

E. All VFD shall be selectable as in both Volts/Hertz or Sensorless Vector Control mode regardless of horsepower rating.



F. All VFD must have a motor preheat function to prevent moisture accumulation in an idle motor.

G. All VFD shall include two independent analog inputs as standard, 0 –10VDC and 4-20mA. Both analog inputs shall be utilized as speed references, or as PID inputs. The analog inputs shall be programmed as an individual reference at a time, or as a com-bined reference together. A second PID loop control shall be provided for control of ex-ternal equipment.

H. All VFD shall include a minimum of 8 multi-function input terminals, capable of being programmed to a function on a change of state. These terminals shall provide up to 30 functions, including, but not limited to: 1. External Trip 2. Forward 3. Reverse 4. Three Wire Control 5. Multi-step Speed Selection 6. Interlock 7. Jog 8. Pre-excite/Motor Preheat

I. The VFD shall provide frequency setting resolution of 0.01 Hz when its Digital Reference is utilized below 100 Hz and 0.1 Hz over 100 Hz. The VFD shall provide frequency set-ting resolution of 0.03 Hz / 60 Hz when Analog Reference is utilized.

J. The VFD shall have the ability to automatically restart after an over-current, over-voltage, under-voltage, or loss of input signal protective trip. The number of restart at-tempts, trial time, and time between reset attempts shall be programmable.

K. The VFD shall be capable of both Automatic and Manual Torque Boost function to over-come sudden fluctuation of the load.

L. The VFD shall be equipped with Auto-tuning feature for motor data analysis resulting in optimized motor performance.

M. The VFD shall be capable of starting into a rotating load (forward or reverse) and accel-erate or decelerate to set-point without safety tripping or component damage (flying start). The VFD shall also be capable of DC injection braking at start to stop a reverse spinning motor prior to ramp.

N. The VFD shall be equipped with an automatic extended power loss ride-through circuit, which will utilize the inertia of the load to keep the drive powered. Minimum power loss ride-through shall be one-cycle, based on full load and no inertia. Typical control power loss ride-through for a fan load shall be 2 seconds minimum.

O. All VFD shall have 1 analog output (0-10VDC) which can be programmed to function as one of the following: Output Frequency, Output Current, Output Voltage, DC Link Volt-age. Default is set to Output Frequency.

P. If the input reference (4-20mA or 0-10V) is lost, the VFD shall give the user the option of either (1) stopping and displaying a fault, (2) running at a programmable preset speed, or (3) hold the VFD speed based on the last good reference received. The drive shall be programmable to signal this condition via a keypad warning, relay output and/or over the serial communication bus.

Q. The customer terminal strip shall be isolated from the line and ground. R. The drive shall employ current limit circuits to provide “trip-less” operation S. The Maximum current limit shall be fixed at 150% (minimum, instantaneous) of the VFD

normal duty current rating. T. The overload rating of the drive shall be 120% of Rated Current for 1 Min., 150% of Rat-

ed Current for 0.5 sec. U. The VFD shall have 8 Step Speeds that are preprogrammed via Digital Input Terminals. V. The VFD shall have standard Emergency Input and Jog Input Terminals.



W. The VFD shall provide from 0 to 6000 seconds of Acceleration and Deceleration time set-ting parameters. Up to 8 Acceleration and 8 Deceleration times shall be programmable.

X. The VFD shall be optimized for various levels of carrier frequency programmable from 1 to 15 kHz (1 – 3 kHz above 40HP) to reduce motor noise and to provide high system ef-ficiency.

Y. The VFD must have an option to operate multiple motors with single VFD and be able to turn on/off each motors independently as well as simultaneously.

Z. The VFD must have an Energy Saving function in auto and manual mode. AA. The VFD must have Bi-directional "Speed search" capability. BB. The VFD shall include provisions for multi-motor control as an option or as standard, en-

abling control of up to 4 motors. CC. All VFD include the following programming adjustment capabilities:

1. Directional Lock selection to prevent the unexpected motor direction. 2. DC Injection start and stop frequency selection from Minimum output frequency to 60

Hz. 3. Three programmable critical frequency lockout ranges to prevent the VFD from oper-

ating the load continuously at an unstable speed. 4. Pre-magnetization selection for the motor to build up an adequate level of flux for en-

hanced starting torque or programmable Volts/Hertz points selection for flexible Vari-able and Constant load demand curve and fluctuation.

5. VFD Voltage-output to motor adjustment feature enabling the VFD to generate from 40% up to 110% of nominal input voltage to the VFD.

6. Five (5) Fault Histories with detailed description of frequency, current, and other op-erational status at the time of each fault.

7. Two independently adjustable acceleration and deceleration ramps. These ramp times shall be adjustable from 1 to 6000 seconds.

8. The VFD shall Ramp or Coast to a stop, DC Injection, as selected by the user. 9. The VFD shall have selectable ‘No-Motor’ parameter to facilitate startup and trouble-

shooting. 10. Manual speed control adjustable by the VFD Keypad shall be available.

DD. The VFD shall have the following protection circuits. In the case of a protective trip, the drive shall stop and announce the fault condition.

• IGBT overcurrent protection

• Overcurrent trip on load output

• DC overvoltage

• Internal overtemperature

• Ground Fault

• Low Voltage

• Open output phase

• Electronic Thermal Protection. The Electronic Thermal Overload protection shall protect the motor based on speed, load curve, and motor parameters.

