project manual / specifications marshall middle school

PROJECT MANUAL / Specifications

MARSHALL MIDDLE SCHOOL

Chiller Replacement 2016

FAUQUIER COUNTY GOVERNMENT & PUBLIC SCHOOLS

FAUQUIER, VIRGINIA

for Bid

ENGINEER LEESBURG, VIRGINIA

October 28th

, 2015

b2e Proj.

#15453

October 28th

, 2015 Page 1

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B2E TABLE OF CONTENTS FOR PROJECT MANUAL

This Table of Contents is for convenience only. Its accuracy and completeness is not guaranteed and it is not to be considered part of the specifications. In case of a discrepancy between the Table of Contents and the Specifications, the Specifications shall govern.

TABLE OF CONTENTS

SECT.

NO. SECTION TITLE

DIVISION 00 GENERAL REQUIREMENTS

IFB#: Marshall Middle School Chiller Replacement 2016

Contractor Access (Attachment to IFB)

DIVISION 03 CONCRETE

033000 CAST-IN-PLACE CONCRETE

DIVISION 05 METALS

051200 STRUCTURAL STEEL FRAMING

DIVISION 07 THERMAL AND MOISTURE PROTECTION 07550 EPDM MEMBRANE PATCHING AND REPAIR 07841 THROUGH-PNETRATION FIRESTOP SYSTEMS 07920 JOINT SEALANTS

DIVISION 23 MECHANICAL

230100 HVAC GENERAL MECHANICAL REQUIREMENTS 230500 COMMON WORK RESULTS FOR HVAC 230513 COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT 230523 GENERAL-DUTY VALVES FOR HVAC PIPING 230529 HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT 230548 SOUND AND VIBRATION CONTROLS FOR HVAC 230553 IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT 230593 TESTING, ADJUSTING, AND BALANCING FOR HVAC 230705 PIPING INSULATION 230900 ENERGY MANAGEMENT SYSTEM (EMS) 230993 SEQUENCE OF OPERATIONS FOR HVAC CONTROLS 232113 HYDRONIC PIPING 232123 HYDRONIC PUMPS 232500 HVAC WATER TREATMENT 236426.1 AIR-COOLED VARIABLE SPEED HELICAL ROTARY SCREW CHILLERS (ALT-A) 236426.2 AIR-COOLED VARIABLE SPEED CONDENSOR FAN MULTIPLE SCROLL CHILLER (ALT-B)

DIVISION 26 ELECTRICAL

260100 ELECTRICAL GENERAL REQUIREMENTS 260200 COMMON WORK RESULTS ELECTRICAL 260519 CONDUCTORS AND CABLES 260526 GROUNDING AND BONDING 260533 RACEWAYS AND BOXES 260915 ENCLOSED CONTROLLERS 262726 WIRING DEVICES 262816 ENCLOSED SWITCHES AND CIRCUIT BREAKERS

END OF TABLE OF CONTENTS

October 28th

, 2015 Page 2

Marshall Middle School Chiller 2016 Contractor Access

Contractor may use this area for parking and material staging for the project duration

Contractor may use access road as arranged in advance with Owner.

Contractor may use this area for equipment and material staging for the project duration.

Contractor shall provide temporary fences and barriers to prevent unauthorized access to hazardous

equipment and material on job site.

For all existing grounds, facilities, and structures affected by the Contractor, the Contractor shall repair

damage and restore to pre-existing condition to the satisfaction of the Owner; this includes seeding and

straw covering grassed areas.

Contractor shall perform hot work, crane lifts, and other potentially hazardous work during other than

school hours. School hours are 7:00 a.m. through 4:40 p.m. Mondays through Fridays, excepting school

holidays. 2016 school holidays include January 1 and 18, February 15, and March 21 through 25.

Contractor shall schedule in advance with the Owner all hot work, crane lifts, and vehicle or equipment

access to and on the site.


Fauquier County Schools, VA


CAST-IN-PLACE CONCRETE 033000 - 1

SECTION 033000

CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 SUMMARY

A. Section includes cast-in-place concrete, including formwork, reinforcement, concrete materials,

mixture design, placement procedures, and finishes.

B. It is not known if existing concrete or other surfaces will support materials or equipment. The

Contractor is responsible to protect existing facilities and to repair or replace to equivalent of

pre-existing condition anything damaged by the Contractor.

1.2 ACTION SUBMITTALS

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

B. Design Mixtures: For each concrete mixture.

C. Steel Reinforcement Shop Drawings: Placing drawings that detail fabrication, bending, and

placement.

D. Formwork Shop Drawings: Prepared by or under the supervision of a qualified professional

engineer detailing fabrication, assembly, and support of formwork.

1.3 INFORMATIONAL SUBMITTALS

A. Welding certificates.

B. Material certificates.

C. Material test reports.

1.4 QUALITY ASSURANCE

A. Manufacturer Qualifications: A firm experienced in manufacturing ready-mixed concrete

products and that complies with ASTM C 94/C 94M requirements for production facilities and

equipment.

1. Manufacturer certified according to NRMCA's "Certification of Ready Mixed Concrete

Production Facilities."





B. Testing Agency Qualifications: An independent agency, acceptable to authorities having

jurisdiction, qualified according to ASTM C 1077 and ASTM E 329 for testing indicated.

C. ACI Publications: Comply with the following unless modified by requirements in the Contract

Documents:

1. ACI 301, "Specifications for Structural Concrete," Sections 1 through 5.”

2. ACI 117, "Specifications for Tolerances for Concrete Construction and Materials."

D. Concrete Testing Service: Engage a qualified independent testing agency to perform material

evaluation tests and to design concrete mixtures.

E. Preinstallation Conference: Conduct conference at Project site.

PART 2 - PRODUCTS

2.1 FORM-FACING MATERIALS

A. Smooth-Formed Finished Concrete: Form-facing panels that will provide continuous, true, and

smooth concrete surfaces. Furnish in largest practicable sizes to minimize number of joints.

B. Rough-Formed Finished Concrete: Plywood, lumber, metal, or another approved material.

Provide lumber dressed on at least two edges and one side for tight fit.

2.2 STEEL REINFORCEMENT

A. Reinforcing Bars: ASTM A 615/A 615M, Grade 60 (Grade 420), deformed.

B. Bar Supports: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening

reinforcing bars and welded wire reinforcement in place. Manufacture bar supports from steel

wire, plastic, or precast concrete according to CRSI's "Manual of Standard Practice.

2.3 CONCRETE MATERIALS

A. Cementitious Material: Use the following cementitious materials, of the same type, brand, and

source, throughout Project:

1. Portland Cement: ASTM C 150, Type I.

B. Normal-Weight Aggregates: ASTM C 33, graded.

1. Maximum Coarse-Aggregate Size: 3/4 inch (19 mm) nominal.

2. Fine Aggregate: Free of materials with deleterious reactivity to alkali in cement.

C. Water: ASTM C 94/C 94M and potable.





2.4 ADMIXTURES

A. Air-Entraining Admixture: ASTM C 260.

B. Chemical Admixtures: Provide admixtures certified by manufacturer to be compatible with

other admixtures and that will not contribute water-soluble chloride ions exceeding those

permitted in hardened concrete. Do not use calcium chloride or admixtures containing calcium

chloride.

1. Water-Reducing Admixture: ASTM C 494/C 494M, Type A.

2. Retarding Admixture: ASTM C 494/C 494M, Type B.

3. Water-Reducing and Retarding Admixture: ASTM C 494/C 494M, Type D.

4. High-Range, Water-Reducing Admixture: ASTM C 494/C 494M, Type F.

5. High-Range, Water-Reducing and Retarding Admixture: ASTM C 494/C 494M,

Type G.

2.5 VAPOR RETARDERS

A. Sheet Vapor Retarder: Polyethylene sheet, ASTM D 4397, not less than 10 mils (0.25 mm)

thick.

2.6 CURING MATERIALS

A. Evaporation Retarder: Waterborne, monomolecular film forming, manufactured for application

to fresh concrete.

B. Absorptive Cover: AASHTO M 182, Class 2, burlap cloth made from jute or kenaf, weighing

approximately 9 oz./sq. yd. (305 g/sq. m) when dry.

C. Moisture-Retaining Cover: ASTM C 171, polyethylene film or white burlap-polyethylene

sheet.

D. Water: Potable.

E. Clear, Waterborne, Membrane-Forming Curing Compound: ASTM C 309, Type 1, Class B,

dissipating.

2.7 CONCRETE MIXTURES

A. Prepare design mixtures for each type and strength of concrete, proportioned on the basis of

laboratory trial mixture or field test data, or both, according to ACI 301.

B. Cementitious Materials: The use fly ash, pozzolan, ground granulated blast-furnace slag, and

silica fume for the purpose of reducing the total amount of portland cement, which would

otherwise be used, is prohibited.

C. Admixtures: Use admixtures according to manufacturer's written instructions.





1. Use water-reducing, high-range water-reducing or plasticizing admixture in concrete, as

required, for placement and workability.

2. Use water-reducing and retarding admixture when required by high temperatures, low

humidity, or other adverse placement conditions.

D. Proportion normal-weight concrete mixture as follows:

1. Minimum Compressive Strength: 3500 psi (24.1 MPa) at 28 days.

2. Slump Limit: 4 inches (100 mm).

2.8 FABRICATING REINFORCEMENT

A. Fabricate steel reinforcement according to CRSI's "Manual of Standard Practice."

2.9 CONCRETE MIXING

A. Ready-Mixed Concrete: Measure, batch, mix, and deliver concrete according to

ASTM C 94/C 94M and furnish batch ticket information.

1. When air temperature is between 85 and 90 deg F (30 and 32 deg C), reduce mixing and

delivery time from 1-1/2 hours to 75 minutes; when air temperature is above 90 deg F (32

deg C), reduce mixing and delivery time to 60 minutes.

PART 3 - EXECUTION

3.1 FORMWORK

A. Design, erect, shore, brace, and maintain formwork, according to ACI 301, to support vertical,

lateral, static, and dynamic loads, and construction loads that might be applied, until structure

can support such loads.

B. Construct formwork so concrete members and structures are of size, shape, alignment,

elevation, and position indicated, within tolerance limits of ACI 117.

C. Chamfer exterior corners and edges of permanently exposed concrete, ¾-inch minimum.

3.2 EMBEDDED ITEMS

A. Place and secure anchorage devices and other embedded items required for adjoining work that

is attached to or supported by cast-in-place concrete. Use setting drawings, templates,

diagrams, instructions, and directions furnished with items to be embedded.





3.3 VAPOR RETARDERS

A. Sheet Vapor Retarders: Place, protect, and repair sheet vapor retarder according to

ASTM E 1643 and manufacturer's written instructions.

1. Lap joints 6 inches (150 mm) and seal with manufacturer's recommended tape.

3.4 STEEL REINFORCEMENT

A. General: Comply with CRSI's "Manual of Standard Practice" for placing reinforcement.

1. Do not cut or puncture vapor retarder. Repair damage and reseal vapor retarder before

placing concrete.

3.5 CONCRETE PLACEMENT

A. Before placing concrete, verify that installation of formwork, reinforcement, and embedded

items is complete and that required inspections have been performed.

B. Deposit concrete continuously in one layer or in horizontal layers of such thickness that no new

concrete will be placed on concrete that has hardened enough to cause seams or planes of

weakness. If a section cannot be placed continuously, provide construction joints as indicated.

Deposit concrete to avoid segregation.

1. Consolidate placed concrete with mechanical vibrating equipment according to ACI 301.

3.6 FINISHING FORMED SURFACES

A. Rough-Formed Finish: As-cast concrete texture imparted by form-facing material with tie holes

and defects repaired and patched. Remove fins and other projections that exceed specified

limits on formed-surface irregularities.

1. Apply to concrete surfaces not exposed to public view.

B. Smooth-Formed Finish: As-cast concrete texture imparted by form-facing material, arranged in

an orderly and symmetrical manner with a minimum of seams. Repair and patch tie holes and

defects. Remove fins and other projections that exceed specified limits on formed-surface

irregularities.

1. Apply to concrete surfaces exposed to public view, (such as the sides of equipment pads).

C. Related Unformed Surfaces: At tops of walls, horizontal offsets, and similar unformed surfaces

adjacent to formed surfaces, strike off smooth and finish with a texture matching adjacent

formed surfaces. Continue final surface treatment of formed surfaces uniformly across adjacent

unformed surfaces unless otherwise indicated.





3.7 FINISHING FLOORS AND SLABS

A. General: Comply with ACI 302.1R recommendations for screeding, restraightening, and

finishing operations for concrete surfaces. Do not wet concrete surfaces.

B. Float Finish: Consolidate surface with power-driven floats or by hand floating if area is small

or inaccessible to power driven floats. Restraighten, cut down high spots, and fill low spots.

Repeat float passes and restraightening until surface is left with a uniform, smooth, granular

texture.

1. Apply float finish to surfaces to receive trowel finish.

C. Trowel Finish: After applying float finish, apply first troweling and consolidate concrete by

hand or power-driven trowel. Continue troweling passes and restraighten until surface is free of

trowel marks and uniform in texture and appearance. Grind smooth any surface defects that

would telegraph through applied coatings or floor coverings.

1. Apply a trowel finish to surfaces exposed to view.

2. Finish and measure surface so gap at any point between concrete surface and an

unleveled, freestanding, 10-ft.- (3.05-m-) long straightedge resting on two high spots and

placed anywhere on the surface does not exceed 1/4 inch (6 mm).

3.8 CONCRETE PROTECTING AND CURING

A. General: Protect freshly placed concrete from premature drying and excessive cold or hot

temperatures. Comply with ACI 306.1 for cold-weather protection and ACI 301 for hot-

weather protection during curing.

B. Evaporation Retarder: Apply evaporation retarder to unformed concrete surfaces if hot, dry, or

windy conditions cause moisture loss approaching 0.2 lb/sq. ft. x h (1 kg/sq. m x h) before and

during finishing operations. Apply according to manufacturer's written instructions after

placing, screeding, and bull floating or darbying concrete, but before float finishing.

C. Cure concrete according to ACI 308.1, by one or a combination of the following methods:

1. Moisture Curing: Keep surfaces continuously moist for not less than seven days.

2. Moisture-Retaining-Cover Curing: Cover concrete surfaces with moisture-retaining

cover for curing concrete, placed in widest practicable width, with sides and ends lapped

at least 12 inches (300 mm), and sealed by waterproof tape or adhesive. Cure for not less

than seven days. Immediately repair any holes or tears during curing period using cover

material and waterproof tape.

3. Curing Compound: Apply uniformly in continuous operation by power spray or roller

according to manufacturer's written instructions. Recoat areas subjected to heavy rainfall

within three hours after initial application. Maintain continuity of coating and repair

damage during curing period.

a. Removal: After curing period has elapsed, remove curing compound without

damaging concrete surfaces by method recommended by curing compound

manufacturer.





4. Curing and Sealing Compound: Apply uniformly to floors and slabs indicated in a

continuous operation by power spray or roller according to manufacturer's written

instructions. Recoat areas subjected to heavy rainfall within three hours after initial

application. Repeat process 24 hours later and apply a second coat. Maintain continuity

of coating and repair damage during curing period.

3.9 CONCRETE SURFACE REPAIRS

A. Defective Concrete: Repair and patch defective areas when approved by Engineer. Remove

and replace concrete that cannot be repaired and patched to Engineer’s approval.

3.10 FIELD QUALITY CONTROL

A. Testing and Inspecting: Owner will engage a qualified testing and inspecting agency to perform

field tests and inspections and prepare test reports.

END OF SECTION




STRUCTURAL STEEL FRAMING 051200 - 1

SECTION 051200

STRUCTURAL STEEL FRAMING

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Structural steel.

B. The structural steel support system for the air-cooled chiller requires penetration of the exterior

metal wall panel at the penthouse. Remove the wall panel and protect the building while the

steel is installed. Replace the panel(s) as necessary with the resultant beam penetrations as

detailed on the structural drawings.

C. Third party inspection and approval of the metal fabrication facility may be substituted for

AISC qualification requirements. Required are structural steel submittals which include

material descriptions, coordinated field verified dimensions, sketches for review and approval,

etc., to meet specified submittal requirements.

1.2 DEFINITIONS

A. Structural Steel: Elements of the structural frame indicated on Drawings and as described in

AISC 303, "Code of Standard Practice for Steel Buildings and Bridges."

1.3 PREINSTALLATION MEETINGS

A. Preinstallation Conference: Conduct conference at Project site.

1.4 ACTION SUBMITTALS

A. Product Data: For each type of product.

B. Shop Drawings: Show fabrication of structural-steel components.

1.5 INFORMATIONAL SUBMITTALS

A. Qualification Data: For Installer, fabricator and testing agency.

B. Welding certificates.

C. Mill test reports for structural steel, including chemical and physical properties.





D. Source quality-control reports.

E. Field quality-control and special inspection reports.


A. Fabricator Qualifications: A qualified fabricator that participates in the AISC Quality

Certification Program.

B. Installer Qualifications: A qualified installer who participates in the AISC Quality Certification

Program and is designated an AISC-Certified Erector, Category CSE.

C. Welding Qualifications: Qualify procedures and personnel according to AWS D1.1/D1.1M,

"Structural Welding Code - Steel."

D. Comply with applicable provisions of the following specifications and documents:

1. AISC 303.

2. AISC 360.

3. RCSC's "Specification for Structural Joints Using ASTM A 325 or A 490 Bolts."

PART 2 - PRODUCTS

2.1 PERFORMANCE REQUIREMENTS

A. Connections: Provide details of simple shear connections required by the Contract Documents

to be selected or completed by structural-steel fabricator to withstand loads indicated and

comply with other information and restrictions indicated.

1. Select and complete connections using schematic details indicated and AISC 360.

2. Use Allowable Stress Design; data are given at service-load level.

B. Construction: Roof Top Chiller Dunnage framing designed to support and distribute the weight

of the Chiller its accessories to the existing structural steel roof and penthouse floor framing.

2.2 STRUCTURAL-STEEL MATERIALS

A. W-Shapes: ASTM A 992/A 992M.

1. Finish: Galvanized.

B. Channels and Angles -Shapes: ASTM A 36/A 36M.


C. Plate and Bar: ASTM A 36/A 36M.






D. Steel Pipe: ASTM A 53, Type E or S, Grade B.

1. Weight Class: Standard


E. Welding Electrodes: Comply with AWS requirements.

2.3 BOLTS, CONNECTORS, AND ANCHORS

A. Zinc-Coated High-Strength Bolts, Nuts, and Washers: ASTM A 325 (ASTM A 325M), Type 1,

heavy-hex steel structural bolts; ASTM A 563, Grade DH (ASTM A 563M, Class 10S) heavy-

hex carbon-steel nuts; and ASTM F 436 (ASTM F 436M), Type 1, hardened carbon-steel

washers.

1. Finish: Hot-dip or mechanically deposited zinc coating.

2. Direct-Tension Indicators: ASTM F 959, Type 325 (ASTM F 959M, Type 8.8),

compressible-washer type with mechanically deposited zinc coating finish.

B. Unheaded Anchor Rods: ASTM F 1554, Grade 55, weldable.

1. Configuration: Straight or Hooked.

2. Interior Finish: Plain.

3. Exterior Finish: Galvanized.

C. Threaded Rods: ASTM A 36/A 36M.

1. Finish: Plain.

2. Exterior Finish: Galvanized.

D. Clevises and Turnbuckles: Made from cold-finished carbon steel bars, ASTM A 108,

Grade 1035. Galvanized finish for exterior locations.

2.4 PRIMER

A. Primer: Fabricator's standard lead- and chromate-free, nonasphaltic, rust-inhibiting primer

complying with MPI#79 and compatible with topcoat.

B. Galvanizing Repair Paint: MPI#18.

2.5 FABRICATION

A. Structural Steel: Fabricate and assemble in shop to greatest extent possible. Fabricate

according to AISC 303, "Code of Standard Practice for Steel Buildings and Bridges," and to

AISC 360.





2.6 SHOP CONNECTIONS

A. High-Strength Bolts: Shop install high-strength bolts according to RCSC's "Specification for

Structural Joints Using ASTM A 325 or A 490 Bolts" for type of bolt and type of joint

specified.

1. Joint Type: Pretensioned.

B. Weld Connections: Comply with AWS D1.1/D1.1M for tolerances, appearances, welding

procedure specifications, weld quality, and methods used in correcting welding work.

2.7 SHOP PRIMING

A. Shop prime steel surfaces except the following:

1. Surfaces embedded in concrete or mortar. Extend priming of partially embedded

members to a depth of 2 inches (50 mm).

2. Surfaces to be field welded.

3. Surfaces to receive sprayed fire-resistive materials (applied fireproofing).

4. Galvanized surfaces.

B. Surface Preparation: Clean surfaces to be painted. Remove loose rust and mill scale and

spatter, slag, or flux deposits. Prepare surfaces according to the following specifications and

standards:

1. SSPC-SP 2, "Hand Tool Cleaning."

C. Priming: Immediately after surface preparation, apply primer according to manufacturer's

written instructions and at rate recommended by SSPC to provide a minimum dry film thickness

of 1.5 mils (0.038 mm). Use priming methods that result in full coverage of joints, corners,

edges, and exposed surfaces.

2.8 GALVANIZING

A. Hot-Dip Galvanized Finish: Apply zinc coating by the hot-dip process to structural steel

according to ASTM A 123/A 123M.

1. Fill vent and drain holes that are exposed in the finished Work unless they function as

weep holes, by plugging with zinc solder and filing off smooth.

2. Galvanize the Chiller Dunnage, including angles and plates.

B. Surface Preparation for Galvanizing Repairs: Clean surfaces to be painted. Remove loose rust

and mill scale and spatter, slag, or flux deposits. Prepare surfaces according to the following

specifications and standards:

1. SSPC-SP 10/NACE No. 2, "Near-White Blast Cleaning."





2.9 SOURCE QUALITY CONTROL

A. Testing Agency: Owner will engage a qualified testing agency to perform shop tests and

inspections.

1. Provide testing agency with access to places where structural-steel work is being

fabricated or produced to perform tests and inspections.

B. Bolted Connections: Inspect and test shop-bolted connections according to RCSC's

"Specification for Structural Joints Using ASTM A 325 or A 490 Bolts."

C. Welded Connections: Visually inspect shop-welded connections according to

AWS D1.1/D1.1M and the following inspection procedures, at testing agency's option:

1. Liquid Penetrant Inspection: ASTM E 165.

2. Magnetic Particle Inspection: ASTM E 709; performed on root pass and on finished

weld. Cracks or zones of incomplete fusion or penetration are not accepted.

3. Ultrasonic Inspection: ASTM E 164.

4. Radiographic Inspection: ASTM E 94.

D. Prepare test and inspection reports.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify, with certified steel erector present, elevations of -bearing surfaces and locations of base

plates, bearing plates, and other field welded connections to the existing structure for

compliance with requirements.

B. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 ERECTION

A. Set structural steel accurately in locations and to elevations indicated and according to

AISC 303 and AISC 360.

B. Base Plates Bearing Plates and Leveling Plates: Clean steel bearing surfaces of debris. Prepare

top flanges of existing roof framing and ends of existing columns for field welded connections.

1. Layout base plate connection locations away from existing joist bearing seats.

2. Set plates level and posts plumb for structural members on steel shims, as required.

3. Weld base plates and shims, to top flanges of existing beams and columns.

C. Maintain erection tolerances of structural steel within AISC 303, "Code of Standard Practice for

Steel Buildings and Bridges."





3.3 FIELD CONNECTIONS

A. High-Strength Bolts: Install high-strength bolts according to RCSC's "Specification for

Structural Joints Using ASTM A 325 or A 490 Bolts" for type of bolt and type of joint

specified.

1. Joint Type: Pretensioned.

B. Weld Connections: Comply with AWS D1.1/D1.1M for tolerances, appearances, welding

procedure specifications, weld quality, and methods used in correcting welding work.

1. Comply with AISC 303 and AISC 360 for bearing, alignment, adequacy of temporary

connections, and removal of paint on surfaces adjacent to field welds.

2. Remove backing bars or runoff tabs, back gouge, and grind steel smooth.

3. Assemble and weld built-up sections by methods that maintain true alignment of axes

without exceeding tolerances in AISC 303, "Code of Standard Practice for Steel

Buildings and Bridges," for mill material.


A. Special Inspections: Owner will engage a qualified special inspector to perform the following

special inspections:

1. Verify structural-steel materials and inspect steel frame joint details.

2. Verify weld materials and inspect welds.

3. Verify connection materials and inspect high-strength bolted connections.

B. Testing Agency: Owner will engage a qualified testing agency to perform tests and inspections.

C. Bolted Connections: Inspect bolted connections according to RCSC's "Specification for

Structural Joints Using ASTM A 325 or A 490 Bolts."

D. Welded Connections: Visually inspect field welds according to AWS D1.1/D1.1M.

1. In addition to visual inspection, test and inspect field welds according to

AWS D1.1/D1.1M and the following inspection procedures, at testing agency's option:

a. Liquid Penetrant Inspection: ASTM E 165.

b. Magnetic Particle Inspection: ASTM E 709; performed on root pass and on

finished weld. Cracks or zones of incomplete fusion or penetration are not

accepted.

c. Ultrasonic Inspection: ASTM E 164.

END OF SECTION




EPDM MEMBRANE PATCHING AND REPAIR 07550 - 1

SECTION 07550

EPDM MEMBRANE PATCHING AND REPAIR

PART 1 - GENERAL

1.1 SUMMARY

A. Work involves patching and modifications of the existing, warranted, EPDM roof system.

B. Extent of EPDM adhered roof system patching as indicated on drawings and by provisions of

this section.

C. Work also includes preparation of new penetrations (including flashing) through existing

EPDM roof system.

D. Contractor shall provide all inspections, documentation of existing conditions, work in

accordance with the manufacturers approved installation details for the roofing type and

application method, as well as final inspections and approvals as required to maintain the

existing roof warranty.

1. Existing Roofing Installer: Autumn Contracting, Inc. installed the existing Firestone Red

Shield system in 2005. The Warranty No. is RO011549; FBPCO #CB5221.

2. Warranty Period: 20 Years starting 10/07/2005.

E. Contractor shall restore roof areas affected by the Contractor’s work to their pre-existing

watertight condition.

1.2 DEFINITIONS

A. Roofing Terminology: Refer to ASTMD 1079 and the National Roofing Contractors

Associations (NRCA) glossary of roofing terms, for definition of terms related to roofing

work in this Section.


A. General: Provide installed adhered roofing membrane and flashings that remain watertight;

do not permit the passage of water; and resist specified uplift pressures, thermally induced

movement, and exposure to weather without failure.

B. Material Compatibility: Provide roofing materials compatible with one another under

conditions of service and application required, as demonstrated by roofing manufacturer.

C. FMB Listing: Provide roofing membrane, flashings, and component materials that comply

with requirements in FMG 4450 and FMG 4470 as part of a roofing system and that are listed





in FMG’s “Approval Guide” for Class 1 or noncombustible construction, as applicable.

Identify materials with FMG markings.

1. Surface Burning Characteristics: UL Class A.

2. Fire/Windstorm Classification: Class 1-90; roof system attachment to the deck shall be

in accordance with the requirements of FMG Class 1-90 for a steel deck. Provide a roof

system supplied by a roofing manufacturer with a minimum FMG 1-90 wind uplift rating

over a steel deck.

3. Hail Resistance: MH

D. All materials, installations, and fastenings shall meet the specifications of the primary

membrane manufacturer for the No Dollar Limit roof system warranty. As such, the system

warranty shall cover all membrane and flashing materials, installations, and their attachment,

as well as all insulation, and accessory materials, installations and their attachment for the

remainder of the existing warranty.

E. Warranty: Contractor shall warranty all work for one (1) year, and shall also issue to the

Owner additional warranty (ies) as described in the project manual. During warranty period,

Contractor shall respond to service request within four (4) hours, and shall repair or replace all

faulty labor and/or material at no cost to the Owner.

F. Contractor shall furnish two (2) printed copies of warranty letter(s) and certificates, additional

to copies included in the operation and maintenance manuals. Warranty letter(s) and

certificates shall include the project title, Contractor name and service contact information,

warranty start and end dates, and the terms of the warranties.

1.4 SUBMITTALS

A. Product Data: For each type of product indicated in Part 2 of this Section.

1. If a listed product is not required for the completion of the project, submit a letter stating

that the product is not required. If it is determined later in the project that the product is

required for a completion of the project, a submittal will be required prior to installation

of product.

B. Submittal Procedure:

1. The Engineer will compare the information submitted to the information and design

concept expressed in the contract documents.

2. Submit five (5) complete sets of “Pre-Job Submittals” to Engineer for review. The Work

may not proceed until the complete Pre-Job Submittal package has been approved by

Owner.

3. Bind Pre-Job Submittals in a three-ring binder with tabbed dividers keyed to items

required under Part 2 of this Section.

4. Update submittals to Engineer by providing five (5) copies of “Progress Submittals” on a

weekly basis to account for all new materials used on the Project.

5. Utilize Submittal Log (provided by Owner) for organization, numbering, and reference.

6. Submittal items shall each be labeled with the corresponding section of the Project

Manual that required the submittal.

7. When material is resubmitted for any reason, provide a new letter of transmittal.





8. On resubmittal, cite the original submittal number of reference or add a suffix such as “-

A, -B” (2-A, 2-B, etc.).

