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SECTION 15510 CHILLED WATER PIPING SYSTEM 1. PART 1 - GENERAL 1.01 DESCRIPTION: A.

The Work under this Section consists of furnishing and installation of chilled water piping system as indicated on the drawings and as specified herein.

1.02 REFERENCES: A. ASME - American Society of Mechanical Engineers: ASME B31.9 B. Building Services Piping.

ASTM - American Society of Testing and Materials: ASTM A 53 ASTM A 234 Pipe, Steel, Black and Hot-Dipped, Zinc Coated (Galvanized), Welded and Seamless. Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures.

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ANSI - American National Standard Institute ANSI B1.20.1 Pipe Threads. ANSI B16.1 ANSI B16.3 ANSI B16.5 Cast Iron Flanges and Flanged Classes 25, 125, 250 and 800. Fittings,

Malleable-Iron Threaded Fittings, Classes 150 and 300. Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys. Alloy Solder-

ANSI B16.22 Wrought Copper and Copper Joint Pressure Fittings. ANSI B16.39 Threaded Pipe Unions, Classes 150, 250 and 300. D. HI - Hydraulic Institute: HI E.35.01 1.03 SUBMITTALS: A. Centrifugal Pumps.

Malleable-Iron,

Product Data: Submit manufacturer's technical product data and installation instructions for chilled water 15510-1 Chilled Water Piping System

piping materials and products. B. Shop Drawings: Submit scaled layout drawings of chilled water piping and fittings including, but not necessarily limited to, pipe sizes, location, elevations and slopes of horizontal runs, wall and floor penetrations, and connections. Show interface and spatial relationship between piping and proximate equipment. Record Drawings: At project closeout, submit record drawings of installed chilled water piping and piping products. Maintenance Data: Submit maintenance data and parts lists for chilled water piping materials and products. Include this data, product data, shop drawings, and record drawings in maintenance manual. Test Results: Submit test results as required.

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2. PART 2 - PRODUCTS 2.01 CHILLED WATER PIPING: A. Pipes: 1. Pipes for above ground installation shall be, seamless, black steel, Schedule 40, conforming to ASTM A 53, with beveled ends.

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Fittings: 1. Install above ground black steel pipes with threaded joints and fittings for 50 mm (2 inch) and smaller, and with VICTAULIC or approved equal fittings for 63 mm (2-1/2 inch) or larger pipes. a. Malleable-Iron Threaded Fittings: ANSI B16.3, Class 150, standard pattern, for threaded joints. Treads shall confirm to ANSI B1.20.1.

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Dielectric Union: Threaded or soldered end connections for the pipe material in which installed; constructed to isolate dissimilar materials, prevent galvanic action, and prevent corrosion. Flexible Connectors: Stainless steel bellows with woven flexible bronze wire reinforcing protective jacket; minimum 150 psig working pressure, maximum o 250 F operating temperature. Connectors shall have flanged or threaded end connections to match equipment connected; and shall be capable of 19 mm 15510-2 Chilled Water Piping System

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misalignment. 4. Gasket Material: Thickness, material, and type suitable for fluid to be handled, and design temperatures and pressures. Welding Materials (Where required): Comply with Section II, Part C ASME Boiler and Pressure Vessel Code for welding materials appropriate for wall thickness and chemical analysis of pipe material being used.

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General Duty Valves: 1. As specified in Section 15100 - VALVES.

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Special Duty Valves: 1. Calibrated Plug Valves: 175 psig water working o pressure, 100 F maximum operating temperature, bronze body, plug valve with calibrated orifice. Provide with connections for portable differential pressure meter with integral check valves and seals. Valve shall have integral pointer and calibrated scale to register degree of valve opening. Valves 50.8 mm and smaller shall have threaded connections and the 63.5 mm valves shall have flanged connections. Circuit Setters: A calibrated balance valve equipped with readout valves and provided with differential pressure meter. Self Contained Flow Control Valves: Class 150, cast iron housing, stainless steel operating parts; threaded connections for 50 mm and smaller, flanged connection for 62 mm and larger. Factory set to automatically control flow rates within plus or minus 5 percent design, while compensating for system operating pressure differential. Provide quick disconnect valves for flow measuring equipment. Provide a metal identification tag with chain for each valve, factory marked with the zone identification, valve model number, and rate flow 3 in m /min.

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Piping Specialties: 1. Manual Air Vent: Bronze body and non-ferrous o internal parts; 150 psig working pressure, 225 F operating temperature; manually operated with screw-driver or thumb-screws; and having 3 mm discharge connection and 12.7 mm inlet connection. Automatic Air Vent: Designed to vent automatically 15510-3 Chilled Water Piping System

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with float principles; bronze body and non-ferrous o internal parts; 150 psig working pressure, 240 F operating temperature; and having 6 mm discharge connection and 12.7 inlet connection. 3. Pressure and Temperature Taps: Install pressure and temperature taps at all coil connections across two port valves, pumps, chiller evaporator, or otherwise as indicated: a. Taps shall be 13 mm solid brass fittings which shall receive either pressure or temperature probe with valve core or Nordel fitted color coded and marked cap and gaskets, and rated at o 135 C and 1000 psig. Furnish No. 500 pressure gauge adapters with 38 mm probe and No. o701, o 125 mm stem pocket thermometers with 25 -125 range for chilled water.