EE. PC software and for parameter upload/download/graphing shall be provided at no additional charge.

2.04 PRODUCT OPTIONS

A. Three switch Manual Bypass shall be provided when indicated by the schedule. VFD and bypass components shall be mounted inside a common NEMA 1 enclosure, fully pre-wired, and ready for installation as a single UL listed device. Bypass shall include the following: 1. Output, and bypass contactors, to switch power from the VFD to bypass.



2. UL 508E Manual Motor Starter with pad-lockable handle to isolate the drive and protect the motor while operating in the bypass mode.

3. Control and safety circuit terminal strip. 4. Drive/Off/Bypass selector switch and Hand/Off/Auto selector switch. 5. Switch selectable smoke purge, auto transfer to bypass and remote transfer functions. 6. Pilot lights (22 mm LEDs) for, “Drive Run” and “Bypass”. 7. Hand/Off/Auto selector switch shall provide the following operation:

• Hand Position - The drive is given a start command, and the drive will run at preset speed- user adjustable.

• Off Position - The start command is removed, all speed inputs are ignored, and power is still applied to the drive. If in bypass mode, the motor is stopped.

• Auto Position - The drive is enabled to receive a start command and speed input from a building automation system. If in bypass mode, the motor start/stop is controlled by the building automation system

8. Annunciation contacts for drive run, drive fault, bypass run and motor OL/safety fault. 9. VFD operator/keypad selection, LCD multi-line display.

B. Enclosure: 1. NEMA 1 extended enclosure, to house additional equipment within the VFD enclosure for

VFDs not requiring Bypass. 2. NEMA 12 FVFF (Forced Ventilation inlet Filter and outlet Filter) enclosures with filters

and blower. 3. NEMA 3R enclosures for outdoor installations.

a. For installation in ambient temperature environment above 104˚F (40˚C), de-rate VFD 20% to increase ambient temperature rating to 122˚F (50˚C).

b. For installation in sustained ambient temperature environment below 14˚F, include panel space heater.

C. Output Filtering: 1. For long VFD to motor lead lengths provide self contained, installation appropriate,

enclosed output reactor or filter: a. Provide output line reactor when lead is greater than 50 ft. at 460V input line

power application. b. Provide output line reactor when lead is greater than 200 ft. at 208/230V input line

power application. c. Provide output dual element filter when lead is greater than 100 ft. at 460V input line

power application. d. Provide output dual element filter when lead is greater than 400 ft. at 208/230V input

line power application. D. Minimum 3% Line Reactors (5% when noted) shall be provided on the input side of the drive

for harmonic suppression and input rectifier protection. DC Link Reactors or Bus Chokes are not acceptable substitute.

E. Integral Disconnect: Motor Circuit Protector (MCP) The MCP shall be a UL listed 508 manual motor starter with magnetic trip elements only. The breaker shall carry a UL 508F rating (up to 100A frame size) with a minimum interrupting rating of 30,000 AIC.

F. Multi-Motor Branch Protection available with adjustable thermal protection and individual disconnects.

G. Surge suppression shall be provided to protect the drive from input power disturbances. H. Engraved cabinet nameplates shall be provided.



PART 3 – EXECUTION

3.01 INSTALLATION

A. Installation shall be the responsibility of the mechanical contractor. The contractor shall install the drive in accordance with the recommendations of the VFD manufacturer as outlined in the installation manual.

B. Power wiring shall be completed by the electrical contractor. The contractor shall com-

plete all wiring in accordance with the recommendations of the VFD manufacturer as outlined in the installation manual.

3.02 START-UP

A. Remote VFD Start-up assistance and training shall be available by factory and/or VFD provider at no additional charge. Start-up technician is not required to be factory certi-fied to preserve factory warranty. A factory supplied start-up form shall be filled out for each drive with a copy provided to the owner, and a copy sent to be kept on file at the manufacturer.

3.03 PRODUCT SUPPORT

A. Factory trained application engineering and service personnel that are thoroughly trained with the supplied VFD and optional packages shall be available via factory re-mote technical assistance at both the specifying and installation locations. Additional lo-cal support to be available through VFD supplier or referred technician for hire or pre-negotiated service terms. Servicing technician does not need to be factory certified to preserve warranty.



HYDRONIC PUMPS 232123 - 1

SECTION 232123 - HYDRONIC PUMPS

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes: 1. Close-coupled, end-suction centrifugal pumps.

1.3 DEFINITIONS

A. Buna-N: Nitrile rubber.

B. EPT: Ethylene propylene terpolymer.


A. Product Data: For each type of pump. Include certified performance curves and rated capacities, operating characteristics, furnished specialties, final impeller dimensions, and accessories for each type of product indicated. Indicate pump's operating point on curves.

B. Shop Drawings: For each pump.

1. Show pump layout and connections. 2. Include setting drawings with templates for installing foundation and anchor bolts and

other anchorages. 3. Include diagrams for power, signal, and control wiring.


A. Operation and Maintenance Data: For pumps to include in emergency, operation, and maintenance manuals.

1.6 MAINTENANCE MATERIAL SUBMITTALS

A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents.