9. One approved Shop Drawing and sample (including data sheets, instruction sheets, etc.)

if required, shall be kept at the job site.

10. Accompany each submittal package with a letter of transmittal showing all information

required for identification and checking, including, but not limited to:

a. Project Title, Engineer, Owner, Contractor or Subcontractor.

b. Consecutive numbering system.

c. Date drawn and dates revised.

d. Contractor’s certification that shop drawings have been checked by Contractor for

compliance with contract requirements.

e. Working dimensions.

f. Arrangements (orientation).

11. Where contents of submitted literature from manufacturers include data not pertinent to

the submittal, clearly show which portions of the contents are being submitted for

review.

C. Shop Drawings: Provide manufacturer approved Shop Drawings showing roof configuration,

fastener patterns on all roof sections included in the work, for all flashings and penetrations.

Identify work by others; Contractor is responsible for coordinating provision of all

components included in accepted shop drawings. Provide layouts at ¼-inch per 12-inches and

details at 1-1/2-inches per 12-inches.

1. Base flashings, cants, and membrane terminations.

2. Tapered insulation, including slopes.

3. Crickets, saddles, and tapered edge strips, including slopes.

4. Insulation fastening patterns.

D. Samples for Verification: For the following products:

1. 12-by-12-inch square of roofing membrane sheet(s).

2. 12-by-12 inch square of roof insulation.

3. 12-by-12-inch square of walkway pad or walkway cap sheet.

4. 12-inch length of metal termination bars.

5. Six insulation fasteners of each type, length, and finish.

E. Installation Manual: Submit three (3) copies of manufacturer’s current Division “7”

installation manual for roofing systems required for project. Any deviation from the printed

instructions must be approved in writing by the roofing system manufacturer’s authorized

representative and the Owner.

F. Manufacturer Notification: Prior to start of work, submit documentation from the

manufacturer that they are aware of the specified modifications and repairs to the existing

warranted EPDM adhered roof system and such modifications and repairs will have no

adverse affect on the existing warranty.

G. Installer Certification: Submit certification that the EPDM adhered roof system installer had

been regularly engaged in the installation of EPDM systems specified. The company must be

currently listed at the time of Bid as an Approved Contractor by the appropriate Warranty

Program of the membrane manufacturer. There must be no deviations made without the prior

written approval of the Engineer and membrane manufacturer.





H. Product Test Reports: Based on evaluation of comprehensive tests performed by

manufacturer and witnessed by a qualified testing agency, for components of roofing system.

I. Storage Requirements: Provide the roof system manufacturers requirements for storage of all

materials to be used.


A. Installer Qualifications: This roofing system must be installed by a company specializing in

EPDM adhered roof application with a minimum of five (5) years experience, capable of

showing successful modifications and repairs similar to work required for project. The

company must be currently listed at the time of Bid as an Approved Contractor by the

appropriate Warranty Program of the membrane manufacturer. There must be no deviations

made without the prior written approval of the Engineer and membrane manufacturer.

B. Manufacturer: Firestone Building Products Company, 250 West 96th Street, Indianapolis, IN

46260 Telephone: (800) 428-4442 or (317) 575-7000, Fax: (317) 575-7100.

C. Fire-Test-Response Characteristics: Provide roofing materials with the fire-test-response

characteristics indicated as determined by testing identical products per test method below by

UL, FMG, or another testing and inspecting agency acceptable to authorities having

jurisdiction. Materials shall be identified with appropriate markings of applicable testing and

inspecting agency.

1. Exterior Fire-Test Exposure: Class A; ASTM 108, for applications indicated.

D. Pre-Roofing Conference: Prior to installation of roofing repair, meet at project site with

Installer (Roofer), and Owner’s representatives. Tour representative areas of roofing, and

discuss substrate conditions. Review requirements of contract documents, submittals, status

of coordinating work, availability of materials and installation facilities, proposed installation

schedule, requirements for inspections and testing or certifications, forecasted weather

conditions, governing regulations, insurance requirements, and proposed installation

procedures.

1.6 INSPECTION AND JOB CONTROL

A. A qualified technical representative of the manufacturer shall be available to make

recommendations necessary to ensure compliance with the specifications and to make

recommendations where unforeseen conditions become apparent to the Engineer/Owner.

B. At the completion of the work arrange for inspection of the modifications and repairs by a

Manufacturers Technical Representative to assure compliance with the manufacturers

requirements to maintain the existing warranty. Make any corrections to the work if required

by the Manufacturer at no additional cost to the Owner. If an inspection is not required by the

Manufacturer to maintain the existing warranty, submit documentation from the Manufacturer

acknowledging the specified modifications and repairs to the existing warranted EPDM

adhered roofing system and that such modifications and repairs are not required to be

inspected to maintain the existing warranty.





1.7 DELIVERY, STORAGE, AND HANDLING

A. Deliver roofing materials to Project site in original containers with seals unbroken and labeled

with manufacturer's name, product brand name and type, date of manufacture, and directions

for storage.

B. Store temperature sensitive materials in original undamaged containers in a clean, dry,

protected location and within temperature range required by manufacturer. Protect stored

liquid material from direct sunlight.

1. Discard and legally dispose of liquid material that cannot be applied within its stated

shelf life.

C. Protect polyisocyanurate as follows:

1. Do not expose to sunlight, except to extent necessary for period of installation and

concealment.

2. Protect against ignition at all times. Do not deliver foam-plastic insulation materials to

Project site before installation time.

3. Complete installation and concealment of plastic materials as rapidly as possible in each

area of construction.

D. Handle and store roofing materials and place equipment in a manner to avoid permanent

deflection of deck.

E. At a minimum, materials are to be covered/protected by reinforced tarpaulins.

F. Do not use cranes to hoist materials onto the roof when the building is occupied.

1.8 PROJECT CONDITIONS

A. Weather Limitations: Begin installation only when existing and forecasted weather conditions

permit roofing system to be installed according to manufacturer's written instructions and

warranty requirements.

1.9 WARRANTY

A. Maintain existing roofing warranty.

B. Provide two-year Contractor's Warranty for materials and workmanship.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Available Manufacturers: Match existing roofing system to maintain existing warranty.





2.2 EPDM-SHEET MATERIALS

A. Base Ply, EPDM Flashing: ASTM D 6162, Type II, Grade S or ASTM D 6164, Type I,

Grade S, minimum 120 mils thick, smooth surfaced, reinforced membrane compliant with

system warranty requirements; suitable for heat welding application method specified.

B. Cap Sheet, EPDM Flashing: ASTM D 6162, Type II, Grade G or ASTM D 6164, Grade G,

Type II with a Class A fire rating (FR), minimum 160 mils thick, polyester-reinforced, EPDM

sheet; smooth rubber surface; suitable for chemical welding application method specified,

with overlapping cap sheet.

C. Base Sheet: As required by primary roof membrane manufacturer for installation over nailable

roof decks and between insulation and membrane, complying with ASTM D4601, Type II.

2.3 AUXILIARY ROOFING MEMBRANE MATERIALS

A. General: Auxiliary materials recommended by roofing system manufacturer for intended use

and compatible with roofing membrane.

B. Asphalt Primer: ASTM D 41.

C. EPDM Flashing Adhesive/Cement: EPDM Adhesive (“MBR”), asbestos free, of consistency

required by roofing system manufacturer for application. ASTM D4586 Type I, Class II.

D. Mastic Sealant: Polyisobutylene, plain or modified bitumen, non-hardening, non-migrating,

non-skinning, and nondrying, applied between layers of metal.

E. Fasteners: Factory-coated steel fasteners and metal plates meeting corrosion-resistance

provisions in FMG 4470, designed for fastening roofing membrane components to substrate,

tested by manufacturer for required pullout strength, and acceptable to roofing system

manufacturer.

F. Miscellaneous Accessories: Provide miscellaneous accessories recommended by roofing

system manufacturer.

2.4 ROOF INSULATION

A. General: Provide preformed roof insulation boards that comply with requirements and

referenced standards, selected from manufacturer's standard sizes and of thicknesses

indicated.

B. Base Insulation: ASTM C 1289, Type II, Class 1, Grade 2 – 20 psi minimum compressive

strength polyisocyanurate foam. Provide 4-foot by 8-foot boards only. Provide one layer of

1-1/2 inch insulation.

C. Tapered Insulation: Provide factory-tapered insulation boards meeting ASTM C 1289

fabricated to slope of 1/4 inch per 12 inches. Provide 4-foot by 4-foot boards only.





D. Provide preformed saddles, crickets, tapered edge strips, and other insulation shapes where

indicated for sloping to drain. Fabricate slope of 1/2 inch per 12 inches, unless otherwise

noted. Provide 4-foot by 4-foot boards only.

E. Cover Board: Expanded perlite roof insulation board with reinforcing cellulosic fibers and

selected binders, ¾-inch, UL classified and tested in accordance with ASTM C 728.

2.5 INSULATION ACCESSORIES

A. General: Roof insulation accessories recommended by insulation manufacturer for intended

use and compatible with membrane roofing.

B. Fasteners: Factory-coated steel fasteners and metal plates meeting corrosion-resistance

provisions in FMG 4470, designed for fastening roof insulation to substrate, and acceptable to

roofing system manufacturer.

1. Maximum length of fasteners shall be no longer than 1-inch longer than the thickness of

insulation being attached.

C. Insulation Cant Strips: ASTM C 728, perlite or ASTM C 208, Type II, Grade 1, cellulosic-

fiber.

2.6 STEEL DECK

A. Replacement steel deck: 22-gauge, galvanized steel roof deck meeting the requirements of

ASTM A653 Grade 50, sized to match existing.

B. Finish on replacement steel deck: Galvanizing shall conform to the requirements of ASTM

A653 coating class G90.

C. Sheet metal for repairs: 18-gauge galvanized sheet metal for areas 12-inch by 12-inch or less.

D. Sheet deck fasteners: Fasteners shall be number 12 screws, 1-1/4 inches long, with thread

length of ½ inch and installed to FMG uplift and Steel Deck Institute requirements.

2.7 WALKWAYS

A. Walkway Cap Sheet Strips: Provide one of the Following:

1. ASTM D 6164, Grade G, Type II, Class A fire-rated (FR), minimum 197-mil thick, 39

inch width, polyester-reinforced, EPDM sheet; smoothr surfaced; suitable for application

method specified.

a. Color: Contrast color to cap sheet, selected from manufacturer’s standards.

2. One layer of the specified EPDM Cap Sheet installed directly over one layer of the

specified EPDM interply sheet for a total of 280 mils thick walkway system.

a. Color: Contrast color to cap sheet, selected from manufacturer’s standards.





PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine substrates, areas, and conditions, with Installer present, for compliance with the

following requirements and other conditions affecting performance of roofing system:

1. Verify that roof openings and penetrations are in place and set and braced.

2. Verify that blocking, curbs, and nailers are securely anchored to roof deck at penetrations

and terminations and that nailers match thicknesses of insulation.

3. Verify that surface plane flatness and fastening of steel roof deck complies with

requirements in this Section.

4. Proceed with installation only after unsatisfactory conditions have been corrected.

B. Wood blocking in addition to that indicated on drawings for roof system installation is not

included in the NRCA standard details or design standard for this roof. Provide wood

blocking in addition to that indicated on drawings if required or preferred by roofing

manufacturer as a condition of warranty as work of this section, subject to Engineer’s

approval, at no additional cost to the Owner.

3.2 PREPARATION

A. Clean substrate of dust, debris, moisture, and other substances detrimental to roofing

installation according to roofing system manufacturer's written instructions. Remove sharp

projections.

B. Prevent materials from entering and clogging roof drains and conductors.

C. Remove existing penetrations that are to be abandoned as designated on Drawings, as

determined by the Renovations.

3.3 WEATHER CONDITIONS

A. Weather Condition Limitations: Proceed with roofing work only when existing and

forecasted weather conditions will permit work to be performed in accordance with

manufactures’ recommendations and warranty requirements.

B. Follow roofing membrane manufacturer and NRCA guidelines for inclement weather or when

air temperature may fall below 40 degrees Fahrenheit. Do not apply roofing membrane to

damp, wet, or frozen deck substrate.

C. Maintain a daily log of working hours and the minimum and maximum air temperatures

experienced during the hours and the presence, amount and severity of precipitation.

3.4 STEEL DECK REPLACEMENT





A. Install replacement steel deck panels in accordance with the applicable specifications and

commentary of SDI Manual of Construction with Steel Deck, manufacturer’s requirements,

and requirements of this section. Place replacement deck panels on supporting framing and

adjust to final position with ends accurately aligned and bearing on supporting framing before

being fastened. Do not stretch or contract side lap interlocks.

B. Metal deck shall be placed with a minimum 12-inch overlap in each direction, and fastened

around the perimeter with flouropolymer coated metal deck fasteners at 12-inches on-center.

C. Place replacement deck panels flat and square and fasten to supporting framing without warp

or deflection. Deck panel span shall not be less that three support members, where feasible.

D. Cut and neatly fit deck panels and accessories around opening and other work projecting

through or adjacent to the decking.

E. Install mechanical fasteners according to deck manufacturer’s instructions. Fasten side laps of

panels with self drilling No. 12 diameter, or larger, carbon steel screws at intervals not

exceeding 36 inches. Install deck ends over supporting framing with a minimum end bearing

of 1.5 inches; lap end joints a minimum of 2 inches. Mechanically fasten end joints with self-

drilling No. 12 diameter, or larger, carbon steel screws at 6 inches on-center. Fasten deck to

intermediate supports with specified screws at 12-inch intervals.

F. Steel decking repair: Overlay damaged area with section of 18-gauge galvanized sheet metal.

Fasten to sound adjacent deck on 6-inch centers with stainless steel fasteners. Overlay shall

be approximately 6-inches larger than the damaged area in each plan direction.

3.5 INSULATION AND BASE SHEET INSTALLATION

A. Comply with roofing system manufacturer's written instructions for installing roof insulation.

B. Insulation Cant Strips: Install and secure preformed 45-degree insulation cant strips at

junctures of roofing membrane system with vertical surfaces or angle changes greater than 45

degrees.

C. Install tapered insulation under area of roofing to conform to slopes indicated.

D. Install insulation with long joints of insulation in a continuous straight line with end joints

staggered between rows, abutting edges and ends between boards. Fill gaps exceeding 1/4

inch with insulation. Cut and fit insulation within 1/4 inch of nailers, projections, and

penetrations. Fit sloping insulation surfaces to meet smoothly without plateaus.

E. Install insulation under area of roofing to achieve required thickness. Where overall

insulation thickness is 2 inches or greater, install 2 or more layers with joints of each

succeeding layer staggered from joints of previous layer a minimum of 6 inches in each

direction.

1. At sloping deck, provide one layer of 1-1/2 inch thickness polyisocyanurate. Crickets,

cants, and tapered edge strips are also in addition to the isocyanurate insulation board

thickness. Install coverboard over this insulation.





2. At level decks, provide polyisocyanurate base insulation thickness indicated in Paragraph

2.4B of this Section. Install tapered insulation over base layer to provide adequate slope

to roof. Crickets, cants, and tapered edge strips are also in addition to the isocyanurate

insulation board thickness for the primary roof planes. Install coverboard over this

insulation.

F. Loose-lay base insulation and tapered insulation on steel deck.

G. Provide crickets, as indicated and required, on the high side of all penetrations to allow for

proper drainage of the roof system.

H. Install cover boards over insulation with long joints in continuous straight lines with end

joints staggered between rows. Stagger joints from joints in insulation below a minimum of 6

inches in each direction. Loosely butt cover boards together and secure to roof deck.

I. Make surfaces free of moisture, foreign material, oil, grease, dirt and other debris before start

of base sheet application.

J. Mechanically fasten base sheet over insulation and coverboard. Attach base sheet in

accordance with manufacturer’s requirements, these specifications, and to meet current FM 1-

90 uplift rating at steel deck.

3.6 ROOFING MEMBRANE INSTALLATION, GENERAL

A. Install roofing membrane according to roofing system manufacturer's written instructions and

applicable recommendations of ARMA/NRCA's “Quality Control Guidelines for the

Application of EPDM Roofing.”

B. Cooperate with Owner’s Roof Inspector.

C. Coordinate repairs so insulation and other components of the roofing membrane system not

permanently exposed are not subjected to precipitation or left uncovered at the end of the

workday or when rain is forecast.

1. Provide tie-offs at end of each day's work to cover exposed roofing membrane sheets and

insulation with a course of coated felt set in roofing cement or hot roofing asphalt with

joints and edges sealed.

2. Complete terminations and base flashings and provide temporary seals to prevent water

from entering completed sections of roofing system.

3. Remove and discard temporary seals before beginning work on adjoining roofing.

D. Prevent foot traffic or vehicle traffic from crossing newly laid membrane until bitumen cools

to below softening point.

3.7 EPDM MEMBRANE INSTALLATION

A. Install EPDM interply sheet and cap sheet according to roofing manufacturer's written

instructions, starting at low point of roofing system. Extend roofing membrane sheets onto

existing roof membrane, installing as follows:





1. Apply adhesive to adjacent roof system, as recommended by existing roofing systems

manufacturer, to provide proper adhesion of the two areas.

2. Unroll roofing membrane sheets and allow them to relax for minimum time period

required by manufacturer.

3. Torch apply interply sheet and cap sheet to substrate. Lap interply 6-inches minimum

onto the existing membrane and lap cap sheet 6-inches beyond the interply sheet onto the

existing membrane.

B. Laps: Accurately align roofing membrane sheets, without stretching, and maintain uniform

side and end laps. Stagger end and side laps of interply and cap sheets. Completely bond and

seal laps, leaving no voids.

1. Repair tears and voids in laps and lapped seams not completely sealed.

C. Install roofing membrane sheets so side and end laps shed water.

D. Smooth Surfacing: Promptly after installing cap sheet, set the adhesive for uniform surface

appearance of roofing.

3.8 FLASHING AND STRIPPING INSTALLATION

A. Install flashings over cant strips and other sloping and vertical surfaces, at roof edges, and at

penetrations through roof, and secure to substrates according to roofing system manufacturer's

written instructions and as follows:

1. Prime substrates with asphalt primer if required by roofing system manufacturer.

B. Flashing Sheet Application: Adhere flashing sheets to substrate by the following method

applied in accordance with requirements of the roofing system manufacturer.

1. Torch apply flashing sheets to substrate.

C. Extend flashings up walls or parapets a minimum of 8 inches above roofing membrane as

required by roofing system manufacturer.

D. Mechanically fasten top of flashing securely at terminations and perimeter of roofing. Space

fasteners at not greater than 6" o.c.

E. Install roof system accessories in accordance with the Project Manual, Drawings, and

Manufacturer’s Specifications.

3.9 WALKWAY INSTALLATION

A. Install rooftop traffic surfacing (walkpads) in accordance with walkpad manufacturer’s

specifications and as required by membrane manufacturer for system warranty.

B. Space traffic surfacing sheets evenly around all rooftop mechanical equipment, equipment

frames, access points and/or as recommended by the membrane manufacturer. Leave 6-inch

gaps between walkpad sections to facilitate drainage. Walkpads shall not be located in

insulation valley lines.





C. Adhere walkpad panels to roof membrane by method of torch-applying; prime or de-granulate

membrane surface as required prior to installation of walkpads.


A. Eliminate Ponding Water Conditions: Roof repairs resulting in ponding water shall be

corrected by adding to or reworking the insulation configuration to eliminate a ponding water

condition prior to acceptance of the completed roof system by Owner at no additional cost to

the Owner.

B. Final Roof Inspection: Arrange for roofing system manufacturer's technical personnel to

inspect roofing repairs on completion and submit report to Architect.

1. Notify Architect or Owner 48 hours in advance of date and time of inspection.

3.11 PROTECTING AND CLEANING

A. Protect roofing system from damage and wear during remainder of construction period. When

remaining construction will not affect or endanger roofing, inspect roofing for deterioration

and damage, describing its nature and extent in a written report, with copies to Architect and

Owner.

B. Correct deficiencies in or remove roofing that does not comply with requirements, repair

substrates, and repair or reinstall roofing system to a condition free of damage and

deterioration at time of Substantial Completion and according to warranty requirements.

C. Clean overspray and spillage from adjacent construction using cleaning agents and procedures

recommended by manufacturer of affected construction.

D. Before moving equipment or materials over completed roof, the Contractor shall protect the

roof from damage during and following roofing work. Movement of equipment and materials

without roof protection shall be cause for the Owner to stop work until protection is provided

and any damage is corrected.

3.12 ROOFING INSTALLER'S WARRANTY

A. WHEREAS <Insert name> of <Insert address>, herein called the “Roofing Installer,” has

performed roofing and associated work (“work”) on the following project:

1. Owner: Fauquier County Public Schools

2. Address: 124 Manor Court, Suite 5, Warrenton, Virginia 20186

3. Building Name/Type: Cedar Lee Middle School

4. Address: 11138 Marsh Road, Bealton, Virginia 22712

5. Area of Work: <Insert information.>

6. Acceptance Date: <Insert date.>

7. Warranty Period: <Insert time.>

8. Expiration Date: <Insert date.>





B. AND WHEREAS Roofing Installer has contracted (either directly with Owner or indirectly as

a subcontractor) to warrant said work against leaks and faulty or defective materials and

workmanship for designated Warranty Period,

C. NOW THEREFORE Roofing Installer hereby warrants, subject to terms and conditions herein

set forth, that during Warranty Period he will, at his own cost and expense, make or cause to

be made such repairs to or replacements of said work as are necessary to correct faulty and

defective work and as are necessary to maintain said work in a watertight condition.

D. This Warranty is made subject to the following terms and conditions:

1. Specifically excluded from this Warranty are damages to work and other parts of the

building, and to building contents, caused by:

a. lightning;

b. peak gust wind speed exceeding 63 mph;

c. fire;

d. failure of roofing system substrate, including cracking, settlement, excessive

deflection, deterioration, and decomposition;

e. faulty construction of parapet walls, copings, chimneys, skylights, vents,

equipment supports, and other edge conditions and penetrations of the work;

f. vapor condensation on bottom of roofing; and

g. activity on roofing by others, including construction contractors, maintenance

personnel, other persons, and animals, whether authorized or unauthorized by

Owner.

2. When work has been damaged by any of foregoing causes, Warranty shall be null and

void until such damage has been repaired by Roofing Installer and until cost and expense

thereof have been paid by Owner or by another responsible party so designated.

3. Roofing Installer is responsible for damage to work covered by this Warranty but is not

liable for consequential damages to building or building contents resulting from leaks or

faults or defects of work.

4. During Warranty Period, if Owner allows alteration of work by anyone other than

Roofing Installer, including cutting, patching, and maintenance in connection with

penetrations, attachment of other work, and positioning of anything on roof, this

Warranty shall become null and void on date of said alterations, but only to the extent

said alterations affect work covered by this Warranty. If Owner engages Roofing

Installer to perform said alterations, Warranty shall not become null and void unless

Roofing Installer, before starting said work, shall have notified Owner in writing,

showing reasonable cause for claim, that said alterations would likely damage or

deteriorate work, thereby reasonably justifying a limitation or termination of this

Warranty.

5. During Warranty Period, if original use of roof is changed and it becomes used for, but

was not originally specified for, a promenade, work deck, spray-cooled surface, flooded

basin, or other use or service more severe than originally specified, this Warranty shall

become null and void on date of said change, but only to the extent said change affects

work covered by this Warranty.

6. Owner shall promptly notify Roofing Installer of observed, known, or suspected leaks,

defects, or deterioration and shall afford reasonable opportunity for Roofing Installer to

inspect work and to examine evidence of such leaks, defects, or deterioration.

7. This Warranty is recognized to be the only warranty of Roofing Installer on said work

and shall not operate to restrict or cut off Owner from other remedies and resources





lawfully available to Owner in cases of roofing failure. Specifically, this Warranty shall

not operate to relieve Roofing Installer of responsibility for performance of original work

according to requirements of the Contract Documents, regardless of whether Contract

was a contract directly with Owner or a subcontract with Owner's General Contractor.

E. IN WITNESS THEREOF, this instrument has been duly executed this <Insert day> day of

<Insert month>, <Insert year>.

1. Authorized Signature: <Insert signature.>

2. Name: <Insert name.>

3. Title: <Insert title.>

END OF SECTION




THROUGH-PENETRATION FIRESTOP SYSTEMS 07841 - 1

SECTION 07841

THROUGH-PENETRATION FIRESTOP SYSTEMS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. The drawings and general provisions of the Contract Documents apply to this Section.

1.2 SUMMARY

A. Section Includes penetrations vertical and horizontal assemblies and smoke barriers.

B. See Mechanical drawings for additional details and requirements.

1.3 SUBMITTALS


PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering

products that may be incorporated into the Work include, but are not limited to, the following:

1. Hilti, Inc.

2. Nelson Firestop Products.

3. 3M Fire Protection Products.

2.2 PENETRATION FIRESTOPPING

A. Provide penetration firestopping that is produced and installed to resist spread of fire according

to requirements indicated, resist passage of smoke and other gases, and maintain original fire-

resistance rating of construction penetrated. Penetration firestopping systems shall be

compatible with one another, with the substrates forming openings, and with penetrating items

if any.

B. Accessories: Provide components for each penetration firestopping system that are needed to

install fill materials and to maintain ratings required. Use only those components specified by

penetration firestopping manufacturer and approved by qualified testing and inspecting agency

for firestopping indicated.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Examine substrates and conditions, with Installer present, for compliance with requirements for

opening configurations, penetrating items, substrates, and other conditions affecting

performance of the Work.

B. Install penetration firestopping to comply with manufacturer's written installation instructions

and published drawings for products and applications indicated.




THROUGH-PENETRATION FIRESTOP SYSTEMS 07841 - 2

C. Install forming materials and other accessories of types required to support fill materials during

their application and in the position needed to produce cross-sectional shapes and depths

required to achieve fire ratings indicated.

3.2 IDENTIFICATION

A. Identify penetration firestopping with preprinted metal or plastic labels.

END OF SECTION




JOINT SEALANTS 07920 - 1

SECTION 07920

JOINT SEALANTS

PART 1 - GENERAL



1.2 SUMMARY

A. Section includes for exterior and interior building applications.

1.3 SUBMITTALS

A. Product Data: For each joint-sealant product indicated.

PART 2 - PRODUCTS

2.1 MATERIALS, GENERAL

A. VOC Content of Interior Sealants: Provide sealants and sealant primers for use inside the

weatherproofing system.

B. Liquid-Applied Joint Sealants: Comply with ASTM C 920 and other requirements indicated for

each liquid-applied joint sealant specified, including those referencing ASTM C 920

classifications for type, grade, class, and uses related to exposure and joint substrates.

2.2 SEALANT TYPES

A. Sealants for Exterior applications: One part non-sag, polyurethane.

B. Sealants for Interior applications: One part, non-sag, silicone acrylic latex, paintable.

C. Sealants for toilet rooms and similar areas: one part silicone sanitary sealant, moisture and

mildew resistant.

2.3 JOINT SEALANT BACKING

A. Cylindrical Sealant Backings: ASTM C 1330 and of size and density to control sealant depth

and otherwise contribute to producing optimum sealant performance.

B. Bond-Breaker Tape: Polyethylene tape or other plastic tape recommended by sealant

manufacturer.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install sealant backings of kind indicated to support sealants during application and at position

required to produce cross-sectional shapes and depths of installed sealants relative to joint

widths that allow optimum sealant movement capability.

B. Install bond-breaker tape behind sealants where sealant backings are not used between sealants

and backs of joints.




JOINT SEALANTS 07920 - 2

C. Tooling of Sealants: Immediately after sealant application and before skinning or curing

begins, tool sealants to form smooth, uniform beads; to eliminate air pockets; and to ensure

contact and adhesion of sealant with sides of joint.

D. Clean off excess sealant or sealant smears adjacent to joints as the Work progresses by methods

and with cleaning materials approved in writing by manufacturers of joint sealants and of

products in which joints occur.

END OF SECTION




HVAC GENERAL MECHANICAL REQUIREMENTS 230100 - 1

SECTION 230100

HVAC GENERAL MECHANICAL REQUIREMENTS

PART 1 - GENERAL

1.1 SUMMARY

A. Drawings and general provisions of the Contract to this Section.

1. This Section compliments and applies to all other Division 23 Sections and all other

sections compliment and apply to this section and each other.

2. Refer to other applicable Sections in this Division, and other Divisions and drawings as

necessary for additional requirements, especially where “See Structural” is indicated on

the mechanical drawings and specifications.

3. Wherever conflict exists for materials and/or labor between specification sections the

more stringent, more expensive requirement shall be provided in the bid price.

4. The design engineer b2E will submit the plans to Fauquier County Department of

Community Development for approval. The Contractor will obtain the permit and pay

permit fees, and shall include the cost of permits and inspections in the bid price.

5. Areas will be made available to the Contractor as shown in the project manual. Days and

times for access and vehicle/equipment travel on site must be approved in advance by

FCPS. All equipment and materials must be appropriately marked off and barricaded and

attended when in use so as to present no hazard to the public at any time.

6. The Contractor must at no time create any hazard to any member of the public or to any

property.

7. When school is in session, the contractor may not block any walking or vehicle pathways,

except temporarily and with specific advance approval by FCPS.

8. The contractor must protect all existing facilities and repair at no additional cost to the

Owner any damage caused by the contractor.