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Chemical Feeder: Bypass type chemical feeders of 19 liter capacity, welded steel construction; 125 psig working pressure; complete with fill funnel and inlet, outlet, and drain valves. Y-Pattern Strainers: Cast iron body, ASTM A126, Class B, flanged ends for 63.5 mm and larger, threaded connections for 50.8 mm and smaller, bolted cover, perforated Type 304 stainless steel basket, bottom drain connection, 125 psig working pressure.

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2.02 DIAPHRAGM-TYPE COMPRESSION TANKS: A. Size and number as indicated; construct of welded 0 carbon steel for 125 psig working pressure, 375 F maximum operating temperature. Separate air charge from system water to maintain design expansion capacity, by means of a flexible diaphragm securely sealed into tank. Provide taps for pressure gauge and air charging fitting, and drain fitting. Support vertical tanks with legs or base; support horizontal tanks with steel saddles. Tank, with taps and supports, shall be constructed, tested, and labeled in accordance with ASME Pressure Vessel Code, Section VIII, Division 1.

2.03 MAKE-UP WATER CONNECTION: A. Provide pressure relief valve and automatic cold sweet water fill assembly complete with pressure reducing valve, after meter arrester, sight glass, backflow preventer with test cocks, water filter, vacuum breaker and valved by-pass. 15510-4 Chilled Water Piping System

2.04 AIR SEPARATOR: A. Type: The air release tank shall be of the in-the-pipeline type with tangential openings for water in and out. The inside shall be specifically designed to create a low velocity vortex for the separation of free air from the water stream. Size: The size of the air release tank shall be based on the line size of the pipe shown on the drawings. Shell: The shell shall be constructed of welded carbon 2 steel; ASME constructed and labeled for 8.78 kg/cm (125 0 psig) water working pressure and 375 F operating temperature. Strainer: The tank shall be equipped with an internal steel strainer with perforations sized for water flow. The strainer shall be installed in a location of assist in the separation of air. The strainer shall be removable from the bottom by unbolting the steel bolt heads. Drain: The tank shall be equipped with a bottom drain and this drain shall be piped to the nearest open site drain. The drain line shall be equipped with a gate valve and a union to facilitate the removal of the strainer.

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2.05 CHILLED WATER PUMPS: A. General: 1. Centrifugal pump fabrication, installation and testing shall be in conformance with Hydraulic Institute Standards. The selection of pump type and pump drive shall be based on each specific application requirements. Pump drivers shall be selected to be nonoverloading over the whole range of the Q-TDH curves, consideration temperature variations of the fluid being pumped. Pump Q-TDH curve shall stable operation for the point on the curve. approximately 25 to 35 head. be such that it provides pump when operating at any Shut-off head shall be percent above the rated

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Pumps shall be of variable or constant speed drive as required and capable of parallel operation. For pumps with variable speed drive, the control system shall include as a minimum, the programmable 15510-5 Chilled Water Piping System

logic pump controller, adjustable frequency drive(s) and remote sensor/transmitter as required. All additional items required to properly execute the sequence of operation shall be provided. B. C. Pumps shall be of the capacities and types as shown on the drawings. Chilled water pump shall be double suction horizontal split case type equipped with mechanical seals. Specific pump ratings and types shall be as indicated on plans. Pump and motor shall be mounted on a high grade, heattreated cast-iron common baseplate. Casing: Cast iron, split volume, rated for greater than o 10.54 kg/cm (150 psi) actual working discharge, with renewable bronze wearing rings, flanged suction and discharge and gauge taping. Impeller: Bronze enclosed double suction type, keyed to shaft with a slightly press and suitable lock-nut arrangement. Shaft: Made of 316 stainless steel shaft sleeves. Drive: Flexible coupling with coupling guard. Commercial pre-lubricated bearings shall be used. grease, or oil-lubricated for specific

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Mechanical or packing seals application shall be used.

suitable

Pump performance tests shall be conducted in accordance with the Hydraulic Institute test codes as described in HI E.35.01, E.37.01 and E.39.01. In addition, each pump shall be tested at five points of operation from shutoff head to runout condition, including the guaranteed pump's performance point. The manufacturer shall submit certificate, including test data to show that pump meets performance specifications.

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2.06 CHEMICAL TREATMENT FOR CHILLED WATER SYSTEM: A. The analysis and treatment recommendation shall be made by a specialist with a minimum of 5 years experience in this field. The Contractor shall supply and/or install the water treatment facilities and chemicals as listed below. 15510-6 Chilled Water Piping System

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Chemicals shall be specially formulated to prevent accumulation of scale and corrosion in piping system and connected equipment, developed based on a water analysis of make-up water. 1. 2. 3. 4. C. Chemical pot feeder complete with sampling point and valving as indicated. Corrosion scale and electrolytic action inhibiter dosing in the chilled water system. Test Kit. Carry out tests on local water necessary finalize details of the water treatment. to

Treatment: 1. Thoroughly clean and system of oil grease and swarf deposits using an approved soluble solvent in accordance with the manufacturer's instructions. Circulate the solution for at least one hour, drain and then flush system thorough with fresh water. 2. Does system with corrosion and electrolytic action and scale inhibitor.