1. Mechanical Seals: One mechanical seal(s) for each pump.

PART 2 - PRODUCTS

2.1 CLOSE-COUPLED, END-SUCTION CENTRIFUGAL PUMPS

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

1. Armstrong Pumps Inc. 2. Aurora Pump; Division of Pentair Pump Group. 3. ITT Corporation; Bell & Gossett. 4. PACO Pumps. 5. Patterson Pump Co.; a subsidiary of the Gorman-Rupp Co. 6. Peerless Pump Company. 7. TACO Incorporated. 8. Thrush Company Inc.

B. Description: Factory-assembled and -tested, centrifugal, overhung-impeller, closed coupled, pump as defined in Hi 1.1-1.2 and HI 1.3; designed for installation with pump and motors hafts mounted horizontally. Rate pump for 170-psig maximum working pressure and a continuous water temperature of 225 deg F.

C. Pump Construction:

1. Casing: Back Pull-out design, cast iron or silicon bronze with threaded gage tappings at inlet and outlet, and flange connections. Casing wear ring shall be made of Bronze, ASTMB505-932. . Provide stamped pump serial number in casing, so as to identify if pump tag is removed.

2. Impeller: ASTM B584-875, cast bronze, statically and dynamically balanced after trimming, keyed to shaft and secured with a locking stainless steel screw. Impeller to have balance holes to reduce axial thrust. Impeller to be trimmed to match specified performance by Pump Manufacture.

3. Pump Shaft: Steel, with bronze shaft sleeve. 4. Seal: Mechanical seal consisting of carbon rotating ring against a silicon carbide seat

held by a 416 stainless-steel spring, and Buna-N bellows and gasket. Include water slinger on shaft between motor and seal.

5. Copper flush seal line shall be installed from discharge of pump to seal gland.

D. Motor: Single speed and rigidly mounted to pump casing with integral pump support.

1. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.

2. Comply with NEMA designation, temperature rating, service factor, and efficiency requirements for motors specified in Division 23 Section "Common Motor Requirements for HVAC Equipment."

a. Enclosure: Open, dripproof. b. Enclosure Materials: Cast iron Rolled steel.



c. Motor Bearings: Grease-lubricated ball bearings.

d. Efficiency: Premium efficient.

E. Capacities and Characteristics: See Schedule.

2.2 PUMP SPECIALTY FITTINGS

A. Suction Diffuser:

1. Angle pattern. 2. 175-psig (1204-kPa) pressure rating, cast-iron body and end cap, pump-inlet fitting. 3. Bronze startup and bronze or stainless-steel permanent strainers. 4. Bronze or stainless-steel straightening vanes. 5. Drain plug. 6. Factory-fabricated support.

B. Triple-Duty Valve:

1. Angle or straight pattern. 2. 175-psig (1204-kPa) pressure rating, cast-iron body, pump-discharge fitting. 3. Drain plug and bronze-fitted shutoff, balancing, and check valve features. 4. Brass gage ports with integral check valve and orifice for flow measurement.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine equipment foundations and anchor-bolt locations for compliance with requirements for installation tolerances and other conditions affecting performance of the Work.

B. Examine roughing-in for piping systems to verify actual locations of piping connections before pump installation.

C. Examine foundations and inertia bases for suitable conditions where pumps are to be installed.

D. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 PUMP INSTALLATION

A. Comply with HI 1.4 and HI 2.4.

B. Install pumps to provide access for periodic maintenance including removing motors, impellers, couplings, and accessories.

C. Independently support pumps and piping so weight of piping is not supported by pumps and weight of pumps is not supported by piping.



D. Equipment Mounting: Install base-mounted pumps on cast-in-place concrete equipment bases. Comply with requirements for equipment bases specified in Division 03 Section "Cast-in-Place Concrete Miscellaneous Cast-in-Place Concrete."

1. Coordinate sizes and locations of concrete bases with actual equipment provided. 2. Construct bases to withstand, without damage to equipment, seismic force required by

code. 3. Construct concrete bases 4 inches (100 mm) high and extend base not less than 6

inches (150 mm) in all directions beyond the maximum dimensions of base-mounted pumps unless otherwise indicated or unless required for seismic-anchor support.

3.3 CONNECTIONS

A. Comply with requirements for piping specified in Division 23 Section "Steam and Condensate Heating Piping." Drawings indicate general arrangement of piping, fittings, and specialties.

B. Where installing piping adjacent to pump, allow space for service and maintenance.

C. Connect piping to pumps. Install valves that are same size as piping connected to pumps.

D. Install suction and discharge pipe sizes equal to or greater than diameter of pump nozzles.

E. Install triple-duty valve on discharge side of pumps.

F. Install Y-type strainer suction diffuser and shutoff valve on suction side of pumps.

G. Install flexible connectors on suction and discharge sides of base-mounted pumps between pump casing and valves.

H. Install single pressure gage with multiple-input selector valve on pump suction and discharge.

I. Ground equipment according to Division 26 Section "Grounding and Bonding for Electrical Systems."

J. Connect wiring according to Division 26 Section "Low-Voltage Electrical Power Conductors and Cables."

3.4 STARTUP SERVICE

A. Perform startup service.

1. Complete installation and startup checks according to manufacturer's written instructions. 2. Check piping connections for tightness. 3. Clean strainers on suction piping. 4. Perform the following startup checks for each pump before starting:

a. Verify bearing lubrication. b. Verify that pump is free to rotate by hand and that pump for handling hot liquid is

free to rotate with pump hot and cold. If pump is bound or drags, do not operate until cause of trouble is determined and corrected.



c. Verify that pump is rotating in the correct direction.