9. The Contractor is responsible to remove the existing chiller; neither the Owner nor the

Engineer are prescribing means and methods. The contractor may disassemble the chiller,

or may remove part of the existing building structure and replace/repair the structure to

the equivalent of its pre-existing condition, or may use other method within the

conditions of the contract. The contractor may remove part of the existing MER wall and

restore it to equivalent of pre-existing condition. These are suggestions only, neither the

Owner nor the Engineer are prescribing particular means and methods. The contractor is

responsible to survey the site and bid the project accordingly.

10. The contract award will be based on either design alternative A or alternative B,

whichever serves in the Owner’s best interest, based upon first cost, estimated energy

cost, and project budget. The Owner will indicate which method of bid evaluation was

utilized to reach final award.

1.2 SPECIAL MECHANICAL REQUIREMENTS





A. Drawing use and interpretation:

1. Drawings are diagrammatic and indicate general arrangement of systems and equipment,

except when specifically dimensioned or detailed.

2. For locations of building elements, refer to structural, mechanical, and electrical

drawings.

3. Field measurements take precedence over drawings.

4. Mechanical plans are intended to indicate size, capacity, approximate location, direction

and general relationship of the work, but not exact detail or arrangement.

5. Field verify locations and arrangement of actual structures, systems and equipment.

6. All systems and equipment shall be installed in accordance with the manufacturer’s

written recommendations and/or written instruction manuals.

B. Installation of systems and equipment:

1. Installation is subject to clarification as indicated in reviewed and approved Shop and

Field Coordination Drawings.

a. Generally, lay out piping requiring gravity drainage first; then lay out large pipe

mains, ductwork and electrical conduit.

b. This procedure is intended to promote orderly installation, but not to establish

trade precedence.

c. Dimensions indicated are limiting dimensions.

d. Do not use equipment that does not meet the manufacturers’ and applicable code

requirements for clear service access. The contractor shall remove and replace any

equipment which does not meet the manufacturer’s and code required clearances

as determined by the Engineer and/or the local authorities having jurisdiction.

e. Coordinate ductwork and piping penetrations through walls, floors and roof with

actual field conditions and dimensions. Contractors shall thoroughly familiarize

themselves with the project requirements and the construction documents prior to

submitting bid price, and shall have measured and coordinated the installations

between trades using manufacturer’s actual equipment dimension drawing prior to

submitting coordinated shop drawings.

f. Under no circumstances shall any mechanical equipment be hung, supported or

suspended from the building ceilings. Ductwork, piping, etc. shall only be hung

directly from the building structure (i.e. steel beam, truss system or steel deck

system). Refer to structural requirements for building attachments.

g. Crane lifts, hot work, and work which transmits disruptive noise into the occupied

areas of the school must be not be performed between 6:30 a.m. and 5:00 p.m. on

days when school is in session. School is not in session weekends, December 21,

2015 through January 1, 2016, January 18, 2016, and February 15, 2016.

C. Utility coordination with Fauquier County: There shall be no unauthorized utility interruptions

throughout the duration of the project.

1. The Contractor shall notify Engineer and obtain approval for any utility interruptions at

least seventy two (72) hours in advance of such interruption and obtain approval from the

Owner through the Engineer before proceeding.

2. Identify extent and duration of utility interruptions.





3. Any damage to the Owner’s materials and equipment due to the Contractor’s work or

utility interruptions shall be entirely the Contractor’s responsibility.

4. Where the Owner finds excessive utility (i.e. gas, water and electricity) usage during the

course of the work the contractor shall share in the expenses as determined by the Owner.

D. Description of systems: Furnish and install materials resulting, upon completion, in functioning

systems in compliance with performance requirements specified, and including all

modifications resulting from reviewed and approved Shop and Field Coordination Drawings.

1. Provide materials and equipment as indicated on the construction documents. Where

items installed are determined by the Owner and the Engineer not in general conformance

with the intent of the construction documents replace materials and equipment at no

additional cost to the Owner.

E. Demolition: Contractor is responsible to coordinate exact systems and equipment which are to

be demolished prior to starting the physical demolition work. Where contractor is unclear if an

item is to be demolished, bring to Engineer/Owner’s attention immediately for direction as how

to proceed.

1. All demolished equipment and debris shall become the property of the contractor and

shall be disposed of properly off-site.

2. Where an item is called out to be salvaged or removed by the owner return item owner is

good condition.

3. Controls and starters removed by the Contractor shall remain on site and the Owner will

take possession of them.

F. Chilled Water System Start-up and Demonstration: The contractor is responsible to provide

complete coordination with Owner’s EMS contractor, start-up and systems demonstrations to

the Engineer/Owner for this project.

G. Damage at Site: Contractor shall immediately replace or repair anything damaged by the

contractor or contractor’s negligence at no additional cost to the Owner.

H. Energy Management System Coordination and Related Work: This project includes installation

of mechanical equipment to be controlled by a Web based electronic control system. The

Energy Management System (EMS) vendor for this project shall be provided by Owner under

separate contract. Provide and install all equipment furnished by the EMS contractor to be

controlled by the EMS Contractor.

1. The EMS contract shall be held by FCG & PS for the scope of work indicated under this

contract.

2. All mechanical equipment provided under this contract shall be connected to the Energy

Management System (EMS) by the EMS Contractor.

3. The contractor installing the mechanical equipment shall provide approved submittal

documentation and other factory documentation to the Owner’s EMS Contractor as

required by the Engineer/Owner.





4. The Contractor's scope of work does not include work indicated in the bid documents to

be performed by the Owners ATC Contractor (also referred to as "EMS Contractor).

This includes the work of specification sections 230900 Energy Management System

and 230993 Sequence of Operations for HVAC Controls. Chiller Contractor shall

coordinate with EMS Contractor, shall communicate requested information to the EMS

Contractor, and shall provide work to prepare the chiller, pumps, and piping to be

connected to the energy management system (EMS).

5. The EMS contractor shall provide power for all EMS panels and devices as necessary to

operate control equipment.

I. Provide all labor and materials as necessary to substantially complete the work on schedule.

Provide after-hours and/or weekend and/or overtime labor for all work required to meet the

contract milestone deadlines and construction completion schedules. Request for additional

payment for after-hours and/or weekend and/or overtime work will not be considered.

J. Warranty: Provide a full one (1) year warranty on all HVAC equipment with a 24 hr. service.

1. Provide greater than one (1) year warranty where indicated.

.

K. Quality Control: Contractor shall install, start up, and test for operation all mechanical,

electrical and other equipment in accordance with manufacturers' recommendations and with

the Project Manual

1.3 DEFINITIONS

A. Finished Spaces: Spaces other than mechanical and electrical equipment rooms, concealed

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.

D. Concealed, Interior Installations: Concealed from view and protected from physical contact by

building occupants. Examples include above ceilings and in duct shafts.

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. Basis of Design: Equipment specifically designated with the term “Basis of Design” as

indicated in the specifications or as scheduled on drawings.

1. The Contractor shall provide the “Basis of Design” or one of the “Acceptable

Manufacturers” listed in the specification. Where “Acceptable Manufacturer’s”





equipment other than the “Basis of Design” is provided, the contractor is responsible to

fully coordinate and provide design changes to structural steel, electrical power to match

nameplate data, controls, ductwork connections, piping connections, unit efficiency,

compatibility with controls, for a complete operating system in accordance with the plans

and specifications.

G. Acceptance: Shall occur after Substantial Completion and at which time all contract

requirements and Commissioning for the HVAC system are completed to the satisfaction of the

Owner and the Engineer.

1. With respect to initiation of warranty, the date when the Engineer signs the certificate for

Substantial Completion for the work.

H. FCG&PS: Fauquier County Government and Public Schools.

I. FCPS: Fauquier County Public Schools.

J. EMS: Energy Management System (Division 23).

K. Acceptable Manufacturer: Equipment that meets the criteria specified and which is fabricated

and assembled by one of the manufacturers listed in the “manufacturer’s” paragraph of the

Specification Section.

L. After-hours: Unoccupied hours of operation for the facility as determined by the Owner.

M. Occupied Area: Any area on the property during occupied hours as determined by the Owner.

N. Scheduled: As scheduled on drawing equipment schedules or as called-out by

manufacturer/model number/designation in the specification.

O. Cutting: Removal of existing construction necessary to permit installation or performance of

other Work.

P. Patching: Fitting and repair work required to restore surfaces to specified “new” or better

conditions after installation or removal of other Work.

Q. TAB: Testing, Adjusting and Balancing.

1.4 SUBMITTALS

A. Product Data: For the following:

1. Shop Drawings.

2. Coordination Drawings.

3. Penetration and Building Attachment Coordination Plans.

4. CAD Generated Coordination and Installation Drawings (1/4 scale).

5. Identifying Devices and Labels.

6. Roof Curbs for built-up roof system.





7. Rated Penetrations.

8. Structured Steel for Supports.

9. Motor Protectors.

10. Commercial Power Relay.

B. Shop Drawings: Detail fabrication and installation for structural steel strengthening, metal

supports and anchorage for mechanical materials and equipment. Provide structural and

mechanical submittals at same time to allow engineering review of complete proposed systems

located on the roof.

1. Nomenclature in the shop drawings, submittals, O&M manuals, warranty documents, and

as-built drawings shall be consistent (do not call the same thing by different names).

C. Coordination Drawings: Detail major elements, components, and systems of mechanical

equipment and materials in relationship with other systems, installations, and building

components. Show space requirements for installation and access. Indicate if sequence and

coordination of installations are important to efficient flow of the Work. Include the following:

1. Clearances for servicing and maintaining equipment, accessories, and specialties,

including space for disassembly required for periodic maintenance, minimum or greater

code required clearance to electric panels, fan shaft pull and compressor and motor

service access shall be indicated.

2. Equipment and accessory service connections and support details.

3. Roof penetrations.

4. Fire-rated wall and floor penetrations.

5. Scheduling, sequencing, movement, and positioning of large equipment into/onto

building during construction.

a. The roof structure may not support concentrated loads. Do not set heavy tools or

equipment on the roof. Obtain permission from the Engineer prior setting any

equipment on the roof.

6. Floor plans, elevations, and details to indicate penetrations in floors, walls, and ceilings

and their relationship to other penetrations and installations.

7. Floor plans to coordinate and integrate installation of all building attachments for piping

equipment, structural steel framing, pipe hangers/supports, etc.

8. Access panel and door locations.

9. Roof plans, elevations, and details to indicate penetrations in roof for piping and conduit,

locations of rooftop equipment, structural steel, walk-ways, equipment service access,

natural gas piping, piping hangers and supports, etc.

10. Operation and Maintenance Data: Provide multiple review submissions to modify or

reorganize format and content as requested by the Engineer at no additional cost to the

Owner.

a. Submit O&M manuals for initial review and comment no later than 90 days after

equipment submittals have been completed.





D. As-Built Drawings: Provide two printed copies of as-built drawings and a pdf file of all

structural, mechanical and electrical as-built drawings.

E. Operation and Maintenance Manuals: Contractor shall furnish two {2) printed copies, bound in

3-ring binders, of operation, maintenance, and repair instructions for material provided by

Contractor. O&M manuals shall include copies of all test and startup reports and all

warranty documents . Provide binders clearly labeled with project title on cover and on spine

1. Contractor shall furnish electronic copies of maintenance manuals which are available

from equipment manufacturers.

2. Provide manuals with spines labeled with the project title and “Operation and

Maintenance Manual”. Include printed copy of as-builts (reduced as needed) in manuals.

3. Contractor shall furnish two (2) printed copies of warranty letter(s) and certificates,

additional to copies included in the operation and maintenance manuals. Warranty

letter(s) and certificates shall include the project title, Contractor name and service

contact information, warranty start and end dates, and the terms of the warranties.

F. Warranty: Contractor shall warranty all work for one (1) year, and shall also issue to the Owner

additional warranty(ies) as described in the project manual. During warranty period, Contractor

shall respond to service request within four (4) hours, and shall repair or replace all faulty labor

and/or material at no cost to the Owner.

1. Label the manuals with project title and “Warranty Manual”.

G. Cleaning: During progress of the work, the Contractor shall daily remove from project site

all discarded materials, rubbish, and debris resulting from the work, or shall neatly contain

rubbish and debris within an approved container(s). Contractor shall maintain the site in safe

and orderly condition at all times. Contractor shall remove all discarded materials, rubbish,

and debris resulting from the work from FCPS property and shall dispose of in a licensed

landfill or as otherwise required by law.


A. Comply with ASME A13.1 for lettering size, length of color field, colors, and viewing angles of

identification devices.

B. Equipment Selection: Provide “Basis of Design” where listed in the drawings and

specifications. “Acceptable Manufacturers” equipment of higher electrical characteristics,

physical dimensions, weight, capacities, and ratings other than indicated as “Basis of Design”,

may be furnished if connecting mechanical and electrical services, circuit breakers, conduit,

motors, bases, structural steel, hangers and supports, and equipment spaces are increased.

Additional costs to the Owner shall not be considered for such modifications, and shall remain

the responsibility of the contractor. Equipment must meet design capacities, minimum energy

ratings or efficiencies and controls requirements.

C. Investigation: Coordinate and provide thorough investigation of concrete slabs and CMU walls

which have penetrations drilled or cut into the slab or wall before proceeding with such work.

Immediately repair and or replace conduit, piping or structural members in or under the





concrete slabs or walls which are damaged during the course of the work at no additional cost to

the Owner.

1. Investigate structures and locate any cables, electric conduit, piping, etc. prior to cutting

or drilling.

D. Structural Elements: Do not cut and patch structural elements in a manner that could change

their load-carrying capacity or load-deflection ratio.

1. Repair or replace the damaged structure immediately as determined by the Engineer.

E. Operational Elements: Do not cut and patch the following operating elements and related

components in a manner that results in reducing their capacity to perform as intended or that

results in increased maintenance or decreased operational life or safety.

1. Primary operational systems and equipment.

2. Air or smoke barriers.

3. Fire-protection systems.

4. Control systems.

5. Communication systems.

6. Conveying systems.

7. Electrical wiring systems.

8. Building structure.

F. Miscellaneous Elements: Do not cut and patch the following elements or related components in

a manner that could change their load-carrying capacity that results in reducing their capacity to

perform as intended or that results in increased maintenance or decreased operational life or

safety.

1. Water, moisture, or vapor barriers.

2. Membranes and flashings.

3. Exterior curtain-wall construction.

4. Equipment supports.

5. Piping, ductwork, vessels, and equipment.

6. Noise- and vibration-control elements and systems.

7. Building structure.

G. Visual Requirements: Do not cut and patch construction in a manner that results in visual

evidence of cutting and patching. Do not cut and patch construction exposed on the exterior or

in occupied spaces in a manner that would, in Engineer’s opinion, reduce the building's

aesthetic qualities. Remove and replace construction that has been cut and patched in a visually

unsatisfactory manner.

H. Perform work in accordance with following codes:

1. International Building Code (IBC 2012).

2. International Mechanical Code (IMC 2012), and Virginia Mechanical Code (2012).

3. International Plumbing Code (IPC 2012).

4. International Fuel Gas Code (IFGC 2012).





5. International Fire Protection Code (IFPC 2012).

6. International Energy Conservation Code (IECC 2012), and Virginia Energy Conservation

Code (VECC).

7. National Fire Protection Association Applicable Codes listed below others applicable

latest editions unless otherwise specified.

a. Standpipes (NFPA 14).

b. Fire pumps (NFPA 20).

c. National Electric Code (NFPA 70).

d. Air Distribution (NFPA 90 A).

8. ASHRAE, Standard 15 - Mechanical Refrigeration Safety Code, (Latest Edition).

9. ASHRAE/IES 90.1, 2007- Energy Code for Commercial and High-Rise Residential

Buildings.

10. ASHRAE/IES 55-2007: Thermal Environmental Conditions for Human Occupancy.

11. SMACNA Fire and Smoke Damper Installation.

12. Underwriters Laboratories (UL) Firestopping Systems Guide. (Latest Edition).

13. ASHRAE Guideline 1-2007: The HVAC Commissioning Process.

14. Virginia Uniform Statewide Building Code (latest amendments).

15. In accordance with local codes, ordinances, amendments, etc. and as required by the

authorities having jurisdiction.


A. Deliver pipes and tubes with factory-applied end caps. Maintain end caps through shipping,

storage, and handling to prevent pipe end damage and prevent entrance of dirt, debris, and

moisture.

B. Protect stored pipes and tubes from moisture and dirt. Elevate above grade. Do not exceed

structural capacity of floor or roof, when rigging materials or equipment.

1. Do not store heavy equipment or materials inside or on the roof.

C. Protect flanges, fittings, and piping specialties from moisture and dirt.

D. Provide covering and shielding for equipment to protect from damage.

E. Protect existing building and building components.

F. Repair, restore, and replace damaged building components and equipment.

G. Protect nameplates on motors, pumps and other equipment.

1.7 COORDINATION, SEQUENCING AND SCHEDULING

A. Coordinate mechanical equipment installation with other building components.





B. The floors, walls and roofs may require electric conduit and piping either under or in the

floor/roof and walls to rough-in equipment. Coordinate and provide electric conduit and piping

as necessary to rough-in for actual equipment connections.

1. Immediately repair any equipment damaged due to cutting the floors, walls and/or roof.

C. Arrange for pipe spaces, chases, slots, and openings in building structure during progress of

construction to allow for mechanical installations.

1. Set sleeves in poured-in-place concrete and other structural components as they are

constructed.

D. Coordinate installation of required supporting devices with actual field conditions to ensure that

maximum support intervals do not exceed code requirements.

E. Sequence, coordinate, and integrate installations of mechanical materials and equipment for

efficient flow of the Work.

F. Coordinate lifting and rigging, and connection of mechanical systems with exterior underground

and overhead utilities and services. Comply with requirements of governing regulations,

franchised service companies, and controlling agencies for setting or moving large equipment.

Perform work in accordance with all applicable codes and local authorities having jurisdiction

and obtain and pay for all permits and other costs.

1. Do not lift or crane any equipment above occupied areas of the site or the building.

G. Coordinate requirements for access panels and doors if mechanical items requiring access are

concealed behind finished surfaces.

H. Coordinate installation of identifying devices after completing covering and painting, if devices

are applied to surfaces. Install identifying devices before installing acoustical ceilings and

similar concealment.

I. Coordinate lifting and rigging and connection of mechanical systems with interior space

limitations and finishes. Remove and replace as necessary existing architectural, mechanical,

electrical, plumbing, etc., building components as required to install large and/or heavy

equipment.

J. Coordinate and provide installation of all work to meet the contract milestone deadlines,

substantial completion, and construction completion dates.

K. Scheduling. Protection and Safety: Contractor shall schedule all work in advance with the

Owner, and shall limit activities to areas, times, and procedures approved in advance by the

Owner. Contractor shall submit a written work schedule to the Owner in advance, and shall

submit an updated schedule each week in advance. Contractor shall work only upon receipt of

approval of the schedule by the Owner. Contractor shall schedule in advance with Owner,

and shall proceed only upon Owner approval, all interruptions of electricity, heating, air

conditioning, water supply, drainage, communications, or other infrastructure services.





L. The Contractor shall institute protective and safety procedures and install protective materials

as required to ensure that work will not cause personnel injury or property damage. Contractor

shall, at no additional cost to the Owner, repair any damage caused by the Contractor, and

shall restore to pre-existing condition any existing structure or equipment affected by. the Con-

tractor.

M. Contractor shall schedule in advance with Owner all hot work, welding, brazing, any work in-

volving flame or high temperature, and any work creating any hazard. Contractor shall plan

and perform suitable measures to control hazards, and shall proceed only after Owner ap-

proves of the schedule and the hazard controls.

N. Contractor shall provide cones, tape, barriers, and other material as needed to mark off work

areas and prevent unauthorized entry. Contractor shall not create any hazard to others; the de-

termination of what constitutes a hazard shall be at the sole discretion of the Owner.

1.8 JOB CONDITIONS

A. Once utilities and services are functional cause as little interference or interruption of utilities

and services as possible.

1. The Contractor shall notify Engineer and obtain approval for any utility interruptions at

least seventy two (72) hours in advance of such interruption and obtain approval from

Engineer before proceeding.

B. Keep roads and parking areas clear of materials and debris.

C. Examine Contract Documents to determine how other work will affect execution of mechanical

work.

D. Examine site and become familiar with actual conditions affecting work.

E. Make arrangements and pay for necessary permits, licenses, and inspections.

F. Record drawings: Shall be provided.

1. Keep a complete set of mechanical drawings in job site office for indicating actual

installation of mechanical systems and equipment.

2. Use this set of drawings for no other purpose.

3. Where material, equipment, or systems components are installed differently from that

indicated, show such differences clearly and neatly.

4. At project completion, submit record set of drawings.

1.9 SUBSTANTIAL COMPLETION AND ACCEPTANCE

A. Acceptance: The mechanical and plumbing systems shall not be accepted by the Engineer until

all systems are installed, fully operational.





1. The Engineer will not accept and will not release payment for retainage until all Contract

Requirements, including Division 23 contract requirements are completed.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Acceptable Manufacturers: Subject to compliance with requirements, provide products by

one of the manufacturers specified.

2.2 IDENTIFYING DEVICES AND LABELS

A. General: Manufacturer's standard products of categories and types required for each

application. If more than one type is specified for application, selection is Installer's option, but

provides one selection for each product category.

2.3 ROOF MOUNTED PIPE SUPPORTS

A. Chiller piping and conduit shall be supported on roof without penetrating roofing membrane.

B. Provide prefabricated elastometric piping supports. Do not cut roofing to install supports.

1. Basis of Design: Caddy Model B-Line C-Port, CE Series with BVT Vibraclamps.

2. Provide channel and locking bolts to allow level or sloped pipe installation.

2.4 RATED PENETRATIONS

A. Review the drawings prior to submitting the bid price. Include in the bid price all required fire

dampers indicated on the mechanical drawings.

B. Wherever fire dampers are indicated on mechanical drawings those walls shall be considered

fire rated walls, and shall be provided with a fire damper and UL listed fire stopping system as

applicable for the penetration type. Any penetrations of piping, conduit and ductwork, etc.,

through those walls shall be firestopped in accordance with UL listed details. Refer to fire

stopping schedules on mechanical drawings.

C. Maintain fire ratings where mechanical items penetrate fire rated building elements (See

Mechanical for fire damper details and UL listed fire stopping schedules). Submit details of UL

listed Firestopping penetrations for review and approval by the Engineer prior to installation.

2.5 STRUCTURAL STEEL FOR SUPPORTS





A. Mechanical Equipment: Maximum allowable operating weights are identified on the mechanical

equipment schedules. The contractor shall ensure that the operating weight of the actual

equipment installed does not exceed the scheduled value.

B. Refer to Structural for other applicable requirements.

2.6 THREE-PHASE MOTOR PROTECTORS

A. Provide all labor and materials for provision, installation, setup and testing motor protectors

which will shut-down and protect all three-phase motors upon detecting overvoltage, under-

voltage, loss of phase, phase reversal, phase imbalance, etc.

B. Provide motor protectors for each 3-phase motor or including AFDS for pumps whether

provided as a factory mounted or field installed motor. Provide for built-up and for factory

fabricated equipment. Provide whether or not equipment is provided with internal motor

protection (i.e. AFD) or not. Provide all motor protectors with auto reset.

C. Basis of Design: ICM 450 or approved equal.

2.7 HEAT TRACING CABLE

A. The Contractor shall provide heat trace cable for all chilled water piping exposed to the

outdoors and in the equipment curbs and HVAC units on the roof. Heat trace shall be provided

whether or not heat transfer fluid is water or glycol solution.

1. Acceptable Manufacturers:

a. Chromalox.

b. Raychem.

c. Markel.

B. Heat tracing cable shall consist of flat, flexible, low heat density strip of parallel circuit

construction.

1. 16 AWG bus bars and a continuous inner core of self-regulating conductive material.

2. Insulate core with a radiation crosslinked polyolefin jacket.

C. Design system with integral thermostat to automatically maintain minimum water temperature

of 40 deg. F to an ambient of 0 deg. F.

1. Interlock electrical power to operate whenever circuit breaker is energized and tempera-

ture is below 40 deg. F.

D. Cable shall be self-regulating and thermostatically controlled.

1. Cable shall respond to varying localized temperature conditions along the pipe by self-

regulating its heat output at each point along its length.





E. Provide power connection kit, splices, end seal kits, glass cloth adhesive tape, and other compo-

nents required for a complete installation.

F. Provide adjustable high limit thermostat for outdoor mounting to prevent pipe temperature from

exceeding 50 deg. F.

G. Power: 120/60/1 or 208/60/1 or 277/60/1 as indicated on the Division 26 contract documents

and for the available power in the building.

1. Refer to Section 260100 for coordination requirements between trades work.

2. Heat trace cable shall be provided by Div. 23; installed by Div. 23, Powered by Div. 26.

H. Systems Protected: The following piping systems shall be protected. The contractor is responsi-

ble to provide calculations indicating the length of cable and quantity of power circuits needed

for each system based on the actual piping length, diameter, insulation thickness, etc. The con-

tractor is responsible to coordinate the quantity and location of power circuits with Division 26

and provide weatherproof power circuits as necessary to affect a complete operating system.

1. Water piping exposed to outdoors shall be on commercial power.

2. CH-1 all piping and equipment exposed to outdoors for CHWS and CHWR.

PART 3 - EXECUTION

3.1 GENERAL

A. When changes in location of work are required, for coordination with the building structural or

between trades work, obtain approval of Engineer before making change.

1. Make changes at no additional cost to the Owner.

B. Provide all necessary offsets and crossovers in piping and ductwork, whether indicated or not,

as required to allow code required maintenance (service) access and architectural ceiling

heights.

C. Do not change indicated sizes without approval of Engineer.

1. Duct sizes indicated shall be inside clear dimensions. Where ducts must be reduced in

height to fit below structure above lighting fixtures etc., or other trades work, provide

duct transition and maintain original duct cross sectional area indicated by design.

D. Electrical equipment:

1. Install no piping in or above electrical equipment rooms and closets.

2. Install no piping above panelboards, switchboards, motor control centers, or motor

control panels.





3. Motor Controllers: All disconnect/starters shall be provided with panel mounted hand-

off-auto (H.O.A.) switches. The H.O.A. switches shall be provided with indicator lights,

and control power transformers.

4. Motor Protectors: Provide motor protectors for all three-phase motors.

a. Provide ICM-45 motor protectors.

b. Mount in NEMA 1 enclosure adjacent motor controller, or inside control panel of

equipment served.

5. Heat Trace Cable: Provide heat trace cables designed to maintain the pipe water

temperature at 40 degF when ambient OAT is 0 degF.

a. Interlock cable with EMS to monitor heat trace status, and issue an alarm if failure

occurs.

b. Provide one separate circuit for each outdoor pipe run.

3.2 MECHANICAL DEMOLITION

A. Disconnect, demolish, and remove mechanical systems, equipment, and components

indicated to be removed. All materials, equipment and components of systems are not

indicated individually where and when items are to be removed. The contractor shall

coordinate the demolition with the new work and remove all unused ductwork, piping,

valves, thermostats, controls, panels, hangers, supports, etc. There shall be no abandoned

materials or equipment above the ceilings or in the walls at the completion of construction.

1. Unused Piping Shall Be Removed: Remove portion of piping whether indicated

individually to be removed or not and cap or plug remaining piping with same or

compatible piping material.

2. Piping Shall Not Be Abandoned in Place: Drain piping, remove and cap or plug

piping with same or compatible piping material.

3. Unused Ducts Shall Be Removed: Remove portion of ducts whether indicated

individually to be removed or not and plug remaining ducts with same or compatible

ductwork material.

4. Ducts Shall Not Be Abandoned in Place: Remove unused portions of ductwork. Cap

or plug ducts with same, or compatible ductwork material.

5. Equipment to Be Removed: Disconnect and cap services and remove equipment.

6. Equipment to Be Removed and Reinstalled: Disconnect and cap services and remove,

clean, and store equipment; when appropriate, refinish, refurbish, reinstall, reconnect,

and make equipment operational.

6. Equipment to Be Removed and Salvaged: Disconnect and cap services and remove

equipment and deliver to Owner.

B. If pipe, insulation, or equipment to remain is damaged in appearance or is unserviceable,

remove damaged or unserviceable portions and replace with new products of equal capacity

and quality.

C. All unused materials removed from this site shall become the property of the contractor and

be legally disposed of off-site.





3.3 LOCATING SERVICEABLE DEVICES

A. Install devices that may require adjustment, service, or maintenance in normally accessible

locations, or provide flush-mounted doors.

1. Such devices include but are not limited to equipment, valves, filters, motors, drives,

compressors, unions, traps, strainers, thermometers, gauges, meters, switches,

measurement devices, coils, detectors, dampers, sensors, monitors, backflow prevention

devices, test stations, signal devices, air vents, expansion joints, system drains, fire

dampers, manual balancing dampers, etc.

2. Arrange piping, conduit, ducts, and related work to facilitate maintenance.

3. Relocate items, which interfere with access, to satisfaction of Engineer.

4. All equipment requiring adjustment, service or maintenance shall be installed no higher

than 8’-0” above finished floor or roof level. Where indicated on drawings, locate at

elevation no higher than scaled in sections, elevations or as noted.

5. Final location of equipment requiring adjustment, service or maintenance shall be

identified on the coordination drawings. The Owner and the Engineer will make the

final determination whether equipment is accessible. The contractor shall relocate at

their own expense any equipment, which is determined inaccessible due to apparent lack

of coordination.