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Handover: 1. 2. 3. 4. The Contractor shall supply a test kit and instruct the user in its use. Full instructions shall be given to the user on the dosing methodology. Prior to handover, Contractor shall carry out his own tests and ensure the system is correctly dosed. Provide the user with 6 months supply of chemicals.

2.07 INSULATION: A. Refer to Section 15250 - MECHANICAL INSULATION.

3. PART 3 - EXECUTION 3.01 INSTALLATION: A. Refer to Section 15050 - BASIC PIPING MATERIALS AND METHODS for basic piping installation instructions. Refer to the drawings for further details. The entire chilled water system installation shall conform to the 15510-7 Chilled Water Piping System

requirements of ASME B 31.9 Building Services Piping, IAPMO Uniform Mechanical Code, ARI Standard 260, and ANSI B 9.1, or equivalent. B. Install above ground black steel pipes with threaded joints and fittings for 50 mm (2 inch) and smaller, and with Victaulic fittings for 63 mm (2-1/2 inch) or larger. For underground pre-insulated pipe use Victaulic fittings. Provide concrete support at the interval of maximum 4000 mm, at both sides of coupling and at change of direction. Provide concrete thrust blocks at each change of direction. Details of concrete support and thrust block shall be as approved by the Engineer. C. Proper foundations for mounting of piping system shall be provided, including supports, vibration isolators, guides, anchors, clamps and brackets. Pumps shall be installed in strict conformance with manufacturer's written instructions. If oil grease lubricated bearings are supplied with the pumps, the oiler shall be filled with the specified lubricating oil, or bearings shall be pre-lubricated with specified grease prior to start-up. Field testing of the pumps shall be performed at the time of overall system start-up and testing. Installed pumps shall meet the performance specifications. Pipe Workmanship: Install completed system, size as shown on the drawings. Install piping parallel or perpendicular to the building construction. Allow for expansion. Air Vents: Provide at all changes in elevation downward in direction of flow. Except where shown, provide automatic air vents. Also provide air vents at system high points. The air separator shall be installed dead level in both directions and shall be supported from the structure so that all pipes can be removed without moving the air separator. The separator shall be installed so that the strainer can be removed without moving the tank. The chilled water piping, valves, fittings, separator and expansion tank shall be insulated as per Section 15250 - MECHANICAL INSULATION. Chilled Water Treatment: 1. Water for the chiller system shall be chemically 15510-8 Chilled Water Piping System

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analyzed and shall be treated to insure its suitability as the permanent system charge. Additional water treatment shall be provided whenever required after final analysis at no additional cost to Owner. 2. Results of the chemical analysis and the proposed treatment method are to be submitted to the Engineer for review and approval prior to the Contractor's filling the system.

3.02 FIELD QUALITY CONTROL A. Preparation for testing: Prepare chilled water piping in accordance with ASME B 31.9 and as follows: 1. 2. Leave joints uninsulated examination during the test. and exposed for

Provide temporary restraints for expansion joints, which cannot sustain the reactions due to test pressure. Flush system with clean water. Clean strainers. Isolate equipment that is not to be subjected to the test pressure from the piping. Install relief valve set at a pressure no more than 1/3 higher than the test pressure, to protect against damage by expansion of liquid or other source of over pressure during the test.

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Testing: Test chilled water piping as follows: 1. 2. Use ambient temperature water as testing medium. Use vents installed at high points in the system to release trapped air while filling the system. Use drains installed at low points for complete removal of the liquid. Subject piping system to a hydrostatic test pressure which at every point in the system in not less than 1.5 times the design working pressure. The test pressure shall not exceed the maximum pressure for any vessel, pump, valve, or other component in the system under test. Make a check to verify that the stress due to pressure at the bottom of vertical runs does not exceed either 90 percent of specified minimum yield strength, or 1.7 times the "SE" value in Appendix A of ASME B 31.9, Code for pressure piping, building services piping. After the hydrostatic 15510-9 Chilled Water Piping System test pressure has been

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applied for at least 10 minutes, examine piping, joints, and connections for leakage. Eliminate leaks by tightening, repairing, or replacing components as appropriate, and repeat hydrostatic test until there are no leaks. 5. For further requirements refer to Section 15990 TESTING, ADJUSTING AND BALANCING.

3.03 ADJUSTING AND CLEANING A. Clean and flush chilled water piping system. Remove, clean, and replace strainer screens. After cleaning and flushing chilled water piping system, but before balancing, remove disposable fine mesh strainers in pump suction diffusers. Mark calibrated name plates of pump discharge valve after chilled water system balancing has been completed, to permanently indicate final balanced position. Chemical treatment: Provide a water analysis prepared by the chemical treatment supplier to determine the type and level of chemicals required for prevention of scale and corrosion. Preform initial treatment after completion of system testing. Check expansion tanks to determine that they are not air bound and that the system is completely full of water. END OF SECTION

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