5. Prime pump by opening suction valves and closing drains, and prepare pump for operation.

6. Start motor. 7. Open discharge valve slowly.

3.5 DEMONSTRATION

A. Train Owner's maintenance personnel to adjust, operate, and maintain hydronic pumps.



BOILER CONTROLS 235218 - 1

SECTION 235218 – BOILER CONTROLS

PART 1 - CONTROL SPECIFICATION 1. When multiple hydronic boilers are to be installed in a common loop, a boiler sequencing control

system shall be used. The sequencing system will monitor, enable/disable and control the firing rate of each boiler in the loop. To ensure accurate temperature control and optimized boiler oper-ating efficiencies, a ModSync Sequencing System shall be used. The hydronic boilers shall be controlled as follows to maximize their operating efficiency:

1) The sequencing system shall monitor the outdoor temperature and calculate a hydronic loop temperature setpoint based on touchscreen selectable user-defined values. The boiler sequencing system will stage operation of the hydronic boilers based on the differ-ence between the actual hydronic loop temperature and the calculated (outdoor air reset) hydronic loop temperature setpoint.

2) When a requirement for heat is determined by the boiler sequencing system, the lead

boiler is energized and its firing rate is maintained at low fire.

3) If the hydronic loop temperature continues to decrease, the boiler sequencing system will enable a lag boiler. The first lag boiler is energized and the lag boiler’s firing rate is main-tained at low fire.

4) As additional heat is required, the boiler sequencing system will enable the remaining lag

boiler stages individually until all of the available boilers in the hydronic loop have been energized. Each boiler will remain at low fire until all of the stages have been enabled.

5) If all of the hydronic boilers are enabled and additional heat is required, the boiler se-

quencing system will release the boilers to modulate. Operating hydronic boilers at lower firing rate levels provides significant efficiency gains. Therefore, hydronic boilers will modulate together as a single unit to keep the hydronic boiler system at the lowest possi-ble firing rate, while satisfying the building load demands.

6) As the hydronic loop temperature increases, the boiler sequencing system will decrease

the firing rate of the hydronic boilers to maintain the hydronic loop temperature. If all of the hydronic boilers are at low fire and the hydronic loop temperature continues to rise, the boiler sequencing system will begin to stage the boilers off. The first lag boiler stage energized will be the last stage to be disabled. The hydronic boilers will continue to be disabled by the boiler sequencing system based on the temperature rise of the hydronic loop.

7) The lead boiler is disabled when the hydronic loop temperature reaches a selectable val-

ue referenced around the hydronic loop setpoint.

2. The boiler sequencing system will be a microprocessor based process controller with a graphical user interface and touchscreen capabilities. Boiler sequencing systems designed with alpha-numeric displays will not be acceptable due to their limited functionality. (ModSync) The active touchscreen display area will be a minimum of 4.7” with a monochrome LCD illuminated display resolution of 320 x 240 pixels.



3. The boiler sequencing system enclosure will be NEMA 4X construction. The enclosure shall be

designed with the ability of be located in outdoor environments. Mounting of the boiler sequenc-ing system inside another panel to provide an outdoor rating will not be acceptable due to the in-creased access time requirements to view and modify the system parameters. Power require-ments for the boiler sequencing panel will be 120/60/1.

4. The boiler sequencing system will be a wall mounted, stand-alone unit. Local boiler controls with integrated lead/lag logic are not acceptable due to their limited logic capabilities and rewiring re-quirements in the event of a sensor or local controller error.

5. Password requirements will prevent access to any of the screens where system configuration parameters can be adjusted, while maintaining the ability of viewing the system performance.

6. Outdoor and Supply Header Temperature sensors supplied with the boiler sequencing system shall be PT-100 RTD type for precise temperature monitoring. Return Temperature monitoring capabilities shall be available and used when BTU calculation is used. The boiler sequencing system will also have the ability to receive temperature values from the Building Management System through a communication protocol. Each temperature input shall have a selection button that allows for independent configuration of where the temperature value will be received from.

7. The boiler sequencing system will provide a series of “Question and Answer” screens to simplify the commissioning process.

8. Multiple Status and Configuration Screens will be available for easy interpretation of the hydronic

loop status and simplified control configuration of the multiple hydronic boiler system. Minimum screens available shall include:

1) Outdoor Reset Configuration 2) Setback Schedule 3) Lead/Lag Configuration 4) Boiler Configuration 5) System Status 6) Alarm Status 7) Alarm History

9. Outdoor Reset - The ability to adjust the hydronic loop temperature setpoint based on the outdoor temperature is a key element of hydronic system efficiency. As the outdoor temperature increas-es, the hydronic loop setpoint can decrease while still maintaining the desired building tempera-ture. Lower return water temperatures can significantly increase the hydronic boiler system effi-ciency. The boiler sequencing system shall provide Outdoor Reset Configuration Screens that include all of the parameters required to effectively configure the hydronic loop setpoint based on the out-door temperature.