7. Provide adequate means for maintenance and inspection and removal of equipment for

repairs. This includes, but is not limited to, removable walls/ceilings, removable

structural, supports, etc. Demonstrate the method for maintenance and inspection and

removal of the equipment with one (1) person to the Engineer and the Owner. If the

Engineer determines that the equipment is not serviceable by one (1) person the

Contractor shall revise the installations until the installation is serviceable as determined

by the Engineer.

3.4 CUTTING AND PATCHING

A. General: Employ skilled workers to perform cutting and patching.

1. Do not cut construction without prior written approval from Structural Engineer.

2. Do not damage the building finishes or structural systems. Fix any building damage

immediately.

3.5 EQUIPMENT INSTALLATION - COMMON REQUIREMENTS

A. Install equipment in accordance with manufacturer’s recommendations, and as specified.

1. Where Air-Cooled Chiller or other equipment is supported on a steel support platform,

dunnage, curb, or concrete floor or pad support structure the structure shall be designed

not to exceed 1/4” maximum deflection over entire unit length.

2. The Equipment Support Structure shall be level. If the chiller or other equipment service

doors cannot be opened (or bind) due to failure to provide a level support, then make

adjustments to the support system, including removing the units and reworking the

support system until level.





3. Continue fixing the structural system until the chiller equipment is level and the service

doors are not binding.

B. Install equipment to provide maximum possible headroom if mounting heights are not

indicated.

C. Install equipment according to approved submittal data. Portions of the Work are shown only in

diagrammatic form. Refer conflicts to Engineer.

D. Install equipment level and plumb, parallel and perpendicular to other building systems and

components in exposed interior spaces, unless otherwise indicated.

I. Install mechanical 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.

J. Provide necessary anchoring devices and supports.

1. Use structural supports suitable for equipment (See Structural).

2. Check loadings and dimensions of equipment with shop drawings.

3. Do not cut or weld to building structural members.

4. Provide equipment supports, for all equipment whether or not, indicated or detailed on

construction documents.

5. Where installed equipment exceeds the maximum weight indicated by the “Basis of

Design” manufacturer, it shall be the contractor’s responsibility to design, provide and

install additional structural work required to support the acceptable manufacturer’s

equipment at no additional cost to the Owner.

K. Verify that equipment will fit exactly in the support layouts indicated.

1. Where substitute equipment is used, revise supports to fit.

L. Arrange for necessary openings in building or clear passage thru building corridors and to allow

entry of equipment.

M. Install rain hoods and metal counter flashings and make penetrations of mechanical piping

ductwork, conduit, and other work through walls and roof both water and weathertight.

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


A. Perform indicated tests to demonstrate workmanship, operation, and performance.

1. Conduct tests in presence of Engineer and the Owner and, if required, inspectors of

agencies having jurisdiction.

2. Arrange date of tests in advance with Engineer and the Owner, manufacturer and

installer.





3. Give inspectors minimum of 24 hours notice, or as required by local inspection

department.

4. Furnish or arrange for use of electrical energy, water or gas required for tests.

5. Furnish materials required for test.

B. Repair or replace equipment and systems found inoperative or defective and retest.

1. If equipment or system fails retest, replace it with products conforming to Contract

Document.

2. Continue remedial measures and retest until satisfactory results are obtained.

3.7 ADJUST AND CLEAN

A. Inspect equipment and put in satisfactory working order.

B. Clean exposed and concealed items:

1. Clean air surfaces of pipes, pumps and controllers.

2. Clean floor drains, cleanouts, and plumbing fixtures.

a. Rod-out all plumbing drains and test to ensure all floor drains are clear and

draining prior to performing any work.

b. Floor drains shall be clear and draining prior to turning building over to the Owner.

3. Clean piping of tags, debris and other construction materials before insulating or

painting.

4. Clean debris out of ductwork.

C. Clean above the ceiling:

1. Clean off the top of all HVAC equipment prior to ceiling close in.

2. Wipe down the entire duct system and equipment all around to remove dust and

debris.

3. Clean the building floors as necessary after the HVAC systems are wiped off and

cleaned.

3.8 PUTTING SYSTEMS IN OPERATION-START-UP

A. Prior to substantial completion, at time agreed to by Engineer, put systems into satisfactory

operation.

1. At first cooling season following Substantial Completion, put systems not yet operated

under their seasonal loads into satisfactory operation.

2. At second cooling season following Substantial Completion put systems not yet

operated under their first seasonal loads into satisfactory operation.

B. System Start-up





Contractor shall perform chiller and pump startup by manufacturer authorized technicians. Prior to startup, Contractor shall contact the Contract Administrator, and shall coordinate with Owner, who may be present during start up. Contractor shall submit start-up reports to En-gineer and Owner prior to demonstration, and shall include start-up reports in the O&M manual.

C. Demonstration and Training Upon completion of the work, Contractor shall demonstrate all equipment and working

systems to the Owner and Engineer. Contractor shall provide a total of four (8) hours of on-site training to the Owner by specialist(s) on operation and maintenance of all equipment provided by the Contractor.

END OF SECTION




COMMON WORK RESULTS FOR HVAC 230500 - 1

SECTION 230500

COMMON WORK RESULTS FOR HVAC

PART 1 - GENERAL

1.1 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. Mechanical sleeve seals for above ground pipe and conduit penetrations.

5. Sleeves.

6. Escutcheons.

7. Grout.

8. Adjust and clean.

9. Painting and finishing.

10. Concrete bases.

1.2 SUBMITTALS


1. Transition fittings.

2. Dielectric fittings.

3. Mechanical sleeve seals.

4. Escutcheons.

5. Flexible connections.

B. Welding certificates.


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.






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.

1.5 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


PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Acceptable Manufacturers: Subject to compliance with requirements, provide products by the

manufacturers specified.

2.2 FLEXIBLE CONNECTORS

A. General: Fabricated from materials suitable for system fluid and that will provide flexible pipe

connections. Include 125-psig minimum working-pressure rating, unless higher working

pressure is indicated, and ends according to the following:

1. 2-Inch NPS and Smaller: Threaded, soldered, or brazed.

2. 2-1/2-Inch NPS and Larger: Flanged.

B. Stainless-Steel-Hose/Steel Pipe, Flexible Connectors: Corrugated, stainless-steel, inner tubing

covered with stainless-steel wire braid. Include steel nipples or flanges, welded to hose.

1. Provide for connections to vibrating equipment.

2.3 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.





2.4 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 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 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. 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 general-duty

brazing, unless otherwise indicated; and AWS A5.8, BAg1, silver alloy for refrigerant piping,

unless otherwise indicated.

F. Welding Filler Metals: Comply with AWS D10.12 for welding materials appropriate for wall

thickness and chemical analysis of steel pipe being welded.

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: Not allowed.

D. Dielectric Flanges: Factory-fabricated, companion-flange assembly, for 150- or 300-psig

minimum working pressure as required to suit system pressures.


a. Capitol Manufacturing Co.

b. Central Plastics Company.

c. Epco Sales, Inc.

d. Watts Industries, Inc.; Water Products Div.





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.


a. Advance Products & Systems, Inc.

b. Calpico, Inc.

c. Central Plastics Company.

d. Pipeline Seal and Insulator, Inc.

2. 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.


a. Calpico, Inc.

b. Lochinvar Corp.

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.


a. Perfection Corp.

b. Precision Plumbing Products, Inc.

c. Sioux Chief Manufacturing Co., Inc.

d. Victaulic Co. of America.

2.6 MECHANICAL SLEEVE SEALS (for above ground pipe and conduit penetrations only)

A. Description: Modular sealing element unit, designed for field assembly, to fill annular space

between pipe and sleeve.



b. Calpico, Inc.

c. Metraflex Co.


2. Sealing Elements: EPDM or NBR interlocking links shaped to fit surface of pipe.

Include type and number required for pipe material and size of pipe.

3. Pressure Plates: Carbon steel or Stainless steel. Include two for each sealing element.





4. Connecting Bolts and Nuts: Carbon steel with corrosion-resistant coating or Stainless

steel of length required to secure pressure plates to sealing elements. Include one for

each sealing element.

2.7 SLEEVES

A. Galvanized-Steel Sheet: 0.0239-inch minimum thickness; round tube closed with welded

longitudinal joint.

B. Steel Pipe: ASTM A 53, Type E, Grade B, Schedule 40, galvanized, plain ends.

C. Cast Iron: Cast or fabricated "wall pipe" equivalent to ductile-iron pressure pipe, with plain

ends and integral waterstop, unless otherwise indicated.

D. Stack Sleeve Fittings: Manufactured, cast-iron sleeve with integral clamping flange. Include

clamping ring and bolts and nuts for membrane flashing.

1. Underdeck Clamp: Clamping ring with set screws.

2.8 ESCUTCHEONS

A. Description: Manufactured wall and ceiling escutcheons and floor plates, with an ID to closely

fit around pipe, tube, and insulation of insulated piping and an OD that completely covers

opening.

B. One-Piece, Deep-Pattern Type: Deep-drawn, box-shaped brass with polished chrome-plated

finish.

C. One-Piece, Cast-Brass Type: With set screw.

1. Finish: Polished chrome-plated or Polished chrome-plated and rough brass to match

adjacent construction.

2.9 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.

2.10 PAINTING AND FINISHING

A. Ferrous Metal: Provide the following finish systems over ferrous metal.





1. Semigloss, Alkyd-Enamel Finish. One finish coat over an enamel undercoater and a

primer.

a. Primer: Quick-drying, rust inhibitive, alkyd-based or epoxy-metal primer, as

recommended by the manufacturer for this substrate, applied at spreading rate

recommended by the manufacturer to achieve a total dry film thickness of not less

than 1.5 mils.

1. Devoe 13101 Mirrolac Rust Penetrating Metal Primer.

2. Fuller: 621-04 Blox-Rust Alkyd Metal Primer.

3. Glidden: 520 Ghd-Guard Tank & Structural Primer, White.

4. Moore: IronClad Retardo Rust-Inhibitive Pain #163.

5. PPG: 6-208 Speedhide Interior/Exterior Rust Inhibitive Steel Primer.

6. S-W: Kem Kromik Metal Primer B50N2/B50WI.

b. Undercoat Alkyd, interior enamel undercoat or semigloss, interior, alkyd-enamel

finish coat, as recommended by the manufacturer for this substrate, applied at

spreading rate recommended by the manufacturer to achieve a total dry film

thickness of not less than 1.2 mils.

1. Devoe 26XX Velour Interior Alkyd Semi-Gloss Enamel.

2. Fuller: 222-07 Interior Alkyd Enamel Undercoat.

3. Glidden: UH 8400 Ultra Traditional Alkyd Semi-Gloss Enamel.

4. Moore: Moore’s Alkyd Enamel Underbody #217.

5. PPG: 6-6 Speedhide Interior Quick-Drying Enamel Undercoat.

6. P & L: S/D 1011 Suprime “11” Interior Alkyd Wood Primer.

7. S-W: ProMar 200 Interior Alkyd Semi-Glass Enamel B34W200.

c. Finish Coat: Odorless, semigloss, alkyd, interior enamel applied at spreading rate

recommended by the manufacturer to achieve a total dry film thickness of not less

than 1.4 mils.

1. Devoe 26XX Velour Interior Alkyd Semi-Gloss Enamel.

2. Fuller: 110-XX Fullerglo Alkyd Semi-Gloss Enamel.

3. Glidden: UH 8400 Ultra Traditional Alkyd Semi-Gloss Enamel.

4. Moore: Satin Impervo #235.

5. PPG: 27 Line Wallhide Low Odor Interior Enamel Wall and Trim

Semi-Gloss Oil.

6. P & L: S/D 5700 Cellu-Tone Alkyd Satin Enamel.

7. S-W: Classic 99 Interior/Exterior Semi-Gloss Alkyd Enamel

A-40 Series.

B. Ferrous Metal above the Roof (outdoors): Metal surfaces shall be protected from corrosion by

one of the following:

a. ASTM A 123 Hot dipped galvanized finish.

b. High performance coating (Refer to Section 09910 “Painting” for other applicable

requirements).





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 required slopes for a complete operating system.

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. Install escutcheons for penetrations of walls, ceilings, and floors according to the following:

1. New Piping:

a. Piping with Fitting or Sleeve Protruding from Wall: One-piece, deep-pattern type.

b. Chrome-Plated Piping: One-piece, cast-brass type with polished chrome-plated

finish.

c. Insulated Piping: One-piece, stamped-steel type with spring clips.

d. Bare Piping at Wall and Floor Penetrations in Finished Spaces: One-piece, cast-

brass type with polished chrome-plated finish.

e. Bare Piping in Unfinished Service Spaces: One-piece, cast-brass type with rough-

brass finish.

f. Bare Piping at Floor Penetrations in Equipment Rooms: One-piece, floor-plate

type.





M. Install sleeves for pipes passing through concrete and masonry walls, gypsum-board partitions,

and concrete floor and roof slabs.

1. Cut sleeves to length for mounting flush with both surfaces.

a. Exception: Extend sleeves installed in floors of mechanical equipment areas or

other wet areas 2 inches above finished floor level. Extend cast-iron sleeve fittings

below floor slab as required to secure clamping ring if ring is specified.

2. Install sleeves in new walls and slabs as new walls and slabs are constructed.

3. Install sleeves that are large enough to provide 1-inch annular clear space between sleeve

and pipe or pipe insulation. Use the following sleeve materials:

a. Steel Pipe Sleeves: For pipes smaller than NPS 6.

b. Steel Sheet Sleeves: For pipes NPS 6 and larger, penetrating gypsum-board

partitions.

c. Stack Sleeve Fittings: For pipes penetrating floors with membrane waterproofing.

Secure flashing between clamping flanges. Install section of cast-iron soil pipe to

extend sleeve to 2 inches above finished floor level.

1) Seal space outside of sleeve fittings with grout.

4. Except for underground wall penetrations, seal annular space between sleeve and pipe or

pipe insulation, using joint sealants appropriate for size, depth, and location of joint.

N. Aboveground, Exterior-Wall Pipe Penetrations: Seal penetrations using sleeves and mechanical

sleeve seals. Select sleeve size to allow for 1-inch annular clear space between pipe and sleeve

for installing mechanical sleeve seals.

1. Install steel pipe for sleeves smaller than 6 inches in diameter.

2. Install cast-iron "wall pipes" for sleeves 6 inches and larger in diameter.

3. Mechanical Sleeve Seal Installation: Select type and number of sealing elements

required for pipe material and size. Position pipe in center of sleeve. Assemble

mechanical sleeve seals and install in annular space between pipe and sleeve. Tighten

bolts against pressure plates that cause sealing elements to expand and make watertight

seal.

O. Fire-Barrier Penetrations: Maintain indicated fire rating of walls, partitions, ceilings, and floors

at pipe penetrations. Seal pipe penetrations with firestop materials. Refer to Section 07841

"Thru-Penetration Firestop Systems" for materials.

P. Verify final equipment locations for roughing-in.

Q. 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.

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 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 AND FINISHING

A. Apply paint to exposed piping according to the following, unless otherwise indicated:

1. Interior, Ferrous Piping: Use semigloss, acrylic-enamel finish. Include finish coat over

enamel undercoat and primer.

1. Interior, Ferrous Supports (misc.): Use semigloss, acrylic-enamel finish. Include finish

coat over enamel undercoat and primer.

2. Exterior, Ferrous Piping: Use semigloss, acrylic-enamel finish. Include two finish coats

over rust-inhibitive metal primer.

3. Exterior, Ferrous Supports (misc.): Use semigloss, acrylic-enamel finish. Include two

finish coats over rust-inhibitive metal primer.

B. Do not paint piping specialties with factory-applied finish.

C. Damage and Touchup: Repair marred and damaged factory-painted finishes with materials and

procedures to match original factory finish.

3.6 CONCRETE BASES

A. Concrete Bases: Anchor equipment to concrete base according to equipment manufacturer's

written instructions and according to seismic codes at Project.

1. Construct concrete bases of dimensions indicated, but not less than 4 inches larger in both

directions than supported unit.

2. Install dowel rods to connect concrete base to concrete floor. Unless otherwise indicated,

install dowel rods on 18-inch centers around the full perimeter of the base.

3. Install epoxy-coated anchor bolts for supported equipment that extend through concrete

base, and anchor into structural concrete floor.

4. Place and secure anchorage devices. Use supported equipment manufacturer's setting

drawings, templates, diagrams, instructions, and directions furnished with items to be

embedded.

5. Install anchor bolts to elevations required for proper attachment to supported equipment.

6. Install anchor bolts according to anchor-bolt manufacturer's written instructions.





7. Use 3000-psi, 28-day compressive-strength concrete and reinforcement.

3.7 ERECTION OF METAL SUPPORTS AND ANCHORAGES

A. Cut, fit, and place miscellaneous metal supports accurately in location, alignment, and elevation

to support and anchor HVAC materials and equipment.

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

3.8 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.

3.9 ADJUST AND CLEAN

A. Inspect equipment and put in satisfactory working order.

B. Clean exposed and concealed items:

1. Clean air surfaces of piping, pumps and motor controllers.

2. Clean floor drains, cleanouts, and plumbing fixtures.

a. Rod-out all plumbing drains and test to ensure all floor drains are clear and

draining prior to performing any work.

b. Floor drains shall be clear and draining prior to turning building over to the Owner.

3. Clean piping of tags, debris and other construction materials before insulating or

painting.

4. Clean debris out of piping.

5. Clean above the ceilings:





a. Clean off the top of and wipe down all around all ductwork, and other HVAC

equipment above the ceiling prior to ceiling close in.

b. Wipe down the entire duct system and equipment all around to remove dust and

debris.

c. Clean the building floors as necessary after the HVAC systems are cleaned.

END OF SECTION




COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT 230513 - 1

SECTION 230513

COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT

PART 1 - GENERAL

1.1 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.

1.2 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.

C. Comply with IEEE 841 for severe-duty motors.

2.2 MOTOR CHARACTERISTICS

A. Motors ¾ HP and Larger: Three phase.

B. Motors Smaller Than ¾ HP: Single phase.

C. Frequency Rating: 60 Hz.





D. Voltage Rating: NEMA standard voltage selected to operate on nominal circuit voltage to

which motor is connected.

E. Duty: Continuous duty at ambient temperature of 40 deg C and at altitude of 3300 feet above

sea level.

F. 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.

G. Enclosure: Open dripproof (ODP) for motors located in airstreams. Totally enclosed fan-

cooled (TEFC) for motors used in unconditioned spaces (i.e. mechanical rooms) with adjustable

frequency drives (AFD’s).

2.3 POLYPHASE MOTORS

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

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

1. Minimum Efficiency Ratings.

a. ½ HP to 1 HP = 85.5%

b. 1 HP to 2 HP = 86.5%

c. 3 HP to 5 HP = 89.5%

d. 7.5 HP to 10 HP = 91.7%

e. 15 HP to 20 HP = 92.4%

f. 25 HP to 30 HP = 93.6%

g. 40 HP to 50 HP = 94.5%

h. > 50 HP = 95.4%

C. Service Factor: 1.15.

D. Multispeed Motors: Variable torque.

1. For motors with 2:1 speed ratio, consequent pole, single winding.

2. For motors with other than 2:1 speed ratio, separate winding for each speed.

E. Multispeed Motors: Separate winding for each speed.

F. Stator: Copper windings.

G. Rotor: Random-wound, squirrel cage.

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

I. Temperature Rise: Match insulation rating.

J. Insulation: Class F.





K. Code Letter Designation:

1. Motors 15 HP and Larger: NEMA starting Code F or Code G.

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

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

frame sizes smaller than 324T.

2.4 POLYPHASE MOTORS WITH ADDITIONAL REQUIREMENTS

A. Motors Used with Reduced-Voltage and Multispeed Controllers: Match wiring connection

requirements for controller with required motor leads. Provide terminals in motor terminal box,

suited to control method.

B. Motors Used with Variable Frequency Controllers: Ratings, characteristics, and features

coordinated with and approved by controller manufacturer.

1. Windings: Copper magnet wire with moisture-resistant insulation varnish, designed and

tested to resist transient spikes, high frequencies, and short time rise pulses produced by

pulse-width modulated inverters.

2. Energy- and Premium-Efficient Motors: Class B temperature rise; Class F insulation.

3. Inverter-Duty Motors: Class F temperature rise; Class H insulation.

4. Thermal Protection: Comply with NEMA MG 1 requirements for thermally protected

motors.

2.5 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.





2.6 EXAMINATION

A. Examine areas to receive field-installed motors for compliance with requirements, installation

tolerances, and other conditions affecting performance.

B. Examine roughing-in of conduit systems to verify actual locations of conduit connections before

motor installation.

C. Proceed with installation only after unsatisfactory conditions have been corrected.

2.7 MOTOR INSTALLATION

A. Anchor each motor assembly to base, adjustable rails, or other support, arranged and sized

according to manufacturer's written instructions. Attach by bolting. Level and align with load

transfer link.

B. Install motors on equipment bases for pumps and on other equipment in accordance with

manufacturer’s written instructions.

C. Comply with mounting and anchoring requirements specified.


A. Prepare for acceptance tests as follows:

1. Align motors, bases, shafts, pulleys, and belts. Tension belts according to manufacture’s

written instructions.

2. Verify bearing lubrication.

3. Run each motor with its controller. Demonstrate correct rotation, alignment, and speed at

motor design load.

4. Test interlocks and control and safety features for proper operation.

5. Verify that current and voltage for each phase comply with nameplate rating and NEMA

MG 1 tolerances.

B. Testing: Engage a qualified testing agency to perform the following field quality-control

testing:

1. Perform each electrical test and visual and mechanical inspection stated in NETA ATS,

Section 7.15.1.

2. Certify compliance with test parameters.

3. Correct malfunctioning units on-site, where possible, and retest to demonstrate

compliance; otherwise, replace with new units and retest.

C. Manufacturer's Field Service: Engage a factory-authorized service representative to perform the

following:





1. Inspect components, equipment installation, and piping and electrical connections for


2. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and

equipment.

3. Verify bearing lubrication.

4. Verify proper motor rotation.

5. Test Reports: Prepare a written report to record the following:

a. Test procedures used.

b. Test results that comply with requirements.

c. Test results that do not comply with requirements and corrective action taken to

achieve compliance.

2.9 ADJUSTING

A. Align motors, bases, shafts, pulleys and belts. Tension belts according to manufacturer's written

instructions.

2.10 CLEANING

A. After completing equipment installation, inspect unit components. Remove paint splatters and

other spots, dirt, and debris. Repair damaged finish to match original finish.

B. Clean motors, on completion of installation, according to manufacturer's written instructions.

2.11 FIELD-INTALLED MOTOR DEMONSTATION

A. Engage a factory-authorized service representative to train Owner’s maintenance personnel to

adjust, operate, and maintain field-installed motors.

END OF SECTION




GENERAL-DUTY VALVES FOR HVAC PIPING 230523 - 1

SECTION 230523

GENERAL-DUTY VALVES FOR HVAC PIPING

PART 1 - GENERAL

1.1 SUMMARY


1. Bronze ball valves.

2. Iron ball valves.

3. Iron Butterfly Valves

4. Bronze swing check valves.

5. Iron swing check valves with closure control.

6. Iron, center-guided check valves.

1.2 DEFINITIONS

A. CWP: Cold working pressure.

B. EPDM: Ethylene propylene copolymer rubber.

C. NBR: Acrylonitrile-butadiene, Buna-N, or nitrile rubber.

D. NRS: Nonrising stem.

E. OS&Y: Outside screw and yoke.

F. RS: Rising stem.

1.3 SUBMITTALS

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:

1. ASME B16.10 and ASME B16.34 for ferrous valve dimensions and design criteria.

2. ASME B31.1 for power piping valves.

3. ASME B31.9 for building services piping valves.






A. Prepare valves for shipping as follows:

1. Protect internal parts against rust and corrosion.

2. Protect threads, flange faces, grooves, and weld ends.

3. Set ball valves open to minimize exposure of functional surfaces.

4. Block check valves in either closed or open position.

B. Use the following precautions during storage:

1. Maintain valve end protection.

2. Store valves indoors and maintain at higher than ambient dew point temperature. If

outdoor storage is necessary, store valves off the ground in watertight enclosures.

C. Use sling to handle large valves; rig sling to avoid damage to exposed parts. Do not use

handwheels or stems as lifting or rigging points.

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. Handwheel: For valves other than quarter-turn types.

2. Handlever: For quarter-turn valves NPS 6 and smaller.

E. Valves in Insulated Piping: With 2-inch 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: Heavy duty butterfly valve; class 250.

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.

G. Valve Bypass and Drain Connections: MSS SP-45.





2.2 BRONZE BALL VALVES

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

1. Acceptable Manufacturers: Subject to compliance with requirements, provide products

by one of the following:

a. American Valve, Inc.

b. Conbraco Industries, Inc.; Apollo Valves.

c. Crane Co.; Crane Valve Group; Crane Valves.

d. Milwaukee Valve Company.

e. NIBCO INC.

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

2. Description:

a. Standard: MSS SP-110.

b. SWP Rating: 150 psig.

c. CWP Rating: 600 psig.

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.

B. Two-Piece, Full-Port, Bronze Ball Valves with Stainless-Steel Trim:



a. Conbraco Industries, Inc.; Apollo Valves.

b. Crane Co.; Crane Valve Group; Crane Valves.

c. Milwaukee Valve Company.

d. NIBCO INC.

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

2. Description:




d. Body Design: Two piece.


f. Ends: Threaded.


h. Stem: Stainless steel.

i. Ball: Stainless steel, vented.

j. Port: Full.





C. Three-Piece, Full-Port, Bronze Ball Valves with Bronze Trim:




b. Milwaukee Valve Company.

c. NIBCO INC.

2. Description:




d. Body Design: Three piece.


f. Ends: Threaded.


h. Stem: Bronze.

i. Ball: Chrome-plated brass.

j. Port: Full.

D. Three-Piece, Full-Port, Bronze Ball Valves with Stainless-Steel Trim:





c. NIBCO INC.

2. Description:




d. Body Design: Three piece.


f. Ends: Threaded.


h. Stem: Stainless steel.

i. Ball: Stainless steel, vented.

j. Port: Full.

2.3 BRONZE SWING CHECK VALVES

A. Class 125, Bronze Swing Check Valves with Bronze Disc:










d. NIBCO INC.

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

2. Description:

a. Standard: MSS SP-80, Type 3.

b. CWP Rating: 200 psig.

c. Body Design: Horizontal flow.

d. Body Material: ASTM B 62, bronze.

e. Ends: Threaded.

f. Disc: Bronze.

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





c. Kitz Corporation.

d. Milwaukee Valve Company.

e. NIBCO INC.

2. Description:

a. Standard: MSS SP-80, Type 3.


c. Body Design: Horizontal flow.

d. Body Material: ASTM B 62, bronze.

e. Ends: Threaded.

f. Disc: Bronze.

2.4 IRON, SINGLE-FLANGE BUTTERFLY VALVES

A. 150 CWP, Iron, Single-Flange Butterfly Valves with EPDM Seat and Aluminum-Bronze Disc:



a. Bray Controls; a division of Bray International.







d. NIBCO INC.

e. Tyco Valves & Controls; a unit of Tyco Flow Control.


2. Description:

a. Standard: MSS SP-67, Type I.


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. 150 CWP, Iron, Single-Flange Butterfly Valves with NBR Seat and Aluminum-Bronze Disc:



a. Bray Controls; a division of Bray International.



d. NIBCO INC.

e. Tyco Valves & Controls; a unit of Tyco Flow Control.


2. Description:



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: NBR.

f. Stem: One- or two-piece stainless steel.

g. Disc: Aluminum bronze.

2.5 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:


b. NPS 2-1/2 to NPS 12, CWP Rating: 200 psig.

c. NPS 14 to NPS 24, CWP Rating: 150 psig.

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.

B. Class 125, Iron Swing Check Valves with Lever and Weight-Closure Control:



a. Crane Co.; Crane Valve Group; Crane Valves.


c. NIBCO INC.

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

2. Description:




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 weight.

2.6 IRON, CENTER-GUIDED CHECK VALVES

A. Class 125, Iron, Compact-Wafer, Center-Guided Check Valves with Resilient Seat:



a. Flo Fab Inc.


c. NIBCO INC.

2. Description:








d. Body Material: ASTM A 126, gray iron.

e. Style: Compact wafer.

f. Seat: EPDM or NBR.

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 check valves for proper direction of flow and as follows:

1. Swing Check Valves: In horizontal position with hinge pin level.

2. Center-Guided Check Valves: In horizontal or vertical position, between flanges.

3. Lift Check Valves: With stem upright and plumb.

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 or heavy duty butterfly valves, class 250.

2. Butterfly Valves: Heavy duty butterfly valves, class 250.

3. Throttling Service: Ball valves.

4. Pump-Discharge Check Valves:

a. NPS 2 and Smaller: Bronze swing check valves with bronze disc.

b. NPS 2-1/2 and Larger: Iron swing check valves with lever and weight or with

spring or iron, center-guided, resilient-seat check valves.

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 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: Flanged ends except where threaded valve-end

option is indicated in valve schedules below.

3. For Copper Tubing, NPS 5 and Larger: Flanged ends.

4. For Steel Piping, NPS 2 and Smaller: Threaded ends.

5. For Steel Piping, NPS 2-1/2 to NPS 4: Flanged ends except where threaded valve-end

option is indicated in valve schedules below.