a) The boiler sequencing system will provide an adjustable reset schedule based on the outdoor temperature. A linear outdoor reset ratio will be determined based on user-defined hydronic loop temperatures at 50ºF and 0ºF outdoor temperatures. Outdoor temperature configuration variables shall be adjustable through the touchscreen to match



designed reset schedule requirements. A reference graphic detailing the calculated reset ratio will be displayed on the Outdoor Reset Configuration screen.

b) Minimum and maximum loop temperature parameters will prevent the outdoor reset schedule from operating outside of a user-defined temperature range.

c) A user-defined Outdoor Temperature Disable parameter will be provided to disable the hydronic loop if a predetermined outdoor temperature is reached. A hysteresis variable will prevent the hydronic system from re-enabling until the outdoor temperature decreas-es a user-defined amount.

d) To meet multiple system control configurations, setpoint mode adjustment capabilities will be included as standard with the boiler sequencing system. Setpoint Modes will include Outdoor Reset, 4-20mA Remote Setpoint, BMS Communication or Manual. The setpoint mode shall be field adjustable by a touchscreen selection button on the Setpoint Configu-ration screen.

e) Provisions for Domestic Hot Water Priority shall be available if required. A temperature

aquastat input is monitored and will automatically adjust the hydronic loop setpoint to meet the Domestic Hot Water demand. When the domestic load is satisfied, the boiler sequencing system will automatically switch the setpoint mode to outdoor reset.

10. Setback Configuration Screens shall be provided to adjust the hydronic loop setpoint based on

Day of the Week/Time of Day variables.

a) Multiple setback schedules shall be available based on whether the building is in Occu-pied or Unoccupied mode. Building Mode selection shall be determined by a user-defined Time of Day / Day of Week touchscreen entry. The Building Mode will automati-cally change between Occupied and Unoccupied based on the user programmed day and times. Manual Building Mode control shall also be available via a Setup menu. Build-ing Mode shall be indicated on the Loop Status Screen for ease of reference.

b) An Anticipation Mode feature shall be provided to automatically switch to Occupied Mode a selectable number of hours earlier than scheduled if the outdoor temperature lowers below a user-defined temperature during the Unoccupied Mode.

11. Lead/Lag Configuration screens shall be used to configure how the hydronic boilers will be as-signed and enabled in the control sequence.

a) The boiler sequencing system will include automatic rotation of the lead boiler based on a user configured lead boiler cycle count or run hours, whichever setting occurs first.

b) When the lead cycle or run hours rotation value is reached, the boiler sequencing system will assign each boiler’s position in the lead/lag sequence based on their previous operat-ing history. Boiler sequencing systems that simply rotate the lead position to the next boiler in the sequence will not be acceptable due to their ineffective ability of maintaining an even cycle count across all of the boiler stages in the hydronic loop.

c) The boiler sequencing system will stage the boilers based on a PID generated control variable value. The Proportional, Integral and Derivative values shall be user-defined through the Lead/Lag Configuration screen. Each lag boiler stage will be enabled and disabled based on a user-defined control variable percentage. Properly tuned loops will provide temperature control accuracy up to +/- 2ºF, based on load demand. Lead boiler



start and stop parameters shall be user-defined through the touchscreen operator inter-face. A Manual Reset parameter will allow the Proportional Band to be shifted around setpoint.

d) A user-defined time delay parameter will be provided that delays enabling and disabling

of the lag boiler stages. This helps to decrease cycling of the lag stages when the build-ing load is close to being satisfied.

e) The boiler sequencing system will have the ability to monitor the outlet temperature of each hydronic boiler in the system. This feature is beneficial for systems that will incor-porate variable flow designs. If the boiler outlet temperature exceeds setpoint by a user-defined amount, the boiler sequencing system will automatically lower the firing rate of the boiler to help prevent a high limit trip at the boiler. As the boiler outlet temperature decreases below a defined variable, the boiler sequencing system will allow the firing rate of the boiler to increase.

12. Boiler Configuration screens will display information regarding each boiler stage in the hydronic

loop.

a) The boiler configuration screens will detail and provide: - Hydronic Boiler Status. - Hydronic Boiler Cycles, Run Hours and Cycle/Hour Ratio calculation. - Hydronic Boiler Outlet Temperature. - Hydronic Boiler Enable/Disable touchscreen selection. - Hydronic Boiler Auto/Manual touchscreen control mode selection. - Hydronic Boiler Manual touchscreen Start/Stop and Firing Rate control.

b) The boiler sequencing system shall include capabilities to enable/disable the boilers

through the operator interface. Boilers that are disabled will not be included in the se-quencing logic.

13. The boiler sequencing system will monitor the operation and status of all temperature sensors

and hydronic boilers in the loop. Sensor errors will be annunciated on the boiler sequencing sys-tems alarm screen. If an outdoor temperature sensor error occurs, the boiler sequencing system will automatically switch to manual setpoint mode and will annunciate the alarm condition.

14. The boiler sequencing system will start a timer when each boiler stage is enabled to run. If the main gas valves do not energize within the user-defined timeframe then a local limit is preventing the boiler from operating. The boiler sequencing system will immediately remove the boiler from the lead/lag sequence and annunciate that a local boiler error exists. An automatic reset option will allow the boiler to be re-enabled after a user-defined timeframe has elapsed.