6. For Steel Piping, NPS 5 and Larger: Flanged ends.

END OF SECTION




HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT 230529 - 1

SECTION 230529

HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes hangers and supports for mechanical system piping and equipment.

1.2 DEFINITIONS

A. MSS: Manufacturers Standardization Society for the Valve and Fittings Industry.

B. Terminology: As defined in MSS SP-90, "Guidelines on Terminology for Pipe Hangers and

Supports."


A. Design channel support systems for piping to support multiple pipes capable of supporting

combined weight of supported systems, system contents, and test water.

B. Design heavy-duty steel trapezes for piping to support multiple pipes capable of supporting

combined weight of supported systems, system contents, and test water.

C. Design hangers and supports for piping and equipment.

1.4 SUBMITTALS

A. Product Data: For each type of pipe hanger, channel support system component, and thermal-

hanger shield insert indicated.

B. Shop Drawings: Signed and sealed by a qualified professional engineer for building

attachments, conduit and piping supports and trapeze hangers. Include design calculations and

indicate size and characteristics of components and fabrication details.

C. Welding Certificates: Copies of certificates for welding procedures and operators.


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

Code: Section IX, "Welding and Brazing Qualifications."





PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Acceptable Manufacturers: Subject to compliance with requirements, provide products by one

of the following:

1. Pipe Hangers:

a. AAA Technology and Specialties Co., Inc.

b. B-Line Systems, Inc.

c. Carpenter & Patterson, Inc.

d. Empire Tool & Manufacturing Co., Inc.

e. Globe Pipe Hanger Products, Inc.

f. Grinnell Corp.

g. GS Metals Corp.

h. Michigan Hanger Co., Inc.

i. National Pipe Hanger Corp.

j. PHD Manufacturing, Inc.

k. PHS Industries, Inc.

l. Piping Technology & Products, Inc.

2. Channel Support Systems:

a. B-Line Systems, Inc.

b. Grinnell Corp.; Power-Strut Unit.

c. GS Metals Corp.

d. Michigan Hanger Co., Inc.; O-Strut Div.

e. National Pipe Hanger Corp.

f. Thomas & Betts Corp.

g. Unistrut Corp.

h. Wesanco, Inc.

3. Saddles:

a. Buckaroos, Inc.

b. Approved equal.

4. Powder-Actuated Fastener Systems:

a. Gunnebo Fastening Corp.

b. Hilti, Inc.

c. ITW Ramset/Red Head.

d. Masterset Fastening Systems, Inc.

2.2 MANUFACTURED UNITS





A. Pipe Hangers, Supports, and Components: MSS SP-58, factory-fabricated components. Refer

to "Hanger and Support Applications" Article in Part 3 for where to use specific hanger and

support types.

1. Galvanized, Metallic Coatings: For piping and equipment that will not have field-applied

finish.

2. Nonmetallic Coatings: On attachments for electrolytic protection where attachments are

in direct contact with copper tubing.

B. Channel Support Systems: MFMA-2, factory-fabricated components for field assembly.

1. Coatings: Manufacturer's standard finish, unless bare metal surfaces are indicated.

2. Nonmetallic Coatings: On attachments for electrolytic protection where attachments are

in direct contact with copper tubing.

C. Thermal Insulation Support System (Saddles and Inserts): Fiberglass insert (blocking) sized to

match insulation thickness. Insert quantity shall be based on pipe size as indicated in the

manufacturer’s literature.

1. Material for Cold Piping: Fiberglass blocking which meets ASTM E-84 for 25 flame

spread index and 50 smoke development index.

2. UL listed for use in return air ceiling plenums.

3. For Trapeze or Clamped System: Insert and shield cover entire circumference of pipe in

accordance with manufacturer’s recommendations.

4. For Clevis, Band or Roller Hanger: Insert and shield cover lower 180 degrees of pipe.

5. Insert length shall be in accordance with manufacturer’s recommendations for each pipe

diameter size.

6. Saddle length and sheet steel gauge thickness shall be in accordance with the

manufacturer’s recommendations.

a. Provide flared and rounded saddle with hanger ridges.

7. For 8-inch and 10-inch pipe size (only) roller hangers may be replaced with sliding

saddled system using dual upper/lower saddles with Teflon (PTFE) inner layer. The

sliding saddle system can be used with clevis hangers (instead of pipe rollers).

8. Basis of Design: Buckaroos, Inc. or approved equal.

a. Single Pipe Saddle with Fiberglass Inserts: Model Flared Roundup Saddles.

b. Sliding Saddle System with Fiberglass Inserts: Model Tru-Balance 2550FS.

c. Contact: Buckaroos.com

2.3 MISCELLANEOUS MATERIALS

A. Powder-Actuated Drive-Pin Fasteners: Powder-actuated-type, drive-pin attachments with pull-

out and shear capacities appropriate for supported loads and building materials where used.

1. Do not use powder-activated drive pipe fasteners without prior written approval by

Structural Engineer. Any building damage due to the use of powder-activated drive pin

fasteners shall be entirely the responsibility of the contractor.

B. Mechanical-Anchor Fasteners: Insert-type attachments with pull-out and shear capacities

appropriate for supported loads and building materials where used.





1. Do not use mechanical-anchor fasteners without prior written approval by Structural

Engineer. Any building damage due to the use of powder-activated drive pin fasteners

shall be entirely the responsibility of the contractor.

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

D. Grout: ASTM C 1107, Grade B, factory-mixed and -packaged, nonshrink and nonmetallic, dry,

hydraulic-cement grout.

1. Characteristics: Post hardening and volume adjusting; recommended for both interior

and exterior applications.

2. Properties: Nonstaining, noncorrosive, and nongaseous.

3. Design Mix: 5000-psi (34.5-MPa), 28-day compressive strength.

PART 3 - EXECUTION

3.1 HANGER AND SUPPORT APPLICATIONS

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

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

piping system Specification Sections.

C. Horizontal-Piping Hangers and Supports: Unless otherwise indicated and except as specified in

piping system Specification 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 (DN15 to DN750).

2. Steel Pipe Clamps (MSS Type 4): For suspension of cold and hot pipes, NPS 1/2 to

NPS 24 (DN15 to DN600), if little or no insulation is required.

3. Adjustable Steel Band Hangers (MSS Type 7): For suspension of noninsulated stationary

pipes, NPS 1/2 to NPS 8 (DN15 to DN200).

4. Adjustable Swivel-Ring Band Hangers (MSS Type 10): For suspension of noninsulated

stationary pipes, NPS 1/2 to NPS 2 (DN15 to DN50).

5. U-Bolts (MSS Type 24): For support of heavy pipe, NPS 1/2 to NPS 30 (DN15 to

DN750).

6. Pipe Stanchion Saddles (MSS Type 37): For support of pipes, NPS 4 to NPS 36 (DN100

to DN900), with steel pipe base stanchion support and cast-iron floor flange and with U-

bolt to retain pipe.

7. Single Pipe Rolls (MSS Type 41): For suspension of pipes, NPS 1 to NPS 30 (DN25 to

DN750), from two rods if longitudinal movement caused by expansion and contraction

might occur.

8. Adjustable Roller Hangers (MSS Type 43): For suspension of pipes, NPS 2-1/2 to

NPS 20 (DN65 to DN500), from single rod if horizontal movement caused by expansion

and contraction might occur.

D. Vertical-Piping Clamps: Unless otherwise indicated and except as specified in piping system

Specification Sections, install the following types:





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

NPS 20 (DN20 to DN500).

2. Carbon- or Alloy-Steel Riser Clamps (MSS Type 42): For support of pipe risers,

NPS 3/4 to NPS 20 (DN20 to DN500), if longer ends are required for riser clamps.

E. Hanger-Rod Attachments: Unless otherwise indicated and except as specified in piping system


1. Steel Clevises (MSS Type 14): For 120 to 450 deg F (49 to 232 deg C) piping

installations.

2. Swivel Turnbuckles (MSS Type 15): For use with MSS Type 11, split pipe rings.

3. Malleable-Iron Sockets (MSS Type 16): For attaching hanger rods to various types of

building attachments.

4. Steel Weldless Eye Nuts (MSS Type 17): For 120 to 450 deg F (49 to 232 deg C) piping

installations.

F. Building Attachments: Unless otherwise indicated and except as specified in piping system


1. Top-Beam C-Clamps (MSS Type 19): For use under roof installations with bar-joist

construction to attach to top flange of structural shape.

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

channels, or angles.

3. Center-Beam Clamps (MSS Type 21): For attaching to center of bottom flange of beams.

4. Welded Beam Attachments (MSS Type 22): For attaching to bottom of beams if loads

are considerable and rod sizes are large.

5. C-Clamps (MSS Type 23): For structural shapes.

6. Top-Beam Clamps (MSS Type 25): For top of beams if hanger rod is required tangent to

flange edge.

7. Side-Beam Clamps (MSS Type 27): For bottom of steel I-beams.

8. Steel-Beam Clamps with Eye Nuts (MSS Type 28): For attaching to bottom of steel I-

beams for heavy loads.

9. Linked-Steel Clamps with Eye Nuts (MSS Type 29): For attaching to bottom of steel I-

beams for heavy loads, with link extensions.

10. Malleable Beam Clamps with Extension Pieces (MSS Type 30): For attaching to

structural steel.

11. 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 (340 kg).

b. Medium (MSS Type 32): 1500 lb (675 kg).

c. Heavy (MSS Type 33): 3000 lb (1350 kg).

12. Side-Beam Brackets (MSS Type 34): For sides of steel beams.

13. Plate Lugs (MSS Type 57): For attaching to steel beams if flexibility at beam is required.

G. Thermal Insulation Support System (Saddles and Inserts): Fiberglass insert (blocking) sized to

match insulation thickness. Insert quantity shall be based on pipe size as indicated in the

manufacturer’s literature.





1. Material for Cold Piping: Fiberglass blocking which meets ASTM E-84 for 25 flame

spread index and 50 smoke development index.

2. UL listed for use in return air ceiling plenums.

3. For Trapeze or Clamped System: Insert and shield cover entire circumference of pipe in

accordance with manufacturer’s recommendations.

4. For Clevis, Band or Roller Hanger: Insert and shield cover lower 180 degrees of pipe.

5. Insert length shall be in accordance with manufacturer’s recommendations for each pipe

diameter size.

6. Saddle length and sheet steel gauge thickness shall be in accordance with the


a. Provide flared and rounded saddle with hanger ridges.

7. For 8-inch and 10-inch pipe size (only) roller hangers may be replaced with sliding

saddled system using dual upper/lower saddles with Teflon (PTFE) inner layer. The

sliding saddle system can be used with clevis hangers (instead of pipe rollers).

8. Basis of Design: Buckaroos, Inc. or approved equal.

a. Single Pipe Saddle with Fiberglass Inserts: Model Flared Roundup Saddles.

b. Sliding Saddle System with Fiberglass Inserts: Model Tru-Balance 2550FS.

c. Contact: Buckaroos.com

3.2 HANGER AND SUPPORT INSTALLATION

A. Pipe Hanger and Support Installation: Comply with MSS SP-69 and MSS SP-89. Install

hangers, supports, clamps, and attachments as required to properly support piping from building

structure.

B. Channel Support System Installation: Arrange for grouping of parallel runs of piping and

support together on field-assembled channel systems.

1. Field assemble and install according to manufacturer's written instructions.

C. Heavy-Duty Steel Trapeze Installation: Arrange for grouping of parallel runs of horizontal

piping and support together on field-fabricated, heavy-duty trapezes.

1. Pipes of Various Sizes: Support together and space trapezes for smallest pipe size or

install intermediate supports for smaller diameter pipes as specified above for individual

pipe hangers.

2. Field fabricate from ASTM A 36/A 36M, steel shapes selected for loads being supported.

Weld steel according to AWS D-1.1.

D. Install building attachments within concrete slabs or attach to structural steel. Space

attachments within maximum piping span length indicated in MSS SP-69. Install additional

attachments at concentrated loads, including valves, flanges, guides, strainers, and expansion

joints, and at changes in direction of piping.

1. The contractor is responsible to provide complete coordinate shop drawings indicating

each building attachment location, type, load, etc. The contractor’s structural engineer

shall submit sealed shop drawings and calculations for each pipe support, duct support,

duct support, conduit support, HVAC unit support, etc.





2. Building damage due to the contractor’s work shall be entirely the responsibility of the

contractor.

E. Install powder-actuated drive-pin fasteners 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.

1. Do not use powder-activated drive pipe fasteners without prior written approval by

Structural Engineer. Any building damage due to the use of powder-activated drive pin

fasteners shall be entirely the responsibility of the contractor.

F. Install mechanical-anchor fasteners in concrete after concrete is placed and completely cured.

Install fasteners according to manufacturer's written instructions.

1. Do not use mechanical-anchor fasteners without prior written approval by Structural

Engineer. Any building damage due to the use of powder-activated drive pin fasteners

shall be entirely the responsibility of the Contractor.

G. Install hangers and supports complete with necessary inserts, bolts, rods, nuts, washers, and

other accessories.

H. 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.

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 so maximum

pipe deflections allowed by ASME B31.9, "Building Services Piping," is not exceeded.

K. Insulated Piping: Comply with the following:

1. Attach clamps and spacers to piping.

a. Piping Operating above Ambient Air Temperature: Clamp may project through

insulation.

b. Piping Operating below Ambient Air Temperature: Use thermal-hanger shield

insert with clamp sized to match OD of insert.

c. Do not exceed pipe stress limits according to ASME B31.9.

2. Install MSS SP-58, Type 39 protection saddles.

a. Basis of Design: Buckaroos, Inc. or approved equal. Refer to Paragraph 2.2.C

and 3.1.8 this section.

3. Install MSS SP-58, Type 40 protective shields on cold piping with vapor barrier.

a. Basis of Design: Buckaroos, Inc. or approved equal. Refer to Paragraph 2.2.C and

3.1.8 this section.





4. Saddle Dimensions for Insulated Pipe (outside diameter of insulation): Not less than the

following:

a. NPS 2 to NPS 5 ½ (O.D.): 12 inches (305 mm) long and 22-gauge galvanized

steel thick.

b. NPS 6 to NPS 11 (O.D.): 12 inches (305 mm) long and 20-gauge galvanized steel

thick.

c. NPS 11 ½ and NPS 14 (O.D.): 15 inches (381 mm) long and 20-gauge galvanized

steel thick.

d. NPS 15 and NPS 16 (O.D): 18-inches (457 mm) long and 18-gauge galvanized

steel thick.

5. Pipes NPS 2 (DN50) and Larger: Include fiberglass inserts. Quantity shall be

determined by pipe diameter based on manufacturer’s recommendations.

6. Insert Material: Length of insert shall be determined by pipe diameter based on


7. Thermal-Hanger Shields: Metal Thermal Hanger Shields not allowed.

3.3 EQUIPMENT SUPPORTS

A. Fabricate structural-steel stands to suspend equipment from structure above or to support

equipment above floor.

B. Grouting: Place grout under supports for equipment and make smooth bearing surface.

3.4 METAL FABRICATION

A. Cut, drill, and fit miscellaneous metal fabrications for heavy-duty steel trapezes 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 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 contours

of welded surfaces match adjacent contours.

3.5 ADJUSTING

A. Hanger Adjustment: Adjust hangers to distribute loads equally on attachments and to achieve

indicated slope of pipe.





3.6 PAINTING

A. Touching Up: 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

(0.05 mm).

B. Touching Up: Cleaning and touchup painting of field welds, bolted connections, and abraded

areas of shop paint on miscellaneous metal are specified in Section.

C. Galvanized Surfaces: Clean welds, bolted connections, and abraded areas and apply

galvanizing-repair paint to comply with ASTM A 780.

END OF SECTION




SOUND AND VIBRATION CONTROLS FOR HVAC 230548 - 1

SECTION 230548

SOUND AND VIBRATION CONTROLS FOR HVAC

PART 1 - GENERAL

1.1 SUMMARY


1. Isolation pads.

2. Isolation mounts.

3. Restrained elastomeric isolation mounts.

4. Freestanding and restrained spring isolators.

5. Housed spring mounts.

6. Elastomeric hangers.

7. Spring hangers.

8. Spring hangers with vertical-limit stops.

1.2 DEFINITIONS

A. IBC: International Building Code.

B. ICC-ES: ICC-Evaluation Service.

1.3 SUBMITTALS


1. Include rated load, rated deflection, and overload capacity for each vibration isolation

device.

B. Submittal: For vibration isolation and restraint details indicated to comply with performance

requirements and design criteria, including analysis data.

1. Vibration Isolation Base Details: Detail overall dimensions, including anchorages and

attachments to structure and to supported equipment. Include auxiliary motor slides and

rails, base weights, equipment static loads, power transmission, component misalignment,

and cantilever loads.

C. Coordination Drawings: Show coordination of seismic bracing for HVAC piping and

equipment with other systems and equipment in the vicinity, including other supports.

D. Welding certificates.





E. Qualification Data: For testing agency.

F. Field quality-control test reports.

G. Operation and Maintenance Data: For air-mounting systems to include in operation and

maintenance manuals.


A. Testing Agency Qualifications: An independent agency, with the experience and capability to

conduct the testing indicated, that is a nationally recognized testing laboratory (NRTL) as

defined by OSHA in 29 CFR 1910.7, and that is acceptable to authorities having jurisdiction.

B. Comply with seismic-restraint requirements in the IBC unless requirements in this Section are

more stringent.

C. Welding: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural

Welding Code - Steel."

PART 2 - PRODUCTS

2.1 VIBRATION ISOLATORS


of the following:

1. Amber/Booth Company, Inc.

2. Kinetics Noise Control.

3. Mason Industries.

4. Vibration Eliminator Co., Inc.

5. Vibration Mountings & Controls, Inc.

B. Elastometric Isolator Pads (ASHRAE Type 1): Arranged in single or multiple layers of

sufficient stiffness for uniform loading over pad area, molded with a nonslip pattern and

galvanized-steel baseplates, and factory cut to sizes that match requirements of supported

equipment.

1. Resilient Material: Oil- and water-resistant neoprene or rubber.

C. Elastometric Isolator Mounts (ASHRAE Type 2): Double-deflection type, with molded, oil-

resistant rubber, hermetically sealed compressed fiberglass, or neoprene isolator elements with

factory-drilled, encapsulated top plate for bolting to equipment and with baseplate for bolting to

structure. Color-code or otherwise identify to indicate capacity range.

1. Materials: Cast-ductile-iron or welded steel housing containing two separate and

opposing, oil-resistant rubber or neoprene elements that prevent central threaded element

and attachment hardware from contacting the housing during normal operation.





2. Neoprene: Shock-absorbing materials compounded according to the standard for bridge-

bearing neoprene as defined by AASHTO.

D. Restrained Elastometric Isolator Mounts (ASHRAE Type 2): All-directional mountings with

seismic restraint.

1. Materials: Cast-ductile-iron or welded steel housing containing two separate and

opposing, oil-resistant rubber or neoprene elements that prevent central threaded element

and attachment hardware from contacting the housing during normal operation.

2. Neoprene: Shock-absorbing materials compounded according to the standard for bridge-

bearing neoprene as defined by AASHTO.

E. Spring Isolators (ASHRAE Type 3): Freestanding, laterally stable, open-spring isolators.

1. Outside Spring Diameter: Not less than 80 percent of the compressed height of the

spring at rated load.

2. Minimum Additional Travel: 50 percent of the required deflection at rated load.

3. Lateral Stiffness: More than 80 percent of rated vertical stiffness.

4. Overload Capacity: Support 200 percent of rated load, fully compressed, without

deformation or failure.

5. Baseplates: Factory drilled for bolting to structure and bonded to 1/4-inch- thick, rubber

isolator pad attached to baseplate underside. Baseplates shall limit floor load to 500 psig.

6. Top Plate and Adjustment Bolt: Threaded top plate with adjustment bolt and cap screw

to fasten and level equipment.

F. Elastomeric Hangers (ASHRAE Type 3): Single or double-deflection type, fitted with molded,

oil-resistant elastomeric isolator elements bonded to steel housings with threaded connections

for hanger rods. Color-code or otherwise identify to indicate capacity range.

G. Spring Hangers (ASHRAE Type 3): Combination coil-spring and elastomeric-insert hanger

with spring and insert in compression.

1. Frame: Steel, fabricated for connection to threaded hanger rods and to allow for a

maximum of 30 degrees of angular hanger-rod misalignment without binding or reducing

isolation efficiency.

2. Outside Spring Diameter: Not less than 80 percent of the compressed height of the

spring at rated load.

3. Minimum Additional Travel: 50 percent of the required deflection at rated load.

4. Lateral Stiffness: More than 80 percent of rated vertical stiffness.

5. Overload Capacity: Support 200 percent of rated load, fully compressed, without

deformation or failure.

6. Elastomeric Element: Molded, oil-resistant rubber or neoprene. Steel-washer-reinforced

cup to support spring and bushing projecting through bottom of frame.

7. Self-centering hanger rod cap to ensure concentricity between hanger rod and support

spring coil.





2.2 FACTORY FINISHES

A. Finish: Manufacturer's standard paint applied to factory-assembled and -tested equipment

before shipping.

1. Powder coating on springs and housings.

2. All hardware shall be galvanized. Hot-dip galvanize metal components for exterior use.

3. Baked enamel or powder coat for metal components on isolators for interior use.

4. Color-code or otherwise mark vibration isolation and control devices to indicate capacity

range.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine areas and equipment to receive vibration isolation and control devices for compliance

with requirements for installation tolerances and other conditions affecting performance.

B. Examine roughing-in of reinforcement and cast-in-place anchors to verify actual locations

before installation.


3.2 APPLICATIONS

A. Multiple Pipe Supports: Secure pipes to trapeze member with clamps approved for application

by the Structural Engineer.

B. Strength of Support and Assemblies: Where not indicated, select sizes of components so

strength will be adequate to carry present and future static loads within specified loading limits.

3.3 VIBRATION-CONTROL DEVICE INSTALLATION

A. Install cables so they do not bend across edges of adjacent equipment or building structure.

B. Install bushing assemblies for anchor bolts for floor-mounted equipment, arranged to provide

resilient media between anchor bolt and mounting hole in concrete base.

C. Install bushing assemblies for mounting bolts for wall-mounted equipment, arranged to provide

resilient media where equipment or equipment-mounting channels are attached to wall.

D. Attachment to Structure: If specific attachment is not indicated, anchor bracing to structure at

flanges of beams, at upper truss chords of bar joists, or at concrete members.

E. Drilled-in Anchors (where approved in writing by the project Structural Engineer):





1. Identify position of reinforcing steel and other embedded items prior to drilling holes for

anchors. Do not damage existing reinforcing or embedded items during coring or

drilling. Notify the structural engineer if reinforcing steel or other embedded items are

encountered during drilling. Locate and avoid prestressed tendons, electrical and

telecommunications conduit, and gas lines.

2. Do not drill holes in concrete or masonry until concrete, mortar, or grout has achieved

full design strength.

3. Wedge Anchors: Protect threads from damage during anchor installation. Heavy-duty

sleeve anchors shall be installed with sleeve fully engaged in the structural element to

which anchor is to be fastened.

4. Adhesive Anchors: Clean holes to remove loose material and drilling dust prior to

installation of adhesive. Place adhesive in holes proceeding from the bottom of the hole

and progressing toward the surface in such a manner as to avoid introduction of air

pockets in the adhesive.

5. Set anchors to manufacturer's recommended torque, using a torque wrench.

6. Install zinc-coated steel anchors for interior and stainless-steel anchors for exterior

applications.


A. Testing Agency: Engage a qualified testing agency to perform tests and inspections.

B. Perform tests and inspections for any system or component which is making excessive noise.

C. Tests and Inspections:

1. Provide evidence of recent calibration of test equipment by a testing agency acceptable to


2. Schedule test with Owner, through Engineer, before connecting anchorage device to

restrained component (unless postconnection testing has been approved), and with at least

seven days' advance notice.

3. Obtain Engineer’s approval before transmitting test loads to structure. Provide temporary

load-spreading members.

4. Test at least four of each type and size of installed anchors and fasteners selected by

Engineer.

5. Test to 90 percent of rated proof load of device.

6. Measure isolator restraint clearance.

7. Measure isolator deflection.

8. Verify snubber minimum clearances.

9. If a device fails test, modify all installations of same type and retest until satisfactory

results are achieved.

D. Remove and replace malfunctioning units and retest as specified above.

E. Prepare test and inspection reports for any system or component which is making excessive

noise.





3.5 ADJUSTING

A. Adjust isolators after piping systems have been filled and equipment is at operating weight.

B. Adjust limit stops on restrained spring isolators to mount equipment at normal operating height.

After equipment installation is complete, adjust limit stops so they are out of contact during

normal operation.

C. Adjust active height of spring isolators.

D. Adjust restraints to permit free movement of equipment within normal mode of operation.

E. Adjust snubbers according to manufacturer’s written recommendations.

3.6 DEMONSTRATION

A. Engage a factory-authorized service representative to train Owner's maintenance personnel to

adjust, operate, and maintain air-mounting systems.

3.7 VIBRATION ISOLATOR SCHEDULE

A. Air-Cooled Chiller on Roof (CH-1):

1. Isolator Type: ASHRAE Type 4 restrained spring.

2. Isolator Material: Steel springs and rubber base in steal housing.

3. Deflection: 1-inch.

4. Internally Isolated Equipment: No.

5. Location: Supported on galvanized steel support system (dunnage) with bolted

connections.

END OF SECTION




IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT 230553 - 1

SECTION 230553

IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT

PART 1 – GENERAL

1.1 SUMMARY

A. This Section includes the following mechanical identification materials and their installation:

1. Equipment nameplates.

2. Equipment markers.

3. Equipment signs.

4. Access panel and door markers.

5. Pipe markers.

6. Duct markers.

7. Stencils.

8. Valve tags.

9. Valve schedules.

10. Warning tags.

B. Ceiling Identification: Provide a tag on the ceiling for each adjustable and/or serviceable device

concealed above the ceiling. Provide engraved tag with min. ¼-inch high lettering and dual

color scheme. Color coordinate identification with engraved plates permanently fastened with

stainless steel screws or rivets (no double stick tape) to the wall and/or ceiling for clear view.

1. Submit visual signage and tags to Owner for review.

C. Valve Numbering and As-Built Drawings: Provide as-built floor plans indicating locations of

all valves and associated valve numbers.

1. Provide numbered valve tag for each valve.

2. Show valve schedule on as-built drawings indicating valve number, type, size, duty and

equipment served.

1.2 SUBMITTALS


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

material and device.

C. Valve numbering scheme.





D. Valve Schedules: For each piping system. Furnish extra copies (in addition to mounted copies)

to include in maintenance manuals.


A. ASME Compliance: Comply with ASME A13.1, "Scheme for the Identification of Piping

Systems," for letter size, length of color field, colors, and viewing angles of identification

devices for piping.

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 location of access panels and doors.

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

PART 2 - PRODUCTS

2.1 EQUIPMENT IDENTIFICATION DEVICES

A. Equipment Nameplates: Metal, with data engraved or stamped, for permanent attachment on

equipment.

1. Data:

a. Manufacturer, product name, model number, and serial number.

b. Capacity, operating and power characteristics, and essential data.

c. Labels of tested compliances.

2. Location: Accessible and visible.

3. Fasteners: As required to mount on equipment.

B. Equipment Markers: Engraved, color-coded laminated plastic. Include contact-type, permanent

adhesive.

1. Terminology: Match schedules as closely as possible.

2. Data:

a. Name and plan number.

b. Equipment service.

c. Design capacity.

d. Other design parameters such as pressure drop, entering and leaving conditions,

and speed.





3. Size: 2-1/2 by 4 inches for control devices, dampers, and valves; 4-1/2 by 6 inches for

equipment.

4. Color Coding: Refer to paragraph 3.2.D.

C. Equipment Signs: ASTM D 709, Type I, cellulose, paper-base, phenolic-resin-laminate

engraving stock; Grade ES-2, black surface, black phenolic core, with white melamine subcore,

unless otherwise indicated. Fabricate in sizes required for message. Provide holes for

mechanical fastening.

1. Data: Instructions for operation of equipment and for safety procedures.

2. Engraving: Manufacturer's standard letter style, of sizes and with terms to match

equipment identification.

3. Thickness: 1/26 inch for units up to 20 sq. in. or 8 inches in length, and 1/8 inch for larger

units.

4. Fasteners: Self-tapping, stainless-steel screws or contact-type, permanent adhesive.

D. Access Panel and Door Markers: 1/26-inch- thick, engraved laminated plastic, with abbreviated

terms and numbers corresponding to identification. Provide 1/8-inch center hole for attachment.

1. Fasteners: Self-tapping, stainless-steel screws or contact-type, permanent adhesive.

2.2 PIPING IDENTIFICATION DEVICES

A. Manufactured Pipe Markers, General: Preprinted, color-coded, with lettering indicating service,

and showing direction of flow.

1. Colors: Comply with ASME A13.1, unless otherwise indicated.

2. Lettering: Use piping system terms indicated and abbreviate only as necessary for each

application length.

3. Pipes with OD, Including Insulation, Less Than 6 Inches: Full-band pipe markers

extending 360 degrees around pipe at each location.

4. Pipes with OD, Including Insulation, 6 Inches and Larger: Either full-band or strip-type

pipe markers at least three times letter height and of length required for label.

5. Arrows: Integral with piping system service lettering to accommodate both directions; or

as separate unit on each pipe marker to indicate direction of flow.

B. Plastic Tape: Continuously printed, vinyl tape at least 3 mils thick with pressure-sensitive,

permanent-type, self-adhesive back.

1. Width for Markers on Pipes with OD, Including Insulation, Less Than 6 Inches: 3/4 inch

minimum.

2. Width for Markers on Pipes with OD, Including Insulation, 6 Inches or Larger: 1-1/2

inches minimum.

C. Pipe Painting for Pipe with Board Insulation and Glass Cloth Jacket: Prepare surface for

painting and paint entire surface of glass cloth jacket pipework (all sides) with color indicated in

paragraph 3.3.B. Provide stencil marking after painting to indicate pipe type, pressure, and

water-flow direction.





D. “Venture Clad” Jacket Color for Exposed Insulated Pipework: Provide the colors indicated in

paragraph 3.3.B. Provide stencil marking to indicate pipe type and air-flow direction.

E. Pipe Painting for Uninsulated Pipe: Prepare surface for painting and paint entire surface of pipe

(all sides) with color indicated in paragraph 3.3.B. Provide stencil marking after painting to

indicate pipe type, pressure, and water-flow direction.

2.3 STENCILS

A. Stencils: Prepared with letter sizes according to ASME A13.1 for piping; minimum letter

height of 1-1/4 inches for ducts; and minimum letter height of 3/4 inch for access panel and

door markers, equipment markers, equipment signs, and similar operational instructions.

1. Stencil Material: Galvanized.

2. Stencil Paint: Exterior, gloss, alkyd enamel or acrylic enamel black, unless otherwise

indicated. Paint may be in pressurized spray-can form.

3. Identification Paint: Exterior, alkyd enamel or acrylic enamel in colors according to

ASME A13.1, unless otherwise indicated.

2.4 VALVE TAGS

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

inch numbers, with numbering scheme approved by Engineer. Provide 5/32-inch hole for

fastener.

1. Material: 0.032-inch thick brass in equipment areas.

2. Valve-Tag Fasteners: Brass wire-link; or S-hook.

2.5 VALVE SCHEDULES

A. Valve Schedules: For each piping system, on standard-size 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-Schedule Frames: Glazed display frame for removable mounting on masonry walls

for each page of valve schedule. Include mounting screws.

2. Frame: Extruded Galvanized.

3. Glazing: ASTM C 1036, Type I, Class 1, Glazing Quality B, 2.5-mm, single-thickness

glass.

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: Approximately 4 by 7 inches

2. Fasteners: Brass grommet and wire.

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 APPLICATIONS, GENERAL

A. Products specified are for applications referenced in other Division 23 Sections. If more than

single-type material, device, or label is specified for listed applications, selection is Installer's

option.

3.2 EQUIPMENT IDENTIFICATION

A. Install color coded “Venture Clad” jackets or painted glass cloth jackets for all equipment and

permanently fasten equipment nameplates on each major item of mechanical equipment.

Locate nameplates where accessible and visible. Include nameplates for the following general

categories of equipment:

1. Fuel-burning units, including boilers and all associated pumps, domestic hot water storage

tanks, etc.

2. Pumps, heat pumps, and similar motor-driven units.

3. Air-handlers, coils, fans, filters, heat exchanger, and similar equipment components.

4. Air-handling units, air distribution systems, primary balancing dampers, mixing boxes,

airflow monitoring systems and air terminal units (VAV boxes), etc.

5. Tanks and pressure vessels, including expansion tank.

6. Strainers, filters, water-treatment systems, and similar equipment.

7. EMS Control Panels, actuators, operators, valves, dampers, switches, temperature sensors,

etc.

8. Any electrical breakers, disconnects, AFD’s, etc. serving mechanical equipment.

B. Install equipment markers on ceiling grid and walls to identify the location of concealed

equipment with minimum two (2) permanent self-tapping screws on or near each major item of

mechanical equipment.

1. Letter Size: Minimum 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.

2. Data: Identify equipment tag with marker.

3. Locate markers where accessible and visible. Include markers for the following general

categories of equipment:

a. Main control and operating valves, including safety devices and hazardous units

such as gas outlets.





b. Meters, gages, thermometers, and similar units.

c. Pumps, chillers, and similar motor-driven units.

d. ERU, and fan, air distribution systems, access doors, manual balancing dampers

and pressure transducers.

e. EMS Control Panels, actuators, operators, valves, dampers, switches, etc.

f. Any electrical disconnects, motor controllers, etc. serving mechanical equipment.

C. Stenciled Equipment Marker: Stenciled markers shall be provided instead of laminated-plastic

equipment markers, if lettering larger than 1 inch high is needed for proper identification

because of distance from normal location of required identification.

D. Install equipment signs with minimum two (2) self-tapping screws on or near each major item

of mechanical equipment. Locate signs where accessible and visible.

1. Identify mechanical equipment with color coded PVC jackets or painted glass cloth

jackets with equipment markers in the following color codes:

a. Blue: For cooling equipment and components.

b. Red: For heating equipment and components.

c. Red/Blue: For combination cooling and heating equipment and components.

d. Green: For energy-reclamation equipment and components.

2. Letter Size: Minimum 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.

3. Data: Distinguish among multiple units, indicate operational requirements, indicate safety

and emergency precautions, warn of hazards and improper operations, and identify units.

4. Include signs for the following general categories of equipment:

a. Main control and operating valves, including safety devices and hazardous units

such as gas outlets.

b. Sprinkler service and stack flow preventers assembly and valves.

c. Meters, gages, thermometers, and similar units.

d. Fuel-burning units, including boilers and all associated pumps, domestic water

storage tanks, etc.

e. Pumps, chillers, drycoolers, and similar motor-driven units.

f. Energy recovery air-handlers, coils, fans, filters, heat exchanger, and similar

equipment components.

g. Rooftop air-handlers, coils, fans, filters, heat exchanger, and similar equipment

components.

h. Air distribution systems, primary balancing dampers, and mixing boxes, and air

terminal units (VAV boxes).

i. Packaged rooftop HVAC units, wall mounted HVAC units, and associated roof

mounted condensing units.

j. Tanks and pressure vessels, including CHW buffer tank and expansion tank

k. Strainers, filters, glycol fill systems, water-treatment systems, and similar

equipment.

l. EMS Control Panels, actuators, operators, valves, dampers, switches, etc.





m. Any electrical breakers, disconnects, AFD’s, MCC’s, etc. serving mechanical

equipment.

E. Stenciled Equipment Sign Option: Stenciled signs may be provided instead of laminated-plastic

equipment signs, at Installer's option, if lettering larger than 1 inch high is needed for proper

identification because of distance from normal location of required identification.

F. Install access panel markers with screws on equipment access panels.

3.3 PIPING IDENTIFICATION

A. Install “Venture Clad” jacket for all insulated exposed piping and concealed fittings and

equipment inside the building. Install aluminum jackets for all piping outside the building.

Install manufactured pipe markers indicating service on each piping system. Install with flow

indication arrows showing direction of flow.

B. Install piping in the following color codes; concealed piping shall be provided with piping

markers with permanent adhesive; exposed piping shall be prepared and completely painted

with stencils and identification. Provide minimum 2 coats of paint on all plumbing and HVAC

piping and/or pipe covering. Provide pipe colors and marker designation symbols in all

mechanical rooms and exposed areas per the following.

Pipe Color Chart:

Piping System Pipe Marker Designation Pipe Color

Domestic Water DCW White

Domestic Hot Water DHW White

Domestic Water Recirc. DWR White

Chilled Water Return CHWR Blue

Chilled Water Supply CHWS Blue

Note: All lettering shall be the color indicated unless pipe color is black in which case

the lettering shall be white. All colors shall be adjusted to match the VMC-2009

applicable codes.

1. ASME A13.1 Colors and Designs with yellow labels: For hazardous material exhaust.

2. Letter Size: Minimum 1 inch for name of units if viewing distance is less than 24 inches

(600 mm), 1-1/2 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.

3. Nomenclature: Include the following:

a. Direction of waterflow.





b. Piping service.

c. Piping origin.

d. Piping destination.

e. Design gallons per minute (water) or cubic feet per hour (gas).

C. Stenciled Piping Marker: Stenciled markers, showing service and direction of flow, shall be

provided instead of laminated-plastic piping markers, if lettering larger than 1-1/2 inch high is

needed for proper identification because of distance from normal location of required

identification.

D. Locate markers near points where piping enter into concealed spaces and at maximum intervals

of 50 feet in each space where piping are exposed or concealed by removable ceiling system.

E. Locate pipe markers where piping is exposed in finished spaces; machine rooms; accessible

maintenance spaces such as shafts, tunnels, and plenums; and exterior nonconcealed 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 nonaccessible 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 along each run. Reduce intervals to 25 feet in

areas of congested piping and equipment.

7. On piping above removable acoustical ceilings. Omit intermediately spaced markers.

3.4 VALVE-TAG INSTALLATION

A. Install tags on all valves and control devices in piping systems, except check valves; plumbing

fixture supply stops; shutoff valves; faucets; convenience and lawn-watering hose connections;

and similar roughing-in connections of end-use fixtures and units. List tagged valves in a valve

schedule.

1. Contractor shall number valves to match control valves schedule for all HVAC equipment

control valves.

2. Contractor shall number isolation valves in each HVAC system circuit as follows; where

“X” denotes a numbering sequence for the actual numbering of valves installed.

a. Equipment Isolation Valves: EI - Equip # - X

b. Plant Isolation Valves: PI-Room # - X

c. Bypass Valves: BP - Device - X

d. Drain Valves: D -Equip # - X

e. Manual Air Vent Valves: MV – Equip # - X

f. Calibrated Balancing Valves: BV – Equip # - X

g. Temperature Control Valves: TC-Equip# - X.





B. Valve-Tag Application Schedule: Tag valves according to size, shape, and color scheme and

with captions similar to those indicated in the following:

1. Valve-Tag Size and Shape:

a. Cold Water: 2 inches, round.

b. Hot Water: 2 inches, round.

c. Fire Protection: 2 inches, round.

d. Gas: 2 inches, round.

2. Valve-Tag Color:

a. Cold Water: Natural.

b. Hot Water: Natural.

c. Fire Protection: Red.

d. Gas: Yellow.

3. Letter Color:

a. Cold Water: Black.

b. Hot Water: Black.

c. Fire Protection: Black.

d. Gas: Black.

3.5 VALVE-SCHEDULE INSTALLATION

A. Mount valve schedule on wall in accessible location in each equipment room.

3.6 WARNING-TAG INSTALLATION

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

required.

3.7 ADJUSTING

A. Relocate mechanical identification materials and devices that have become visually blocked by

other work.

3.8 CLEANING

A. Clean faces of mechanical identification devices and glass frames of valve schedules.

END OF SECTION




TESTING, ADJUSTING, AND BALANCING 230593 - 1

SECTION 230593

TESTING, ADJUSTING, AND BALANCING

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes TAB to produce design objectives for the following:

1. Hydronic Piping Systems:

a. Constant-flow systems.

b. Variable Flow systems.

2. Verifying that automatic control devices are functioning properly.

3. Reporting results of activities and procedures specified in this Section.

B. The Contractor is responsible to thoroughly review the requirements of this section and all other

applicable sections of the Project Manual prior to submitting their bid price.

C. Pre-Tab: Provide pre-tab to ensure the existing flow rates are with the design. If not determine

actual flows are within final flow tolerance.

1. Provide a report to Engineer within 7 business days prior to starting demolition work.

2. Do not demolish systems before preliminary TAB is complete on the following pumps:

a. PHWP-X: Primary Chilled Water Pump (Lead/Lag).

b. SCHWP-1: Secondary Chilled Water Pump #1.

c. SCHWP-2: Secondary Chilled Water Pump #2.

D. Testing, Adjusting, and Balancing: Contractor shall adjust all materials, systems and equipment

and place them in normal satisfactory operating condition. Contractor shall replace any compo-

nent which cannot be adjusted for proper operation at no additional cost to the Owner; however,

the Contractor is not responsible for pre-existing material which cannot be adjusted or which

does not function as a result of a defect which was not caused by the Contractor. Contractor shall

perform air and water test, adjust, and balance, and shall provide a report to the Owner. Contrac-

tor shall provide air and water flow measuring devices as needed.

1.2 DEFINITIONS

A. Adjust: To regulate fluid flow rate and air patterns at the terminal equipment, such as to reduce

fan speed or adjust a damper.





B. Balance: To proportion flows within the distribution system, including submains, branches, and

terminals, according to indicated quantities.

C. NC: Noise criteria.

D. Procedure: An approach to and execution of a sequence of work operations to yield repeatable

results.

E. Report Forms: Test data sheets for recording test data in logical order.

F. Static Head: The pressure due to the weight of the fluid above the point of measurement. In a

closed system, static head is equal on both sides of the pump.

G. Suction Head: The height of fluid surface above the centerline of the pump on the suction side.

H. TAB: Testing, adjusting, and balancing.

I. Test: A procedure to determine quantitative performance of systems or equipment.

J. Testing, Adjusting, and Balancing (TAB) Firm: The entity responsible for performing and

reporting TAB procedures.

1.3 SUBMITTALS

A. Qualification Data: Within 30 days from Contractor's Notice to Proceed, submit 6 copies of

evidence that TAB firm and this Project's TAB team members meet the qualifications specified

in "Quality Assurance" Article.

B. Contract Documents Examination Report: Within 45 days from Contractor's Notice to Proceed,

submit 6 copies of the Contract Documents review report as specified in Part 3.

C. Strategies and Procedures Plan: Within 90 days from Contractor's Notice to Proceed, submit 6

copies of TAB strategies and step-by-step procedures as specified in Part 3 "Preparation"

Article. Include a complete set of report forms intended for use on this Project.

D. Certified TAB Reports: Submit two copies of reports prepared, as specified in this Section, on

approved forms certified by TAB firm.

E. Sample Report Forms: Submit two sets of sample TAB report forms.

F. Warranties specified in this Section.

G. Submit 2 copies of the special warranty specified in the “warranty” Article below.


A. TAB Firm Qualifications: Engage a TAB firm certified by either AABC or NEBB.

B. TAB Team Members:





1. Supervisors are to be certified via either AABC or NEBB.

2. Field Technicians are to be qualified by either AABC or NEBB. If Contractor cannot

meet this criterion, then the following information shall be submitted within the

Qualification Data.

a. Technician name

b. The Technicians shall have successfully completed testing, adjusting, and

balancing classes and shall present for review their certification of training.

c. The Technicians’ previous work experiences shall not be less than five years.

d. Technicians’ references (including contact names and phone numbers) from all

jobs during the past 12 months shall be presented.

3. Substitutions of personnel not listed in the Qualifications Data are subject to approval by

the Owner.

C. TAB Conference: Meet with Owner's and Engineer's representatives on approval of TAB

strategies and procedures plan to develop a mutual understanding of the details. Ensure the

participation of TAB team members, equipment manufacturers' authorized service

representatives; HVAC controls installers, and other support personnel. Provide seven days'

advance notice of scheduled meeting time and location.

1. Agenda Items: Include at least the following:

a. Submittal distribution requirements.

b. Daily Report distribution requirements, contacts, numbers and emails.

c. The Contract Documents examination report.

d. TAB plan.

e. Work schedule and Project-site access requirements.

f. Coordination and cooperation of trades and subcontractors.

g. Coordination of documentation and communication flow.

D. TAB contractor will be responsible to carry out the commissioning requirements specified in

Section 23 0813. Allow additional time to meet with the commissioning agent to discuss:

a. The proposed methods of TAB.

b. Demonstrations of methods of TAB.

c. Special project requirements.

d. Coordination with the commissioning agent.

E. Certification of TAB Reports: Certify TAB field data reports. This certification includes the

following:

1. Review field data reports to validate accuracy of data and to prepare certified TAB

reports.

2. Certify that TAB team complied with approved TAB plan and the procedures specified

and referenced in this Specification.

F. TAB Report Forms: Use standard forms from AABC's "National Standards for Testing and

Balancing Heating, Ventilating, and Air Conditioning Systems” or NEBB's "Procedural





Standards for Testing, Adjusting, and Balancing of Environmental Systems.” TAB firm's forms

must be approved by Engineer.

G. Instrumentation Type, Quantity, and Accuracy: As described in AABC's "National Standards

for Testing and Balancing Heating, Ventilating, and Air Conditioning Systems or NEBB's

"Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems,"

Section II, "Required Instrumentation for NEBB Certification."

H. Instrumentation Calibration: Calibrate instruments at least every six months or more frequently

if required by instrument manufacturer.

1. Keep an updated record of instrument calibration that indicates date of calibration and the

name of party performing instrument calibration.


A. Owner Occupancy: Owner may occupy completed areas of building before Substantial

Completion. Cooperate with Owner during TAB operations to minimize conflicts with Owner's

operations.

1.6 COORDINATION

A. Schedule of completion:

1. Commencement of submittals shall be as defined in section 1.4 A, B, & C above.

2. Commence Examinations (section 3.1) immediately.

3. Commence site work portions of the Examinations (section 3.01) as soon as possible and

absolutely no later than 30 days after major equipment start-up. Major equipment start-

up shall be defined as the powering and engagement of primary air moving equipment,

primary water moving equipment, or central plant equipment including chillers, boilers,

and towers for the purpose of maintaining the building environment (either temporarily or

permanently).

4. Daily Deficiency Reports as defined in section 3.14 will commence at beginning of any

site work and continue to completion of the TAB work.

5. Completion of all remaining TAB work under Part 3 “Execution” is to closely follow the

completion schedule of the project and its systems in whole or in part. Portions of

systems that are ready for TAB procedures must be pursued so as not to delay completion

of other parts of the system.

B. Coordinate the efforts of factory-authorized service representatives for systems and equipment,

HVAC controls installers, and other mechanics to operate HVAC systems and equipment to

support and assist TAB activities.

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

times.

D. Perform TAB after leakage and pressure tests on air and water distribution systems have been

satisfactorily completed.





E. Flow values (GPM) shown on the contract documents are subject to change. The APPROVED

mechanical equipment submittals are to be reviewed and any changes to measured values such

as flows, drops, capacities, and quantities are to be included in the balancing plan. Verify with

the Engineer.

1.7 WARRANTY

A. National Project Performance Guarantee: Provide a guarantee on AABC's "National Standards

for Testing and Balancing Heating, Ventilating, and Air Conditioning Systems" forms stating

that AABC will assist in completing requirements of the Contract Documents if TAB firm fails

to comply with the Contract Documents. Guarantee includes the following provisions:

B. Special Guarantee: Provide a guarantee on NEBB forms stating that NEBB will assist in

completing requirements of the Contract Documents if TAB firm fails to comply with the

Contract Documents. Guarantee shall include the following provisions:

1. The certified TAB firm has tested and balanced systems according to the Contract

Documents.

2. Systems are balanced to optimum performance capabilities within design and installation

limits.

PART 2 - PRODUCTS (Not Applicable)

PART 3 - EXECUTION

3.1 TAB SPECIALISTS

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

1. Annandale Air Balancing, Co.

2. Comfort Control, Inc.

3. Other approved TAB contractor.

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.

1. Contract Documents are defined in the General and Supplementary Conditions of

Contract.

2. Verify that balancing devices, such as test ports, gage cocks, thermometer wells, flow-

control devices, balancing valves and fittings, and manual volume dampers, are required

by the Contract Documents. Verify that quantities and locations of these balancing

devices are accessible and appropriate for effective balancing and for efficient system and

equipment operation.





B. Examine approved submittal data of HVAC systems and equipment. Flow values (CFM/GPM)

shown on the contract documents are subject to change. The APPROVED mechanical

equipment submittals are to be reviewed and any changes to measured values such as flows,

drops, capacities, and quantities are to be included in the balancing plan. Verify with the

Engineer.

C. 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. Report any discrepancies,

suggestions, or opinions, in the Contract Documents Examination Report submittal.

D. Examine equipment performance data including fan and pump curves. 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. Calculate system

effect factors to reduce performance ratings of HVAC equipment when installed under

conditions different from those presented when the equipment was performance tested at the

factory. To calculate system effects for air systems, use tables and charts found in AMCA 201,

"Fans and Systems," Sections 7 through 10; or in SMACNA's "HVAC Systems--Duct Design,"

Sections 5 and 6. Compare this data with the design data and installed conditions. Report any

discrepancies, suggestions, or opinions in the Contract Documents Examination Report

submittal.

E. Examine system and equipment installations to verify that they are complete and that testing,

cleaning, adjusting, and commissioning specified in individual Sections have been performed.

F. Examine system and equipment test and start-up reports.

G. Examine HVAC system and equipment installations to verify that indicated balancing devices,

such as test ports, gage cocks, thermometer wells, flow-control devices, balancing valves and

fittings, and manual volume dampers, are properly installed, and that their locations are

accessible and appropriate for effective balancing and for efficient system and equipment

operation. Indicate deficiencies in the Daily Deficiency Reports.

H. Examine systems for functional deficiencies that cannot be corrected by adjusting and balancing

or will impair or delay an accurate TAB process. Indicate deficiencies in the Daily Deficiency

Reports. These deficiencies may include:

1. Incorrect location or orientation of control valves (ie: valve installed on supply side of

coil or installed backwards).

2. Three-way valves incorrectly installed for their intended function of diverting or mixing

fluid flows.

3. Incorrect control valve (ie: wrong CV).

4. Circulation pumps installed backwards.

5. Missing or inaccessible water pressure ports

6. Missing or inaccessible circuit setters/balancing valves

I. Examine HVAC equipment to ensure that clean filters have been installed, bearings are greased,

belts are aligned and tight, and equipment with functioning controls is ready for operation.

J. Examine strainers for clean screens and proper perforations.





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

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

M. Examine equipment for installation and for properly operating safety interlocks and controls.

N. Examine automatic temperature system components to verify the following:

1. Valves, and other controlled devices are operated by the intended controller.

2. Valves are in the position indicated by the controller.

3. Integrity of valves for free and full stroke operation.

4. Automatic modulating and shutoff valves, including two-way valves and three-way

mixing and diverting valves, are properly connected and oriented in the pipe with

adequate room for service.

5. Sensors are located to sense only the intended conditions.

6. Sequence of operation for control modes is according to the Contract Documents.

7. Controller set points are set at indicated values.

8. Interlocked systems are operating.

O. 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 system readiness reports. Verify the following:

1. The Qualification Data, Examination Report, and Strategies and Procedures Plan have

been submitted and approved.

2. Permanent electrical power wiring is complete.

3. Hydronic systems are filled, clean, and free of air.

4. Isolating and balancing valves are open and control valves are operational.

5. Access to water balancing valves is provided.

6. Isolating and balancing valves are open and control valves are operational.

3.4 GENERAL PROCEDURES FOR TESTING AND BALANCING

A. Perform testing and balancing procedures on each system according to the procedures contained

in NEBB’s “Procedural Standards for Testing, Adjusting, and Balancing of Environmental

Systems”.

B. Cut insulation, ducts, pipes, and equipment cabinets for installation of test probes to the

minimum extent necessary to allow adequate performance of procedures. After testing and

balancing, close probe holes and patch insulation with new materials identical to those removed.

Items that are beyond the TAB contractor’s ability to repair appropriately must be submitted in





writing to the general contractor for coordination with appropriate parties. Restore vapor barrier

and finish according to insulation Specifications for this Project.

C. Mark equipment and balancing device settings with paint or other suitable, permanent

identification material, including damper-control positions, valve position indicators, fan speed

control levers, and similar controls and devices, to show final settings.

D. All valves and dampers are to be placed in normal operating conditions whenever possible. At

no time should the TAB contractor close or manually regulate valves and dampers to offer

temporary resolution of balance, mechanical, or temperature control problems, unless it is

necessary to prevent damage to property. Such deficiencies must be recorded in the Daily

Deficiency Report, and the General Contractor is to be informed immediately.

E. Take and report testing and balancing measurements in IP units. Utilize engineering units

described within the reporting requirements of this section.

F. Perform a subjective review of vibration and make recommendations for measurements where

vibrations appear inappropriate, excessive, or are producing undesirable side effects.

G. Perform a subjective review of sound levels and make recommendations for measurements

where sound levels appear inappropriate, excessive, or are producing undesirable side effects.

H. The procedures outlined below are to be taken in whole for the project. Some procedures while

not completely applicable to a particular system may contain parts that are applicable as

subsystems.

3.5 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 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 expansion tank. Verify if precharge air pressure was adjusted before filling with

water. Factory precharge is a holding charge only and must be pressurized to equal the

final system fill pressure setpoint before introducing water. Refer to product installation

literature.

a. If tanks are of the captive air type, with suspended liquid bladder noted by a

flanged top connection, the tank should typically sound hollow upon striking. If

the tank appears flooded by this preliminary test, the tank must be drained at the

system connection and the air side precharge pressure verified per manufacturers





recommendation. Absence of suitable pressure or repeated failure to pass this test

indicates a faulty bladder. The bladder may need to be replaced.

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 all shipping restraints are removed and vibration isolation equipment will allow

free movement.

9. Check air vents for a forceful liquid flow exiting from vents when manually operated.

10. Check safety pressure and temperature valves for location, settings, and ratings per

contract documents. Note any indications of safeties that have operated automatically.

11. is a holding charge only and must be pressurized to equal the final system

12. Check expansion tank liquid level.

13. Check makeup-water-station pressure gage for adequate pressure for highest vent.

14. Check flow-control valves for specified sequence of operation and set at indicated flow.

15. 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.

16. Set system controls so automatic valves are wide open to heat exchangers.

17. Check pump-motor load. If motor is overloaded, throttle main flow-balancing device so

motor nameplate rating is not exceeded.

18. Check air vents for a forceful liquid flow exiting from vents when manually operated.

3.6 PROCEDURES FOR HYDRONIC SYSTEMS

A. Preliminary flow measurement 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.

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.

3. If pressure drop exceeds the design and the pump pressure readings indicate a flow in

excess of design, the pump impeller may have to be trimmed. Submit this data to the

Engineer for early review, before proceeding with balancing to determine if an impeller

trim is warranted. If impeller trim is warranted, submit all written data including existing

performance and desired performance to facilitate an appropriate trimming. Pump

disassembly, impeller trim, and reassembly to be performed at the sole expense of the

mechanical contractor. TAB retesting as necessary is at the sole expense of the TAB

contractor.

4. 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.

5. Report flow rates that are not within plus or minus 5% percent of design.

B. Set precalibrated balancing valves, if installed, at calculated settings.

C. 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.

D. Measure flow at main balancing station and set main balancing device to achieve flow that is 5

percent greater than indicated flow.

E. 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.

F. Final Pump Measurements

1. With all remote stations balanced, measure pump flow rate and make final measurements

of pump amperage, voltage, rpm, pump heads, and systems’ pressures and temperatures

including outdoor-air temperature.

G. Measure the differential pressure control valve settings at the conclusion of balancing.

H. Place system in a normal state of operating control. If systems are not returned to a 100%

operational condition at end of testing, record the reason on the Daily Deficiency Report and

report the condition to the General Contractor immediately.

3.7 PROCEDURES FOR MOTORS

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

1. Manufacturer, model, and serial numbers.

2. Motor horsepower rating.

3. Motor Insulation Class (B,F,H)

4. Motor rpm.

5. Efficiency rating.

6. Nameplate and measured voltage, each phase.

7. Nameplate and measured amperage, each phase.

8. 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 for the controller to prove proper





operation. Record observations, including controller manufacturer, model and serial numbers,

and nameplate data.

3.8 PROCEDURES FOR CHILLERS (CHW)

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.

B. Engage the ATC system and Mechanical contractor to manipulate the system as necessary to

place a stable full load on the boilers. Verify the boiler attains full available input rate.

Calculate BTU via ΔT and flow and record this running output against the nameplate rate

output. Note any deficiencies.

C. Place system in the normal state of operating control. If systems are not returned to a 100%

operational condition at end of testing, record the reason on the Daily Deficiency Report and

report the condition to the General Contractor immediately.

3.9 TEMPERATURE-CONTROL VERIFICATION

A. Verify that controllers are calibrated and commissioned.

B. Check transmitter and controller locations and note conditions that would adversely affect

control functions.

C. Record controller settings and note variances between set points and actual measurements.

D. Check the operation of limiting controllers (i.e., high- and low-temperature controllers).

E. Check the sequence of operation of control devices. Note air pressures and device positions and

correlate with airflow and water flow measurements. Note the speed of response to input

changes.

F. Check the interaction of electrically operated switch transducers.

G. Check the interaction of interlock and lockout systems.





H. Check main control supply-air pressure and observe compressor and dryer operations.

I. Record voltages of power supply and controller output. Determine whether the system operates

on a grounded or nongrounded power supply.

J. Note operation of electric actuators using spring return for proper fail-safe operations.

3.10 TOLERANCES

A. Set HVAC system airflow and water flow rates within the following tolerances:

1. Chilled-Water Flow Rate: minus 5 percent to plus 5 percent.

3.11 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: As Work progresses, prepare 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.

3.12 FINAL REPORT

A. General: Typewritten, or computer printout in letter-quality font, on standard bond paper, in

three-ring binder, tabulated and divided into sections by tested and balanced systems.

B. Include a certification sheet in front of binder signed and sealed by the certified testing and

balancing engineer.

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

2. Include a certification sheet at the front of the report’s binder, signed and sealed by the

certified testing and balancing engineer.