15. An Alarm Status screen will give a text description of any current alarm conditions. Boiler se-quencing systems that use codes or symbols to detail alarm conditions will not be acceptable. The boiler sequencing system will automatically adjust the boiler sequencing status and remove the boiler from the sequencing logic if an alarm occurs. The boiler will automatically be added back into the rotation loop as soon as the boiler sequencing system senses that the alarm has been cleared.

16. The boiler sequencing panel will include an Alarm History screen that allows for the (ModSync) - last 8



17. A System Status screen will detail current outdoor, hydronic system and control variable values. The status screen will also display enable/disable and firing rate information for each of the boil-ers in the hydronic loop.

18. The boiler sequencing system will have the ability to communicate to a Building Management

System using multiple protocols including Modbus RTU, BacNet, LonWorks or N2. Standard point mapping will be provided with the boiler sequencing system. Selection of modbus serial connectivity (RS-232/RS-485) and baud rate will be field-adjustable using a configuration screen on the boiler sequencing system. Selection of BacNet MS/TP or IP shall be field adjustable through a dip-switch setting. The ability to field adjust custom project points will be available through an easy to configure and freely distributed software package.

19. To decrease installation wiring requirements, wireless interfacing capabilities between the boiler sequencing system and each boiler shall be available.

20. Boiler isolation valve control capabilities will be provided by the boiler sequencing system. The boiler sequencing system will keep the lead boiler’s isolation valve open at all times to provide a continuous flow path and prevent dead-heading of the main system pump(s). A lag boiler’s isola-tion valve will be enabled when the boiler is called to run and will remain enabled until a user de-fine timeframe elapses after the boiler is disabled. This will allow for any residual heat in the boil-er to dissipate before the isolation valve closes and prevent the possibility of a high limit trip at the boiler.

21. The boiler sequencing system shall have the ability for the internal control logic to be

field-modified to meet system design changes that may arise during commissioning of the hy-dronic system or future system expansion. The control logic shall be field adjustable through a downloadable, freely distributed software package that does not require a licensing fee. Se-quencing systems with fixed control logic that cannot be modified in the field will not be accepta-ble due to their inherent limitations.




SECTION 239000 – VARIABLE FREQUENCY DRIVES

PART 1-GENERAL

1.01 SECTION INCLUDES

A. Variable Frequency Drive(VFD)

1.02 REFERENCES

A. NEMA250 B. EN 50178 (LVD) C. EN 61800-3, EN 61000-4-2(-3,-4,-5-6)/A2, EN 61000-2-1, EN 60146-1-1/A1 D. IEEE 519 E. UL 508C (Power Conversion)

1.03 SUBMITTALS

A. Shop drawing shall include: Wiring diagrams, electrical schematics, front and side views of enclosures, overall dimensions, conduit entrance locations and requirements, name-plate legends, physical layout and enclosure details.

B. Product Data: Provide data sheets showing; voltage, ratings of customer use of switching and over-current protective devices, short circuit rating, and weights.

C. Manufacturer’s Installation Instructions and Technical Manuals: Indicate application con-ditions and limitations of use stipulated by product testing agency specified under regula-tory requirements. Include instructions for storage, handling, protection, examination, preparation, installation, and starting of Adjustable Frequency Drive. Document the se-quence of operation, cautions and warnings, trouble shooting procedures, spare parts lists and guidance.

1.04 QUALIFICATIONS

A. Manufacturer must have minimum of 20 years of documented experience, specializing in variable frequency drives.

B. UL and ULc approval on all VFDs specified


A. Accept VFD on site in original packing. Inspect for damage. B. Store in a clean, dry space. Maintain factory wrapping, or provide additional heavy can-

vas, or heavy plastic cover, to protect units from dirt, water, construction debris, and traf-fic.

C. Handle carefully, in accordance of manufacturer’s written instruction, to avoid damage to components, enclosure, and finish.



1.06 WARRANTY

A. Provide VFD warranty, for 5 years from date of start up – P Drives for variable torque ap-plications. Warranty shall include parts, and labor at factory for repair. Servicing techni-cian on VFD does not need factory certification to preserve warranty.

PART 2 – PRODUCTS

2.01 MANUFACTURERS

A. VFD shall be manufactured by Cerus Industrial.

2.02 RATINGS:

A. Input 380/415/440/460 VAC +/- 10%, 3 phase, 48-63 Hz or input 200/208/220/230 VAC +/- 10%, 3 phase, 48-63 Hz.

B. Output Frequency 0 to 120 Hz

C. Environmental operating conditions: -10 to 40°C, 0 to 3300 feet above sea level, less than 95% humidity, non-condensing.

D. Enclosure shall be UL Type 1, unless otherwise noted. E. Starting Torque: 175% starting torque shall be available from .5 Hz to 60 Hz. F. Minimum operating efficiency greater than 96% G. Input Power Factor is greater than 95% from no load to full load. H. Must meet RFI requirements as specified by IEC STD EN 61000-2(-4)(2001) for variable

frequency drives.

2.03 DESIGN

A. All VFD must be solid state, utilizing Space Vector PWM control for lower motor operat-ing temperature and lower THD on the output. The VFD package as specified herein shall be enclosed in a UL Type 1 enclosure, completely assembled and tested by the manufacturer.