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

1. Pump curves.

2. Manufacturers' test data.

3. Field test reports prepared by system and equipment installers.

4. Other information relative to equipment performance, but do not include Shop Drawings

and Product Data.





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

final report, as applicable:

1. Title page.

2. Name and address of TAB firm.

3. Project name.

4. Project location.

5. Owner’s name and address.

6. Engineer's name and address.

7. Contractor's name and address.

8. Report date.

9. Signature of TAB firm 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, type size, and fittings.

14. Notes to explain why certain final data in the body of reports varies from indicated

values.

15. Test conditions for fans and pump performance forms including the following:

E. System Diagrams: Include schematic layouts of hydronic distribution systems. Present each

system with single-line diagram and include the following:

1. Water flow rates.

2. Pipe and valve sizes and locations.

3. Balancing stations.

4. Position of balancing devices.

F. Packaged Chiller Reports:

1. Unit Data:

a. Unit identification.

b. Make and model number.

c. Manufacturer's serial number.

d. Refrigerant type and capacity in gal..

e. Starter type and size.

f. Starter thermal protection size.

g. Compressor make and model number.

h. Compressor manufacturer's serial number.

2. Air-Cooled Condenser Test Data (Indicated and Actual Values):





a. Refrigerant pressure in psig.

b. Refrigerant temperature in deg F.

c. Entering-Air temperature in deg F.

d. Leaving-Air temperature in deg F.

3. Evaporator Test Reports (Indicated and Actual Values):

a. Refrigerant pressure in psig.

b. Refrigerant temperature in deg F.

c. Entering-water temperature in deg F.

d. Leaving-water temperature in deg F.

e. Entering-water pressure in feet of head or psig.

f. Water pressure differential in feet of head or psig.

4. Compressor Test Data (Indicated and Actual Values):

a. Suction pressure in psig.

b. Suction temperature in deg F.

c. Discharge pressure in psig.

d. Discharge temperature in deg F.

e. Oil pressure in psig.

f. Oil temperature in deg F.

g. Voltage at each connection.

h. Amperage for each phase.

i. Kilowatt input.

j. Crankcase heater kilowatt.

k. Chilled-water control set point in deg F.

l. Condensing-Temperature control set point in deg F.

m. Refrigerant low-pressure-cutoff set point in psig.

n. Refrigerant high-pressure-cutoff set point in psig.

5. Refrigerant Test Data (Indicated and Actual Values):

a. Oil level.

b. Refrigerant level.

c. Relief valve setting in psig.

d. Unloader set points in psig.

e. Percentage of cylinders unloaded.

f. Bearing temperatures in deg F.

g. Vane position.

h. Low-temperature-cutoff set point in deg F.

G. 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 and serial numbers.

f. Water flow rate in gpm (L/s).

g. Water pressure differential in feet of head or psig (kPa).

h. Required net positive suction head in feet of head or psig (kPa).

i. Pump rpm.

j. Impeller diameter in inches (mm).

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.

2. Test Data (Indicated and Actual Values):

a. Static head in feet of head or psig (kPa).

b. Pump shutoff pressure in feet of head or psig (kPa).

c. Actual impeller size in inches (mm).

d. Full-open flow rate in gpm (L/s).

e. Full-open pressure in feet of head or psig (kPa).

f. Final discharge pressure in feet of head or psig (kPa).

g. Final suction pressure in feet of head or psig (kPa).

h. Final total pressure in feet of head or psig (kPa).

i. Final water flow rate in gpm (L/s).

j. Voltage at each connection.

k. Amperage for each phase.

H. Instrument Calibration Reports:

1. Report Data:

a. Instrument type and make.

b. Serial number.

c. Application.

d. Dates of use.

e. Dates of calibration.

3.13 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. Randomly check the following for each system:

a. Measure water flow to building system.





b. Verify that balancing devices are marked with final balance position.

c. Note deviations to the Contract Documents in the Final Report.

B. Final Inspection:

1. After initial inspection is complete and evidence 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 Owner and Engineer.

2. TAB firm test and balance engineer shall conduct the inspection in the presence of Owner

and Engineer.

3. Owner and Engineer shall randomly select measurements documented in the final report

to be rechecked. The 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 the 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.

6. TAB firm shall recheck all measurements and make adjustments. Revise the final report

and balancing device settings to include all changes and resubmit the final report.

7. Request a second final inspection. If the second final inspection also fails, Owner shall

contract the services of another TAB firm to complete the testing and balancing in

accordance with the Contract Documents and deduct the cost of the services from the

final payment.

3.14 ADDITIONAL TESTS

A. Warranty Period: TAB services may be required during the Warranty Period to facilitate

resolution of deficiencies or malfunctions that occur during the Warranty Period. Perform TAB

services during the Warranty Period at no additional cost to Owner as deemed necessary by the

Engineer. If the TAB report is found to have errors during the Warranty Period, the TAB firms

hall repeat the requirements of the Initial Inspection as needed to the satisfaction of the Owner

and generate a new Final Report.

END OF SECTION




PIPING INSULATION 230705 - 1

SECTION 230705

PIPING INSULATION

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes preformed, rigid pipe insulation; insulating cements; field-applied jackets;

accessories and attachments; and sealing compounds.

B. The contractor shall insulate all piping affected by the scope of work whether installed (new),

existing-to-remain, or existing-to-be-relocated.

1. Existing piping: Remove existing insulation and insulate all mechanical chilled water

piping insulation in the mechanical room in accordance with this section.

2. Contractor shall remove remaining CHW insulation on existing piping and replace with

new in accordance with this section.

3. Contractor shall insulate existing CHW piping which is damaged or warn out. Include in

bid primary chilled water piping insulation up to and including the de-coupler. Also

include three feet either side of a temperature, flow or pressure sensor.

4. Contractor shall provide new pump impeller insulation boxes on each of the four (4)

CHW pumps.

a) Refer to detail on drawings.

1.2 SUBMITTALS

A. Product Data: Identify thermal conductivity, thickness, and jackets (both factory and field

applied, if any), for each type of product indicated.

B. Shop Drawings: Show fabrication and installation details for the following:

1. Application of protective shields, saddles, and inserts at pipe hangers for each type of

insulation and hanger.

2. Attachment and covering of heat trace inside insulation.

3. Insulation application at pipe expansion joints for each type of insulation.

4. Insulation application at elbows, fittings, flanges, valves, and specialties for each type of

insulation.

5. Removable insulation at piping specialties and equipment connections.

6. Application of field-applied jackets.

C. Samples: For each type of insulation and jacket. Identify each Sample, describing product and

intended use. Submit Samples in the following sizes:

1. Preformed Pipe Insulation Materials: 12 inches (300 mm) long by NPS 2 (DN50).

2. Sheet Form Insulation Materials: 12 inches (300 mm) square.

3. Jacket Materials: 12 inches (300 mm) long by NPS 2 (DN50).





4. Manufacturer's Color Charts: Show the full range of colors available for each type of

field-applied finish material indicated.

D. 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.

E. Installer Certificates: Signed by the Contractor certifying that installers comply with

requirements.


A. Installer Qualifications: Skilled mechanics who have successfully completed an apprenticeship

program or another craft training program certified by the U.S. Department of Labor, Bureau of

Apprenticeship and Training.

B. Fire-Test-Response Characteristics: As determined by testing materials identical to those

specified in this Section according to ASTM E 84, NFPA-255 and ANSI/UL-723 by a testing

and inspecting agency acceptable to authorities having jurisdiction. Factory label insulation and

jacket materials and sealer and cement material containers with appropriate markings of

applicable testing and inspecting agency.

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

rating of 50 or less.

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

rating of 150 or less.


A. Packaging: Ship insulation materials in containers marked by manufacturer with appropriate

ASTM specification designation, type and grade, and maximum use temperature.

1.5 COORDINATION

A. Coordinate size and location of supports, hangers, and insulation shields as specified.

B. Coordinate clearance requirements with piping Installer for insulation application.

C. Coordinate installation and testing of electric heat tracing.

1.6 SCHEDULING

A. Schedule insulation application after testing piping systems and, where required, after installing

and testing heat-trace cable. Insulation application may begin on segments of piping that have

satisfactory test results.





PART 2 - PRODUCTS

2.1 MANUFACTURERS


of the following:

1. Mineral-Fiber:

a. CertainTeed Manson.

b. Knauf FiberGlass GmbH.

c. Owens-Corning Fiberglas Corp.

d. Schuller International, Inc. (Manville).

2. Jacketing:

a. Brocar Products

b. Ceel.

c. Childers Products.

d. Schulter International, Inc. (Manville)

e. RPR Metals.

f. Pabco.

g. Truebro.

3. Prefabricated Fitting Covers:

a. Ceel.

b. CertainTeed Manson.

c. Childers Products.

d. Knauf Fiber Glass.

e. Schuller International Inc. (Manville).

f. Proto Corporation.

g. RPR Metals.

h. Pabco.

4. Adhesives, Mastics, Caulkings and Finishes:

a. Fuller, HB.

b. Armstrong Insulation Products.

c. Chicago (CMC).

d. Childers Products.

e. Dow Corning.

f. Shuller International, Inc. (Manville).

2.2 INSULATION MATERIALS

A. Mineral-Fiber Insulation: Glass fibers bonded with a thermosetting resin complying with the

following:





1. Preformed Pipe Insulation: Comply with ASTM C 547, Type 1, with factory-applied, all-

purpose, vapor-retarder jacket.

2. Fire-Resistant Adhesive: Comply with MIL-A-3316C in the following classes and

grades:

a. Class 1, Grade A for bonding glass cloth and tape to unfaced glass-fiber insulation,

for sealing edges of glass-fiber insulation, and for bonding lagging cloth to unfaced

glass-fiber insulation.

b. Class 2, Grade A for bonding glass-fiber insulation to metal surfaces.

3. Vapor-Retarder Mastics: Fire- and water-resistant, vapor-retarder mastic for indoor

applications. Comply with MIL-C-19565C, Type II.

4. Mineral-Fiber Insulating Cements: Comply with ASTM C 195.

5. Expanded or Exfoliated Vermiculite Insulating Cements: Comply with ASTM C 196.

6. Mineral-Fiber, Hydraulic-Setting Insulating and Finishing Cement: Comply with

ASTM C 449/C 449M.

B. Prefabricated Thermal Insulating Fitting Covers: Comply with ASTM C 450 for dimensions

used in preforming insulation to cover valves, elbows, tees, and flanges.

C. Flexible Elastomeric Thermal Insulation: Closed-cell, sponge-or expanded-rubber materials.

Comply with ASTM C5B4, Type 1 for tubular materials and Type 2 for sheet materials.

1. Ultraviolet-Protective Coating: As recommended by insulation manufacturer.

2.3 FIELD-APPLIED JACKETS

A. General: ASTM C 921, Type 1, unless otherwise indicated.

B. PVC Jacket: High-impact, ultraviolet-resistant PVC; 20 mils (0.5 mm) thick; roll stock ready

for shop or field cutting and forming (Indoor exposed piping).

1. Adhesive: As recommended by insulation material manufacturer.

2. PVC Jacket Color: Color-code piping jackets based on materials contained within the

piping system.

3. Pipe Color Chart:

Piping System Pipe Marker Designation Pipe Color

Chilled Water Return CHWR Lt. Blue

Chilled Water Supply CHWS Lt. Blue

Air Conditioning Condensate Drain COND White

Domestic Cold Water DWC Green

Domestic Hot Water DHW Red

Domestic Hot Water Circulating DWHR Red

Fire Protection Sprinkler Sprinkler Red

Natural Gas Gas Yellow

Refrigerant Piping REF Black

Note: All lettering shall be black unless pipe color is black in which case the lettering





shall be white.

C. Standard PVC Fitting Covers: Factory-fabricated fitting covers manufactured from 20-mil-

(0.5-mm-) thick, high-impact, ultraviolet-resistant PVC (Indoor concealed and exposed Piping).

1. Shapes: 45- and 90-degree, short- and long-radius elbows, tees, valves, flanges, reducers,

end caps, soil-pipe hubs, traps, mechanical joints, and P-trap and supply covers for

lavatories for the disabled.

2. Adhesive: As recommended by insulation material manufacturer.

3. Aluminum Jacket: Aluminum roll stock, ready for shop or field cutting and forming to

indicated sizes. Comply with ASTM B 209 (ASTM B 209M), 3003 alloy, H-14 temper.

(Outdoor Piping, valves and fittings.).

4. Finish and Thickness: Painted finish, 0.016 inch (0.40 mm) thick.

a. Drain Piping (Outdoor): Blue

b. Domestic Water (Outdoor): Green

c. Storm Water (Outdoor): White

5. Moisture Barrier: 1-mil- (0.025-mm-) thick, heat-bonded polyethylene and kraft paper.

6. Elbows: Preformed, 45- and 90-degree, short- and long-radius elbows; same material,

finish, and thickness as jacket.

2.4 ACCESSORIES AND ATTACHMENTS

A. Glass Cloth and Tape: Comply with MIL-C-20079H, Type I for cloth and Type II for tape.

Woven glass-fiber fabrics, plain weave, pre-sized a minimum of 8 oz./sq. yd. (270 g/sq. m).

1. Tape Width: 4 inches (100 mm).

B. Bands: 3/4 inch (19 mm) wide, in one of the following materials compatible with jacket:

1. Stainless Steel: ASTM A 666, Type 304; 0.020 inch (0.5 mm) thick.

2. Galvanized Steel: 0.005 inch (0.13 mm) thick.

3. Aluminum: 0.007 inch (0.18 mm) thick.

C. Wire: 0.080-inch (2.0-mm), nickel-copper alloy; 0.062-inch (1.6-mm), soft-annealed, stainless

steel; or 0.062-inch (1.6-mm), soft-annealed, galvanized steel.

2.5 VAPOR RETARDERS

A. Mastics: Materials recommended by insulation material manufacturer that are compatible with

insulation materials, jackets, and substrates.

PART 3 - EXECUTION





3.1 EXAMINATION

A. Examine substrates and conditions for compliance with requirements for installation and other

conditions affecting performance of insulation application.


3.2 PREPARATION

A. Surface Preparation: Clean and dry pipe and fitting surfaces. Remove materials that will

adversely affect insulation application.

3.3 GENERAL APPLICATION REQUIREMENTS

A. Apply insulation materials, accessories, and finishes according to the manufacturer's written

instructions; with smooth, straight, and even surfaces; free of voids throughout the length of

piping, including fittings, valves, and specialties.

B. Refer to schedules at the end of this Section for materials, forms, jackets, and thicknesses

required for each piping system.

C. Use accessories compatible with insulation materials and suitable for the service. Use

accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or

dry state.

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

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

F. Seal joints and seams with vapor-retarder mastic on insulation indicated to receive a vapor

retarder.

G. Keep insulation materials dry during application and finishing.

H. Apply insulation with tight longitudinal seams and end joints. Bond seams and joints with

adhesive recommended by the insulation material manufacturer.

I. Apply insulation with the least number of joints practical.

J. Apply insulation over fittings, valves, and specialties, with continuous thermal and vapor-

retarder integrity. Refer to special instructions for applying insulation over fittings, valves, and

specialties.

K. Hangers and Anchors: Where vapor retarder is indicated, seal penetrations in insulation at

hangers, supports, anchors, and other projections with vapor-retarder mastic.

1. Apply insulation continuously through hangers and around anchor attachments.

2. For insulation application where vapor retarders are indicated, extend insulation on

anchor legs at least 12 inches (300 mm) from point of attachment to pipe and taper





insulation ends. Seal tapered ends with a compound recommended by the insulation

material manufacturer to maintain vapor retarder.

3. Install insert materials and apply insulation to tightly join the insert. Seal insulation to

insulation inserts with adhesive or sealing compound recommended by the insulation

material manufacturer.

4. Cover inserts with jacket material matching adjacent pipe insulation. Install shields over

jacket, arranged to protect the jacket from tear or puncture by the hanger, support, and

shield.

L. Insulation Terminations: For insulation application where vapor retarders are indicated, taper

insulation ends. Seal tapered ends with a compound recommended by the insulation material

manufacturer to maintain vapor retarder.

M. Apply adhesives and mastics at the manufacturer's recommended coverage rate.

1. Vapor-Retarder Mastics: Where vapor retarders are indicated, apply mastic on seams and

joints and at ends adjacent to flanges, unions, valves, and fittings.

2. At penetrations in jackets for thermometers, sensors and pressure gages, etc., fill and seal

voids with vapor-retarder mastic.

N. Roof Penetrations: Apply insulation for interior applications to a point even with top of roof

flashing.

1. Seal penetrations with vapor-retarder mastic.

2. Apply insulation for exterior applications tightly joined to interior insulation ends.

3. Extend metal jacket of exterior insulation outside roof flashing at least 2 inches (50 mm)

below top of roof flashing.

4. Seal metal jacket to roof flashing with vapor-retarder mastic. Coordinate details with

roofer maintaining roof warranty.

a. See Architectural.

O. Interior Wall and Partition Penetrations: Apply insulation continuously through walls and

floors.

P. Fire-Rated Wall and Partition Penetrations: Apply insulation continuously through penetrations

of fire-rated walls and partitions.

1. Firestopping and fire-resistive joint sealers are specified in Division 7.

3.4 MINERAL-FIBER INSULATION APPLICATION

A. Apply insulation to straight pipes and tubes as follows:

1. Secure each layer of preformed pipe insulation to pipe with wire, tape, or bands without

deforming insulation materials.

2. Where vapor retarders are indicated, seal longitudinal seams and end joints with vapor-

retarder mastic. Apply vapor retarder to ends of insulation at intervals of 15 to 20 feet

(4.5 to 6 m) to form a vapor retarder between pipe insulation segments.





3. For insulation with factory-applied jackets, secure laps with outward clinched staples at 6

inches (150 mm) o.c.

4. For insulation with factory-applied jackets with vapor retarders, do not staple longitudinal

tabs but secure tabs with additional adhesive as recommended by the insulation material

manufacturer and seal with vapor-retarder mastic.

B. Apply insulation to flanges as follows:

1. Apply preformed pipe insulation to outer diameter of pipe flange.

2. Make width of insulation segment the same as overall width of the flange and bolts, plus

twice the thickness of the 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. Apply canvas jacket material with manufacturer's recommended adhesive, overlapping

seams at least 1 inch (25 mm), and seal joints with vapor-retarder mastic.

C. Apply insulation to fittings and elbows as follows:

1. Apply pre-molded insulation sections of the same material as straight segments of pipe

insulation when available. Secure according to manufacturer's written instructions.

2. When pre-molded insulation elbows and fittings are not available, apply mitered sections

of pipe insulation, or glass-fiber blanket insulation, to a thickness equal to adjoining pipe

insulation. Secure insulation materials with wire, tape, or bands. Apply one coat of

mineral fiber cement, finish with glass Fab embedded in two (2) coats of Foster 30 – 36

adhesive (or approved equal).

3. Cover fittings with standard PVC or aluminum fitting covers as required.

D. Apply insulation to valves and specialties as follows:

1. Apply pre-molded insulation sections of the same material as straight segments of pipe

insulation when available. Secure according to manufacturer's written instructions.

2. When pre-molded insulation sections are not available, apply glass-fiber blanket

insulation to valve body. Arrange insulation to permit access to packing and to allow

valve operation without disturbing insulation. For check valves, arrange insulation for

access to strainer basket without disturbing insulation.

3. Apply insulation to flanges as specified for flange insulation application.

4. Use preformed standard PVC fitting covers for valve sizes where available. Secure

fitting covers with manufacturer's attachments and accessories. Seal seams with tape and

vapor-retarder mastic.

5. For larger sizes where PVC fitting covers are not available, seal insulation with canvas

jacket and sealing compound recommended by the insulation material manufacturer.

3.5 FLEXIBLE ELASTOMERIC THERMAL INSULATION APPLICATION (Pump boxes only)

A. Apply insulation to pump insulation boxes:

1. Follow manufacturer’s written instruction for applying insulation.

2. Seal longitudinal seams and end joints with manufacturer’s recommended adhesive.

Cement to avoid openings in insulation that will allow passage of air to the pipe surface.





B. Apply insulation to fittings and elbows as follows:

1. Apply mitered sections of box insulation.

2. Secure insulation materials and seal seams with manufacturers recommend adhesive.

Cement to avoid openings in insulation that will allow passage of air to the pipe surface.

C. Apply insulation to valves and specialties as follows:

1. Apply preformed valve covers manufactured of the same material as pipe insulation and

attached according to the manufacturer’s written instructions.

2. Apply cut segments of pipe and sheet insulation to valve body. Arrange insulation to

permit access to packing and to allow valve operation without disturbing insulation. For

check valves, fabricate removable sections of insulation arranged to allow access to

strainer basket.

3. Secure insulation to valves and specialties and seal seams with manufacturer’s

recommended adhesive. Cement to avoid openings in insulation that will allow passage

of air to the pipe surface.

3.6 FIELD-APPLIED JACKET APPLICATION

A. Apply glass-cloth jacket, directly over bare insulation or insulation with factory-applied jackets.

Use where piping shall be painted in exposed areas.

1. Apply jacket smooth and tight to surface with 2-inch (50-mm) overlap at seams and

joints.

2. Embed glass cloth between two 0.062-inch- (1.6-mm-) thick coats of jacket

manufacturer's recommended adhesive.

3. Completely encapsulate insulation with jacket, leaving no exposed raw insulation.

B. Apply PVC jacket with 1-inch (25-mm) overlap at longitudinal seams and end joints. Seal with

manufacturers recommended adhesive. Use for exposed piping for straight sections and for

concealed or exposed fittings, valves, etc.

C. Apply metal jacket where indicated, with 2-inch (50-mm) overlap at longitudinal seams and end

joints. Overlap longitudinal seams arranged to shed water. Seal end joints with weatherproof

sealant recommended by insulation manufacturer. Secure jacket with stainless-steel bands 12

inches (300 mm) o.c. and at end joints. Use for outdoor piping.

3.7 FINISHES

A. PVC Jacketed Insulation: Factory finish color as indicated previously in paragraph 2.3.

B. Aluminum Jacketed Insulation: Factory finish color as indicated previously in paragraph 2.3.

3.8 PIPING SYSTEM APPLICATIONS

A. Insulation materials and thicknesses are specified in schedules at the end of this Section.






A. Inspection: Engage a qualified inspection agency to perform the following field quality-control

inspections, after installing insulation materials, jackets, and finishes, to determine compliance

with requirements:

B. Inspection: Perform the following field quality-control inspections, after installing insulation

materials, jackets, and finishes, to determine compliance with requirements:

1. Inspect fittings and valves randomly selected by Engineer.

2. Remove fitting covers from 5 elbows for various pipe sizes.

3. Remove fitting covers from 5 valves for various pipe sizes.

C. Insulation applications will be considered defective if sample inspection reveals noncompliance

with requirements. Remove defective Work and replace with new materials according to these

Specifications.

D. Reinstall insulation and covers on fittings and valves uncovered for inspection according to

these Specifications.

3.10 INSULATION APPLICATION SCHEDULE, GENERAL

A. Refer to insulation application schedules for required insulation materials, vapor retarders, and

field-applied jackets.

B. Application schedules identify piping system and indicate pipe size ranges and material,

thickness, and jacket requirements.

3.11 INTERIOR INSULATION APPLICATION SCHEDULE

A. Service: Existing and new chilled water piping supply and return.

1. Operating Temperature: 38 to 200 deg F (5 to 93 deg C).

2. Insulation Material: Mineral fiber with factory applied all-purpose jacket for exposed

and concealed pipe, and standard weight PVC fitting covers for fittings.

3. Insulation Thickness: Apply the following insulation thicknesses:

a. Steel 2 ½” and larger: 2-inch.

4. Field-Applied Jacket (indoors): ASJ for all indoor piping (with PVC Fitting Covers).

5. Vapor Retarder Required: Yes.

6. Finish: Field Painted Color, as indicated in paragraph 2.3.

B. Service CHW Pumps (Primary and Secondary)

1. Optional Temperature: 38 to 100 deg F (5 to 38 deg C)

2. Insulation Material: 20 gauge galv. steel box with piano hinges and latches. Internal

insulation shall be flexible elastomeric material. Refer to detail on plans.

3. Insulation Thickness: Apply the following insulated thickness:

a) Pump boxes 2-inch thick.

4. Vapor Barrier Required: Yes





5. Finish: Galvanized steel.

3.12 OUTDOOR INSULATION APPLICATION SCHEDULE

A. Service CHW Piping

1. Operating Temperature: 38 to 100 deg F (5 to 38 deg C).

2. Insulation Material: Mineral Fiber.

3. Insulation Thickness: 3-inches.

4. Field-Applied Jacket (outdoors): Aluminum

a . Jacket thickness: 0.04-inches thick, smooth.

5. Vapor Retarder Required: Yes.

6. Heat Trace Required: Yes, min 2-circuits.

END OF SECTION 230705




ENERGY MANAGEMENT SYSTEM (EMS) 230900 - 1

SECTION 230900

ENERGY MANAGEMENT SYSTEM (EMS)

PART 1 - GENERAL



1.2 SCOPE

A. The intent of this Specification Section is to provide the Owner an automatic temperature

control system consisting of, but not limited to electric and electronic controls to control the

chilled water plant. The temperature control system is to meet all of the performance

requirements as shown on drawings and as outlined in this and related Sections of the

Specifications.

B. The existing controls system consists of Invensys-Siebe with a Tridium JACE network

controller. A new digital electronic EMS system is being provided under a separate contract by

the Owner. HVAC equipment shall be provided with DDC and/or electric controls as specified

and shall be connected to the automation system as specified herein after.

C. All control EMS and ATC work shall be installed by the Owners ATC Contractor for this

school for a complete fully operational control system. All labor, materials, equipment,

software, and services necessary for the installation of the equipment provided under this

contract.

1. The mechanical contractor shall provide pipe welds and pressure taps in locations selected

by the EMS Contractor.

2. The ATC Contractor shall provide temperature sensors and pump differential pressure

sensors including installation in the pipe welds and pump flanges.

D. Equipment and labor not specifically referred to herein or on the plans that are required to meet

the functional intent shall be provided without additional cost to the Owner.

1.3 TEST AND GUARANTEE

A. The entire control system for the building shall be guaranteed free from all mechanical,

electrical, and software defects for a period of one (1) year. During this period, the Contractor

shall be responsible for the proper adjustments of all systems, equipment, and apparatus

installed by him and do all work necessary to insure efficient and proper functioning of the

systems hardware and software.





1.4 PERMITS AND INSPECTIONS

A. The Owner’s ATC contractor shall be responsible for obtaining and paying for electrical

permits for any power wiring performed in the execution of the controls work. Certificate of

final inspection shall be delivered to the Owner upon completion of the work.

PART 2 – PRODUCTS

2.1 MANUFACTURERS

A. Acceptable Manufacturers:

1. Basis of Design: Owners ATC Contractor, “TBD”.

2.2 OPERATOR INTERFACE (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

2.3 CONTROLLER SOFTWARE (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

2.4 CONTROLLERS (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

2.5 POWER SUPPLIES AND LINE FILTERING (PROVIDED BY THE OWNER’S ATC

CONTRACTOR)

2.6 CONTROL DEVICES (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

2.7 WIRING AND RACEWAYS (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

2.8 FIBER OPTIC CABLE SYSTEM (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

2.9 GRAPHICS (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

PART 3 -EXECUTION

3.1 HARDWARE INSTALLATION (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

3.2 SOFTWARE: (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

3.3 SEQUENCES OF OPERATION/CONTROL STRATEGIES:

1. Refer to detailed sequence of operation in section 230993.





3.4 COORDINATION WITH TAB:

A. The Owner’s ATC Contractor shall allocate 8 man-hours to the testing and balancing

procedures; providing a competent technician to assist the TAB Contractor. This time shall be

in addition to that required for start-up and testing of the controls, and for the time required to

respond to any punch list generated by the TAB Contractor or to the Commissioning process.

3.5 DOCUMENTATION, DEMONSTRATIONS, AND ACCEPTANCE (PROVIDED BY THE

OWNER’S ATC CONTRACTOR)

A. ATC Contractor shall demonstrate EMS to Owner. Contractor shall submit a written

demonstration plan to Owner and Engineer, and shall demonstrate system upon Owner’s and

Engineer’s approval of the plan. Contractor shall verify correct action of each output point,

accuracy of temperature sensors to within 1 degree F, and accurate sensing of binary conditions.

Contractor shall demonstrate entire sequence of operation including alarms, data logging, and

interactive graphics. Contractor shall submit printed trend logs to Owner and Engineer

verifying correct EMS operations, and shall demonstrate EMS in the field upon Owner’s and

Engineer’s approval of trend logs.

PART 4 - ENERGY MANAGEMENT AUTOMATION SYSTEM POINTS LIST

4.1 GENERAL:

A. The Input/Output Summary Table included on the drawings represents the minimum

requirements control points listing, alarm, and software functions to be included in the project.

B. Contractor shall prepare and submit a Contractor prepared original points list tailored to the

system he proposes to install to meet the functional requirements of this entire specification.

C. Section 230993, SEQUENCES OF OPERATION and the Points List on the drawings are

complementary. All control strategies specified in Section 230993 shall be satisfied even if

some of the required control points or alarm or software have been inadvertently left off of the

Points List. Similarly, control points and alarm and software strategies indicated on the Points

List shall be provided even if a written sequence has been inadvertently omitted from Section

230993.