B. All VFD shall include a digital display, and keypad, regardless of horsepower rating. The keypad is to be used for local control, for setting all parameters, and for stepping through the displays and menus. The keypad shall be removable, capable of remote mounting, and shall have its own non-volatile memory. The keypad shall allow for uploading and downloading of parameter settings as an aid for start-up of multiple VFDs. 1. The keypad shall display motor speed (in Hz or RPM, selectable), current amps and

start/stop and speed control settings. 2. The keypad shall display VFD status (run, power, fault) and all available fault condi-

tions. C. All VFD must have adjustable carrier frequency and up to 4 programmable V/Hz points. D. All VFD must have BAS (Building Automation System) protocols such as Johnson Meta-

sys N2, Modbus, and RS485 as standard and LonWorks, Profibus or BACnet as an op-tion.

E. All VFD shall be selectable as in both Volts/Hertz or Sensorless Vector Control mode regardless of horsepower rating.



F. All VFD must have a motor preheat function to prevent moisture accumulation in an idle motor.

G. All VFD shall include two independent analog inputs as standard, 0 –10VDC and 4-20mA. Both analog inputs shall be utilized as speed references, or as PID inputs. The analog inputs shall be programmed as an individual reference at a time, or as a com-bined reference together. A second PID loop control shall be provided for control of ex-ternal equipment.

H. All VFD shall include a minimum of 8 multi-function input terminals, capable of being programmed to a function on a change of state. These terminals shall provide up to 30 functions, including, but not limited to: 1. External Trip 2. Forward 3. Reverse 4. Three Wire Control 5. Multi-step Speed Selection 6. Interlock 7. Jog 8. Pre-excite/Motor Preheat

I. The VFD shall provide frequency setting resolution of 0.01 Hz when its Digital Reference is utilized below 100 Hz and 0.1 Hz over 100 Hz. The VFD shall provide frequency set-ting resolution of 0.03 Hz / 60 Hz when Analog Reference is utilized.

J. The VFD shall have the ability to automatically restart after an over-current, over-voltage, under-voltage, or loss of input signal protective trip. The number of restart at-tempts, trial time, and time between reset attempts shall be programmable.

K. The VFD shall be capable of both Automatic and Manual Torque Boost function to over-come sudden fluctuation of the load.

L. The VFD shall be equipped with Auto-tuning feature for motor data analysis resulting in optimized motor performance.

M. The VFD shall be capable of starting into a rotating load (forward or reverse) and accel-erate or decelerate to set-point without safety tripping or component damage (flying start). The VFD shall also be capable of DC injection braking at start to stop a reverse spinning motor prior to ramp.

N. The VFD shall be equipped with an automatic extended power loss ride-through circuit, which will utilize the inertia of the load to keep the drive powered. Minimum power loss ride-through shall be one-cycle, based on full load and no inertia. Typical control power loss ride-through for a fan load shall be 2 seconds minimum.

O. All VFD shall have 1 analog output (0-10VDC) which can be programmed to function as one of the following: Output Frequency, Output Current, Output Voltage, DC Link Volt-age. Default is set to Output Frequency.

P. If the input reference (4-20mA or 0-10V) is lost, the VFD shall give the user the option of either (1) stopping and displaying a fault, (2) running at a programmable preset speed, or (3) hold the VFD speed based on the last good reference received. The drive shall be programmable to signal this condition via a keypad warning, relay output and/or over the serial communication bus.

Q. The customer terminal strip shall be isolated from the line and ground. R. The drive shall employ current limit circuits to provide “trip-less” operation S. The Maximum current limit shall be fixed at 150% (minimum, instantaneous) of the VFD

normal duty current rating. T. The overload rating of the drive shall be 120% of Rated Current for 1 Min., 150% of Rat-

ed Current for 0.5 sec. U. The VFD shall have 8 Step Speeds that are preprogrammed via Digital Input Terminals. V. The VFD shall have standard Emergency Input and Jog Input Terminals.



W. The VFD shall provide from 0 to 6000 seconds of Acceleration and Deceleration time set-ting parameters. Up to 8 Acceleration and 8 Deceleration times shall be programmable.

X. The VFD shall be optimized for various levels of carrier frequency programmable from 1 to 15 kHz (1 – 3 kHz above 40HP) to reduce motor noise and to provide high system ef-ficiency.

Y. The VFD must have an option to operate multiple motors with single VFD and be able to turn on/off each motors independently as well as simultaneously.

Z. The VFD must have an Energy Saving function in auto and manual mode. AA. The VFD must have Bi-directional "Speed search" capability. BB. The VFD shall include provisions for multi-motor control as an option or as standard, en-

abling control of up to 4 motors. CC. All VFD include the following programming adjustment capabilities:

1. Directional Lock selection to prevent the unexpected motor direction. 2. DC Injection start and stop frequency selection from Minimum output frequency to 60

Hz. 3. Three programmable critical frequency lockout ranges to prevent the VFD from oper-

ating the load continuously at an unstable speed. 4. Pre-magnetization selection for the motor to build up an adequate level of flux for en-

hanced starting torque or programmable Volts/Hertz points selection for flexible Vari-able and Constant load demand curve and fluctuation.

5. VFD Voltage-output to motor adjustment feature enabling the VFD to generate from 40% up to 110% of nominal input voltage to the VFD.

6. Five (5) Fault Histories with detailed description of frequency, current, and other op-erational status at the time of each fault.

7. Two independently adjustable acceleration and deceleration ramps. These ramp times shall be adjustable from 1 to 6000 seconds.

8. The VFD shall Ramp or Coast to a stop, DC Injection, as selected by the user. 9. The VFD shall have selectable ‘No-Motor’ parameter to facilitate startup and trouble-

shooting. 10. Manual speed control adjustable by the VFD Keypad shall be available.

DD. The VFD shall have the following protection circuits. In the case of a protective trip, the drive shall stop and announce the fault condition.

• IGBT overcurrent protection

• Overcurrent trip on load output

• DC overvoltage

• Internal overtemperature

• Ground Fault

• Low Voltage

• Open output phase

• Electronic Thermal Protection. The Electronic Thermal Overload protection shall protect the motor based on speed, load curve, and motor parameters.

EE. PC software and for parameter upload/download/graphing shall be provided at no additional charge.

2.04 PRODUCT OPTIONS

A. Three switch Manual Bypass shall be provided when indicated by the schedule. VFD and bypass components shall be mounted inside a common NEMA 1 enclosure, fully pre-wired, and ready for installation as a single UL listed device. Bypass shall include the following: 1. Output, and bypass contactors, to switch power from the VFD to bypass.



2. UL 508E Manual Motor Starter with pad-lockable handle to isolate the drive and protect the motor while operating in the bypass mode.

3. Control and safety circuit terminal strip. 4. Drive/Off/Bypass selector switch and Hand/Off/Auto selector switch. 5. Switch selectable smoke purge, auto transfer to bypass and remote transfer functions. 6. Pilot lights (22 mm LEDs) for, “Drive Run” and “Bypass”. 7. Hand/Off/Auto selector switch shall provide the following operation:

• Hand Position - The drive is given a start command, and the drive will run at preset speed- user adjustable.

• Off Position - The start command is removed, all speed inputs are ignored, and power is still applied to the drive. If in bypass mode, the motor is stopped.

• Auto Position - The drive is enabled to receive a start command and speed input from a building automation system. If in bypass mode, the motor start/stop is controlled by the building automation system

8. Annunciation contacts for drive run, drive fault, bypass run and motor OL/safety fault. 9. VFD operator/keypad selection, LCD multi-line display.

B. Enclosure: 1. NEMA 1 extended enclosure, to house additional equipment within the VFD enclosure for

VFDs not requiring Bypass. 2. NEMA 12 FVFF (Forced Ventilation inlet Filter and outlet Filter) enclosures with filters

and blower. 3. NEMA 3R enclosures for outdoor installations.

a. For installation in ambient temperature environment above 104˚F (40˚C), de-rate VFD 20% to increase ambient temperature rating to 122˚F (50˚C).

b. For installation in sustained ambient temperature environment below 14˚F, include panel space heater.

C. Output Filtering: 1. For long VFD to motor lead lengths provide self contained, installation appropriate,

enclosed output reactor or filter: a. Provide output line reactor when lead is greater than 50 ft. at 460V input line

power application. b. Provide output line reactor when lead is greater than 200 ft. at 208/230V input line

power application. c. Provide output dual element filter when lead is greater than 100 ft. at 460V input line

power application. d. Provide output dual element filter when lead is greater than 400 ft. at 208/230V input

line power application. D. Minimum 3% Line Reactors (5% when noted) shall be provided on the input side of the drive

for harmonic suppression and input rectifier protection. DC Link Reactors or Bus Chokes are not acceptable substitute.

E. Integral Disconnect: Motor Circuit Protector (MCP) The MCP shall be a UL listed 508 manual motor starter with magnetic trip elements only. The breaker shall carry a UL 508F rating (up to 100A frame size) with a minimum interrupting rating of 30,000 AIC.

F. Multi-Motor Branch Protection available with adjustable thermal protection and individual disconnects.

G. Surge suppression shall be provided to protect the drive from input power disturbances. H. Engraved cabinet nameplates shall be provided.



PART 3 – EXECUTION

3.01 INSTALLATION

A. Installation shall be the responsibility of the mechanical contractor. The contractor shall install the drive in accordance with the recommendations of the VFD manufacturer as outlined in the installation manual.

B. Power wiring shall be completed by the electrical contractor. The contractor shall com-

plete all wiring in accordance with the recommendations of the VFD manufacturer as outlined in the installation manual.

3.02 START-UP

A. Remote VFD Start-up assistance and training shall be available by factory and/or VFD provider at no additional charge. Start-up technician is not required to be factory certi-fied to preserve factory warranty. A factory supplied start-up form shall be filled out for each drive with a copy provided to the owner, and a copy sent to be kept on file at the manufacturer.

3.03 PRODUCT SUPPORT

A. Factory trained application engineering and service personnel that are thoroughly trained with the supplied VFD and optional packages shall be available via factory re-mote technical assistance at both the specifying and installation locations. Additional lo-cal support to be available through VFD supplier or referred technician for hire or pre-negotiated service terms. Servicing technician does not need to be factory certified to preserve warranty.


DIVISION 23 – HEATING VENTILATING AND AIR CONDITIONING...G. Welded Joints: Construct joints...

Documents

Transcript of DIVISION 23 – HEATING VENTILATING AND AIR CONDITIONING...G. Welded Joints: Construct joints...