END OF SECTION




SEQUENCE OF OPERATIONS FOR HVAC CONTROLS 230993 - 1

SECTION 230993

SEQUENCE OF OPERATIONS FOR HVAC CONTROLS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes control sequences for HVAC systems, subsystems, and equipment.

1.2 DEFINITIONS

AFD-X: Adjustable Frequency Drive Tag

AI: Analog Input to the EMS

AO: Analog Output from the EMS

ASC: Application Specific Controllers

ATC: Automatic Temperature Controls

BI: Digital or Binary Input to the EMS

BO: Digital or Binary Output from the EMS

CCP: Chiller Control Panel

CF: Cubic Feet

CO2: Carbon Dioxide Sensor

CV: Constant Volume

DAT: Discharge Air Temperature

DDC: Direct-digital Controls.

D-X: Damper Tag

EF-X: Exhaust Fan Tag

EMS: Energy Management System

Furnish: Supply Materials and/or Equipment

HOA: Hands-Off-Auto Switch





I/O: Input/Output

Install: Install Materials and/or Equipment furnished by others.

LAN: Local Area Network.

M: Motor

MAT: Mixed Air Temperature

MC: Motor Controller

MOD: Motor Operated Damper

MS/TP: Master-slave/token-passing.

OAT: Outside Air Temperature

PB: Pushbutton Override

PI: Proportional Integral

PID: Proportional Integral Derivative.

Provide: Furnish and Install Materials and/or Equipment and start-up, adjust and completely

make ready for use.

RAT: Return Air Temperature

SAT: Supply Air Temperature

TE: Temperature Element

TCV: Temperature Control Valve

TOD: Time of day.

TT-X: Temperature Transmitter (Tag)

V: Valve

WAN: Wide Area Network

1.3 CHILLER PLANT

A. The intent is to allow chiller operation year round. The individual chiller compressor circuits

may be periodically shut down for maintenance but CHW production shall be available at all

times to satisfy de-humidification and internal heat load requirements.





B. The actual control of the individual chiller’s starts and stops, chiller capacity modulation,

chilled water supply temperature control, compressor loading, etc. is all controlled by the

individual chiller control panel (CCP).

1. The EMS shall provide chiller enable/disable commands to the CCP.

2. The EMS shall provide a signal to the CCP to change the Leaving Water Temperature set

point in the CCP. This shall be an automatically adjustable outdoor set point. Automatic

reset of the CHWS set point is required. Set point is to be set for 44 deg. F @ 95°F OAT;

48 deg. F @ 60°F OAT, adjustable.

3. The CCP shall generate a signal “Request for Pumping” to the EMS. The EMS shall

incorporate this signal into the control programming to ensure pumps remain operational

for the required amount of time after the chillers are shut down to prevent damage to the

evaporator (refrigeration) circuits.

a. The EMS shall have control of the pumps for pre-start and lead/lag sequences etc.

C. Primary CHW Pump Control

1. The two (2) Primary CHW pumps (PCHWP-1 and PCHWP-2) shall be coordinated with

the chiller operation by the EMS. The CCP shall signal the EMS for a primary chilled

water pump to start. The EMS shall then start the lead chilled water pump. Upon

detecting water flow through the chiller by the CCP, the chiller shall be enabled.

a. If one primary pump fails the lag pump shall immediately start. A trouble signal

shall be initiated at the EMS.

2. The lead/lag status of the two primary (2) chilled water pumps shall be automatically

rotated to equalize their respective run times by the EMS. The program shall allow

weekly alternating and lead status manually selected via the EMS graphical front end

accessible at the operator workstation and via modem connection from a remote (offsite)

location. This rotation of the active status is to equalize pump runtimes and ensure the

pumps are operational at all times.

3. Primary CHW Pump Start/Stop

a. The EMS shall monitor pump HOA switch status, any previous pump failure

alarms and select the active pump for the associated chiller.

b. Any pump with an active alarm or an indication that the HOA switch is not

configured for pump operation shall be removed from active status.

c. The EMS shall coordinate the active pump(s) and the associated chillers in

preparation for a pump start signal.

1. Chiller Start: When the EMS determines a request for cooling, the chiller CCP shall be

enabled. The CCP initiates the chilled water pump start sequence to the EMS. The EMS

selects the lead pump. The lead chilled water pump shall start and run continuously.

Water flow shall be detected through CHW tubes prior to the CCP signaling the chiller to

start. Once positive flow is established through the chiller the CCP shall initiate a chiller

start signal.





d. At chiller shut down the EMS shall monitor the chiller CCP “Request for

Pumping” and continue to run the pumps after the chiller has stopped for the

appropriate amount of time, (2 min., adj.).

4. Secondary CHW Pump Start/Stop Control (Typ. each zone)

1. The secondary chilled water zone pump shall run when the zone is in the occupied

mode and the chiller is enabled by the EMS.

2. The secondary chilled water pumps shall stop when the zone is in unoccupied

mode or when the chiller is disabled by the EMS.

5. Primary CHW Pump Failure Sequence

a. Upon detection of a CHW Pump failure via a pump current switch or a loss of

water flow as detected by the chiller the EMS shall initiate a “CHW Pump Failure”

sequence. This sequence shall immediately start the lag pump to attempt to keep

the chiller on line. If the chiller trips on low pressure and the lag pump is running

it shall attempt to start (automatic reset). A message shall be recorded to indicate

the problem detected and the automatic pump rotation to continue operation. It is

expected the chiller will shut down during the flow interruption. The lag pump,

now rotated to the active status, is to be used for pumping during the chiller restart.

b. Should a lag pump fail to start or fail to produce water flow through the chiller

three (3) times in one hour (adjustable) the EMS shall stop the malfunctioning lag

pump and initiate a “CHW Pump Failure Alarm”. Nuisance loss of commercial

power shall not cause the pumps to be locked-out.

c. Should both Chiller Primary Pumps fail to operate a “Cooling System Failure”

alarm shall be recorded. The chiller shall be locked out to prevent additional

attempts to start.

D. Chiller Compressor Sequencing

1. The CCP shall monitor the status of the chiller compressors and maintain an accumulated

run time log. The CCP shall provide a rotational lead/lag configuration of the chiller

compressors and attempt to operate the chiller compressors in a manner that equalizes

their respective run times. Chiller compressor lead/lag status shall be automatically

rotated as controlled by the CCP, the EMS shall be able to reset the lead/lag rotation each

time the chiller starts, weekly or manually selected via the EMS graphical front end

accessible at the operator workstation and via modem connection from a remote (offsite)

location.

E. Pre-Start Sequence and Interlocks

1. The CCP shall not signal a start command until water flow is provided through the

evaporator.

2. Prior to signaling for a chiller start the CCP shall:

a. Modulate the head pressure control dampers (air cooled condenser) to maintain

condenser head pressure.





3. During this pre-start circulation the CCP shall monitor the condenser temperature.

a. Low Ambient chiller startup is automatically controlled by the chiller control panel

(CCP).

4. Once the condenser head pressure has exceeded minimum pressure (temperatures) and is

stabilized. The condenser head pressure control dampers shall modulate to maintain

differential refrigerant pressure in the chiller.

F. Chiller Control

1. The Chiller Plant shall be controlled to maintain leaving water temperature set point and

shall be enabled by the EMS based on Occupied/Un-occupied function, interior space

temperatures, interior humidity conditions, outside air temperature sensor set point and

Optimum Start/Stop.

a. The EMS system shall send a request for cooling signal to the CCP.

b. The request for cooling signal shall be generated when any AHU served by the

chiller is running and OAT > 70 degF (adjustable).

G. Chiller Staging Sequence

1. The dual compressor chiller is controlled by the CCP.

a. The EMS shall monitor all chilled water loop temperatures.

b. The EMS shall have minimum run times, minimum off times and minimum delay

times between enabling/disabling the chiller. All time delays shall be adjustable and

coordinated with the chiller manufacturer.

c. The CCP shall enable the CCP to start the chiller and enable compressors in sequence

to maintain the load. The CCP shall allow it to load to 100%, as monitored by the

mapped data point.

d. The CCP shall stage the chiller compressors based on system demands. The exact

staging criteria shall be coordinated with the chiller manufacturer.

H. Shut Down Sequence

a. The EMS shall disable the chiller plant. Upon a signal from the CCP to the EMS, the

EMS shall shut down the CHW pumps.

I. Chiller Failure Sequence

1. Upon detection of the “Chiller Failure” (CH-1) the EMS shall shut down the chilled

water pump.

2. Upon detection of a chiller failure a “Chiller Plant Failure” sequence shall be initiated.

This sequence shall consist of a 2-3 min. delay during which the EMS continues to

monitor the chiller status. After this delay if the EMS still detects a chiller failure the

EMS shall shut down and lockout (automatic reset) all CHW pumps. A message

“Cooling System Failure” shall be recorded to indicate the problem was detected and the

system was automatically shut down.





J. Cooling System Failure

1. The EMS system shall record the “Cooling System Failure” and transmit this signal over

the EMS controller network.

2. Chilled Water is used for AHU’s water coils for space cooling and dehumidification.

Anytime a “Cooling System Failure” is recorded the control programs for all HVAC

equipment shall respond appropriately, see sequences for each type of equipment.

K. System Monitoring and Alarming

1. The chiller CCP shall monitor proof of water flow in the primary CHW loop. Should, at

any time a chiller safety or loss of water flow be registered the CCP shall provide the

appropriate response. The EMS shall monitor the alarm contacts in each CCP.

2. The EMS shall monitor operations and input or output data, including but not limited to:

Chiller CHW supply and return water temperatures, pump motor status, heat trace status,

and CCP interface points (hardware and software).

3. The system will accept alarm limits for all of the above data and will provide an operator

notification as they exceed user defined alarm limits.

4. The EMS system shall monitor the CHW production system. If a failure is detected

where CHW is not being sent out to the building a “Cooling System Failure” alarm is to

be transmitted over the EMS network.

5. All alarm messages shall be transmitted to the local operator’s workstation in the building

engineer’s office. The EMS will pass all alarms onto the FCPS offsite pager with alpha-

numeric message. FCPS personnel shall be able to access the EMS on the FCPS WAN

or via modem connection from a remote (offsite) location.

6. The EMS (operator workstation and laptop) shall be programmed to provide a dynamic,

animated graphic representation of each of the Chilled Water Production System and

Chillers in response to a mouse “click” from a graphic menu or any zone/unit graphic

screen at anytime. The graphic representation will contain the above listed operating data

in a real time, dynamic, animated format. All sensor data, control points, etc. shall show

current conditions and automatically update as conditions change.

a. The Graphic of the chiller system shall contain software switches to allow an

operator, with the appropriate password, to signal a start or stop command to the

CCP.

7. From terminal mode communication with the EMS Controllers via direct or any of the

remote data ports a text “Chillers and Chilled Water System Report” shall be menu

selected. This report shall contain the above listed operating data. Format and Content

of this report shall be as required by the Engineer.

1.4 ALARMS (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

A. Alarms shall be as noted within the specifications, the input/output summary sheets and as

established with the Engineer.

B. Chiller alarms shall be communicated to the EMS via the chiller BACnet interfaces.

1.5 REPORTS (PROVIDED BY THE OWNER’S ATC CONTRACTOR)





1.6 GRAPHICS (PROVIDED BY THE OWNER’S ATC CONTRACTOR)

PART 2 - PRODUCTS (Not Applicable)

PART 3 - EXECUTION (Not Applicable)

END OF SECTION




HYDRONIC PIPING 232113 - 1

SECTION 232113

HYDRONIC PIPING

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes piping, special-duty valves, and hydronic specialties for chilled water,

makeup water for the closed loop system; and blow-down and overflow/drain lines.

B. Existing CW pump and primary and secondary CHW pumps shall be replaced.

1. Provide impeller insulation boxes for all new pumps provided under this contract.

C. Existing cooling tower and associated CW and fill piping shall be removed.

D. Existing water-cooled chiller and associated CW piping and CHW piping shall be removed

back to point of disconnection on load side of secondary pumps.

E. System Flushing and Cleaning: The system shall be flushed and cleaned as often as necessary to

prevent dirt and debris from entering the chiller and other equipment. The contractor shall drain

and fill back with water as often as necessary to complete the work and keep the system clean.

1. The system does not contain glycol solution.

1.2 SYSTEM DEMONSTRATION

A. The project includes, but is not limited to, installation of an air-cooled chiller and chilled water

piping system. The new system shall have a primary/secondary piping arrangement. There are

two (2) primary pumps and two (2) secondary pumps. Each secondary pump serves a separate

zone.

B. Make-up Water Assembly: The domestic water backflow preventor for the service make-up

water piping assembly (1) serving make-up water to the CHW closed-loop shall be field

assembled and wall mounted in the chiller plant room.

C. The mechanical equipment room shall be provided with plant isolation valves at all CHW

piping entrances to the room. The valves shall be provided with min. 3/4-inch drain ball valves

with hose connection cap and chain on both sides of the plant isolation valves. Each

mechanical room shall be able to be completely drained for service while keeping the remaining

mechanical equipment filled.

D. Plant Isolation Valves: The mechanical penthouse shall be isolated using sets of isolation valves

with drains added at each CHW supply and return into the room for future isolation of the

building from the plant without having to drain the building.

1. Chilled water cooling system.





1.3 SUBMITTALS

A. Product Data: For each type of special-duty valve indicated. Include flow and pressure drop

curves based on manufacturer's testing for diverting fittings, calibrated balancing valves, and

automatic flow-control valves.

B. Shop Drawings: Detail fabrication of pipe anchors, hangers, special pipe support assemblies,

alignment guides, and their attachment to the building and steel support structure. Detail

location of anchors and alignment guides.

C. Welding Certificates: Copies of certificates for welding procedures and personnel.

D. Field Test Reports: Written reports of tests specified in Part 3 of this Section. Include the

following:

1. Test procedures used.

2. Test results that comply with requirements.

3. Failed test results and corrective action taken to achieve requirements.

E. Maintenance Data: For hydronic specialties and special-duty valves to include in maintenance

manuals.

F. Water Analysis: Submit a copy of the water analysis to illustrate water quality available at

Project site.

G. CAD generated coordination and installation drawings (1/4 scale) shall be provided for the

following systems. The drawings shall show the building structure and other trades work.

1. Air-cooled chiller (CH-1) and all associated primary and secondary pumps, piping,

valves, sensors, etc.

2. Indicate location of all firestopping pipe through penetrations and identify as scheduled

the UL listed assembly number for each penetration on the coordination drawings.


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

Code: Section IX, "Welding and Brazing Qualifications."

B. 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 the ASME Boiler

and Pressure Vessel Code, Section VIII, Division 1.

C. Plastic Piping: Plastic piping is not allowed in this building for hydronic or domestic water

piping.

1.5 COORDINATION





A. Coordinate layout and installation of hydronic piping and suspension system components with

other construction, including light fixtures, HVAC equipment, and partition assemblies.

1. Provide rises and drops in piping as necessary to coordinate between trades and maintain

architectural ceiling heights indicated.

B. Coordinate pipe sleeve installations for shaft, wall and roof penetrations.

1. Wall and Floor Penetrations: See plans.

C. Coordinate piping installation with roof curbs, floor mounted piping support steel, equipment

supports, and roof penetrations.

D. Coordinate pipe fitting pressure classes with products specified.

E. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into base. Concrete,

reinforcement, and formwork requirements.

F. Coordinate installation of pipe sleeves for penetrations through exterior walls and floor

assemblies. Coordinate with requirements for firestopping for fire wall and floor assemblies.

G. Coordinate locations of hangers and supports above (roof framing/structure) with structural

engineer. Do not install anchors/fasteners into existing structure without prior approval of

Structural Engineer.

1.6 EXTRA MATERIALS

A. Manual Air Vents: Provide 2 extra.

B. Automatic Air Vents: Provide 2 extra.

C. Strainer Screens, Stainless Steel: Provide one (1) extra for each strainer.

D. Pressure Relief Valves: Provide one (1) extra (50-75psi).

E. 1-inch Brass Plugs: Provide two (2) extra.

PART 2 - PRODUCTS

2.1 MANUFACTURERS


of the following:

1. Calibrated Balancing Valves:

a. Armstrong Pumps, Inc.

b. Flow Design, Inc.





c. Gerand Engineering Company.

d. Griswold Controls.

e. ITT Bell & Gossett; ITT Fluid Technology Corp.

f. Taco, Inc.

g. Vitaulic.

2. Pressure-Reducing Valves:

a. Amtrol, Inc.

b. Armstrong Pumps, Inc.

c. Conbraco Industries, Inc.

d. ITT Bell & Gossett; ITT Fluid Technology Corp.

e. Spence Engineering Company, Inc.

f. Watts Industries, Inc.; Watts Regulators.

3. Safety Valves:

a. Amtrol, Inc.


c. Conbraco Industries, Inc.

d. ITT McDonnell & Miller Div.; ITT Fluid Technology Corp.

e. Kunkle Valve Division.

f. Spence Engineering Company, Inc.

4. Expansion Tanks:

a. Amtrol, Inc.


c. ITT Bell & Gossett; ITT Fluid Technology Corp.

d. Taco, Inc.

5. Air Separators and Air Purgers:

a. Amtrol, Inc.


c. ITT Bell & Gossett; ITT Fluid Technology Corp.

d. Taco, Inc.

2.2 PIPING MATERIALS

A. General: Refer to Part 3 "Piping Applications" Article for applications of pipe and fitting

materials.

2.3 COPPER TUBE AND FITTINGS

A. Drawn-Temper Copper Tubing: ASTM B 88, Type L (ASTM B 88M, Type B).

B. DWV Copper Tubing: ASTM B 306, Type DWV.





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

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

E. Solder Filler Metals: ASTM B 32, 95-5 tin antimony.

2.4 STEEL PIPE AND FITTINGS

A. Steel Pipe, NPS 2 (DN 50) and Smaller: ASTM A 53, Type S (seamless), Grade A,

Schedule 40, black steel, plain ends.

B. Steel Pipe, NPS 2-1/2 through NPS 12 (DN 65 through DN 300): ASTM A 53, Type E

(electric-resistance welded), Grade A, Schedule 40, black steel, plain ends.

C. Malleable-Iron Threaded Fittings: ASME B16.3, Classes 150 and 300.

D. Malleable-Iron Unions: ASME B16.39; Classes 150, 250, and 300.

E. Wrought-Steel Fittings: ASTM A 234/A 234M, wall thickness to match adjoining pipe.

F. 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.

G. Welding Materials: Comply with Section II, Part C, of the ASME Boiler and Pressure Vessel

Code for welding materials appropriate for wall thickness and for chemical analysis of pipe

being welded.

H. Gasket Material: Thickness, material, and type suitable for fluid to be handled; and design

temperatures and pressures.

2.5 VALVES

A. Globe, check, and ball valves are specified in Division 23 Section "Valves."

B. Refer to Part 3 "Valve Applications" Article for applications of each valve.

C. Calibrated Balancing Valves, NPS 2-1/2 (DN 65) and Smaller: Bronze body, ball type, 125-

psig (860-kPa) working pressure, 250 deg F (121 deg C) maximum operating temperature, and

having threaded ends. Valves shall have calibrated orifice or venturi, connections for portable

differential pressure meter with integral seals, and be equipped with a memory stop to retain set

position.

D. Calibrated Balancing Valves, NPS 3 (DN 75) and Larger: Cast-iron or steel body, ball type,

125-psig (860-kPa) working pressure, 250 deg F (121 deg C) maximum operating temperature,

and having flanged or grooved connections. Valves shall have calibrated orifice or venturi,





connections for portable differential pressure meter with integral seals, and be equipped with a

memory stop to retain set position.

E. Pressure-Reducing Valves: Diaphragm-operated, bronze or brass body with low inlet pressure

check valve, inlet strainer removable without system shutdown, and noncorrosive valve seat and

stem. Select valve size, capacity, and operating pressure to suit system. Valve shall be factory

set at operating pressure and have capability for field adjustment.

F. Safety Valves: Diaphragm-operated, bronze or brass body with brass and rubber, wetted,

internal working parts; shall suit system pressure and heat capacity and shall comply with the

ASME Boiler and Pressure Vessel Code, Section IV.

G. Differential Pressure Relief Valves: Class 150, cast iron housing, stainless steel operating parts;

threaded connections for 2-inch NPS (DN50) and smaller, flanged connections for 2 ½ inch

NPS (DN 65) and larger. Factory set pilot operated differential relief pressure to 275 gpm flow

at 50 psig, adjustable. Provide metal identification tag with chain for each valve factory marked

with valve model number, spring type and pressure setting. Cla-val Model 50-32, or approved

equal.

1. Installation in chilled water plant room as indicated, or directed by Enginee

H. Reduced-Pressure-Principle Backflow Preventers: ASSE 1013, Continuous-pressure

applications, maximum 12 psig pressure loss through middle 1/3 of flow range, NPS 1-1/2, 25

gpm, pressure Loss at flow rate - 5 psig for NPS 1-1/2, bronze body, Threaded end connections

designed for horizontal, straight through flow, with ball valve isolation and ASME A112.1.2

Air-Gap Fitting spilling to nearest drain.

2.6 HYDRONIC SPECIALTIES

A. Manual Air Vent: Bronze body and nonferrous internal parts; 150-psig (1035-kPa) working

pressure; 225 deg F (107 deg C) operating temperature; manually operated with screwdriver or

thumbscrew; with NPS 1/8 (DN 6) discharge connection and NPS 1/2 (DN 15) inlet connection.

1. Where manual air vent is indicated for piping installed at elevation higher than 8’-0”

above the finished floor, the contractor shall install a ½-inch copper drain line run from

the top of the pipe on the wall to a hose valve. Mount hose valve at 3’-6” above finished

floor.

a. Provide thread-o-let with steel nipple and dielectric coupling for connection of

copper piping.

B. Automatic Air Vent: Designed to vent automatically with float principle; bronze body and

nonferrous internal parts; 150-psig (1035-kPa) working pressure; 240 deg F (116 deg C)

operating temperature; with NPS 1/4 (DN 8) discharge connection and NPS 1/2 (DN 15) inlet

connection.

1. Provide and install piping connection, and copper drain line from automatic air vent to

closest mechanical room floor drain.





C. Expansion Tanks: Welded carbon steel, rated for 125-psig (860-kPa) working pressure and 375

deg F (191 deg C) maximum operating temperature. Separate air charge from system water to

maintain design expansion capacity by a flexible diaphragm securely sealed into tank. Include

drain fitting and taps for pressure gage and air-charging fitting. Support vertical tanks with steel

legs or base; support horizontal tanks with steel saddles. Factory fabricate and test tank with

taps and supports installed and labeled according to ASME Boiler and Pressure Vessel Code,

Section VIII, Division 1.

D. Tangential-Type Air Separators: Welded black steel; ASME constructed and labeled for 125-

psig (860-kPa) minimum working pressure and 250 deg F (191 deg C) maximum operating

temperature; perforated stainless-steel air collector tube designed to direct released air into

automatic air vent; tangential inlet and outlet connections; flanged strainer assembly, threaded

connections for NPS 2 (DN 50) and smaller; flanged connections for NPS 2-1/2 (DN 65) and

larger; threaded blowdown connection. Provide units in sizes for full-system flow capacity.

E. Air Purgers: Cast-iron body with internal baffles that slow the water velocity to separate the air

from solution and divert it to the vent for quick removal. Maximum working pressure of 150

psig (1035 kPa) and temperature of 250 deg F (121 deg C).

F. 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.

G. Diverting Fittings: 125-psig (860-kPa) working pressure; 250 deg F (121 deg C) maximum

operating temperature; cast-iron body with threaded ends, or wrought copper with soldered

ends. Indicate flow direction on fitting.

H. Y-Pattern Strainers: 125-psig (860-kPa) working pressure; cast-iron body (ASTM A 126,

Class B), flanged ends for NPS 2-1/2 (DN 65) and larger, threaded connections for NPS 2

(DN 50) and smaller, bolted cover, perforated stainless-steel basket, and bottom drain

connection.

I. Basket Strainers: 125-psig (860-kPa) working pressure; high-tensile cast-iron body

(ASTM A 126, Class B), flanged-end connections, bolted cover, perforated stainless-steel

basket, and bottom drain connection.

J. T-Pattern Strainers: 750-psig (5170-kPa) working pressure; ductile-iron or malleable-iron

body, grooved-end connections, stainless-steel basket with 57 percent free area; removable

access coupling and end cap for strainer maintenance.

K. Flexible Connectors: Stainless-steel bellows with woven, flexible, stainless steel, wire-

reinforcing protective jacket; 150-psig (1035 –kPa) minimum working pressure and 250 deg F

(121 deg C) maximum operating temperature. Connectors shall have flanged or threaded-end

connections to match equipment connected and shall be capable of ¾-inch (20-mm)

misalignment.

PART 3 - EXECUTION





3.1 PIPING APPLICATIONS

A. Chilled Water, and condenser water NPS 2 (DN 50) and Smaller: Aboveground, use Type L

(Type B) drawn-temper copper tubing with soldered joints or Schedule 40 steel pipe with

threaded joints.

B. Chilled Water, NPS 2 ½ (DN 65) and Larger: Above ground use ASTM A53, grade A

schedule 40 steel pipe with welded and flanged joints.

C. Close Loop (CHW) System Make up Water: ASTM B88, Type L drain to copper tubing with

soldered joints.

3.2 VALVE APPLICATIONS

A. General-Duty Valve Applications: Use the following valve types:

1. Shutoff Duty: Ball valves.

2. Throttling Duty: Heavy Duty Butterfly and ball valves.

B. Install shutoff duty valves at each branch connection to supply mains, at supply connection to

each piece of equipment, unless only one piece of equipment is connected in the branch line.

Install throttling duty valves at each branch connection to return mains, at return connections to

each piece of equipment, and elsewhere as indicated.

C. Install calibrated balancing valves in the return water line of each chiller and elsewhere as

required to facilitate system balancing.

D. Install safety valves as required by the ASME Boiler and Pressure Vessel Code. Install safety-

valve discharge piping, with union at valve connection and without valves, to floor. Comply

with the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, for installation

requirements.

1. All safety valves shall be provided with piped drain to closest floor drain. Provide union

adjacent safety valve to allow easy removal of drain piping.

E. Install pressure-reducing valves as required to regulate system pressure.

F. Install drain valves at low points in mains, risers, branch lines, and elsewhere as required for

system drainage.

G. Install air vents where indicated on piping plans.

1. Install ½” weld-0-let with steel nipple to dielectric union to ½” copper drain line with ½”

ball valve with ¾” hose thread and brass cap on chain.

2. Install ½-inch (DN50) ball valve with hose connection. Valve shall be installed at 3’-6”

above finished floor.

H. Install plant isolation/shut-off valves at piping leaving plant (mechanical rooms) with drain

valves on system and plant side to facilitate plant or system drain down without draining entire

systems.





3.3 PIPING INSTALLATIONS

A. Refer to Division 23 Section "Basic Mechanical Materials and Methods" for basic piping

installation requirements.

1. Provide piping through penetrations in accordance with UL listed Firestopping system

selected for actual condition.

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

of valves.

C. 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.

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

E. Reduce pipe sizes using correct reducer fitting installed with level side up.

1. Vertical Piping: Concentric reducer.

2. Horizontal Water Piping: Eccentric reducer with level side up.

F. Unless otherwise indicated, install branch connections to mains using tee fittings in main pipe,

with the takeoff coming out the bottom of the main pipe. For up-feed risers, install the takeoff

coming out the side of the main pipe.

G. Install strainers on supply side of each chiller or other element with a control valve. In addition,

install strainers on the supply side of each pump, 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).

H. Anchor piping for proper direction of expansion and contraction.

3.4 HANGERS AND SUPPORTS

A. Hanger, support, and anchor devices are specified in Division 23 Section "Hangers and

Supports." Comply with requirements below for maximum spacing of supports.

B. Install the following hangers and supports:

1. Adjustable ASTM A123 hot-dipped galvanized steel clevis hangers for individual

horizontal piping less than 20 feet (6 m) long.

2. Adjustable ASTM A 123 hot-dipped galvanized sliding saddle hangers and spring

hangers for individual horizontal piping 20 feet (6 m) or longer. Provide springs within

20 feet of vibrating equipment.

3. Adjustable ASTM A123 hot-dipped galvanized sliding saddle hangers and spring hangers

for heavy duty trapeze or channel support for multiple horizontal piping runs more than

20 feet (6m) or longer. Provide springs within 20 feet of vibrating equipment.





C. All hangers and supports shall be protected against galvanized corrosion. There shall be no

non-insulated piping on this project. All hangers and supports shall be high performance coated

steel.

D. Piping support Spacing Schedule: Install piping with the following minimum rod sizes and

maximum spacing:

Pipe Size Steel Pipe Maximum Hanger

Spacing

Copper Tube

Maximum

Hanger Spacing

Rod Hanger

Diameter

Water Service Gas or

Air Service

1/2 to 3/4 inch 7 Ft. 8 Ft. 5 Ft. 3/8 inches

1 to 1-1/4 inches 7 Ft. 8 Ft. 6 Ft. 3/8 inches

1 – 1/2 inches 7 Ft. 9 Ft. 7 Ft. 3/8 inches

2 inches 9Ft. 9 Ft. 7 Ft. 3/8 inches

2-1/2 inches 10 Ft. 10 Ft. 8 Ft. 1/2 inches

3 inches 10 Ft. 10 Ft. 9 Ft. 1/2 inches




8 inches 6 Ft. --- 6 Ft. 3/4 inches

10 inches 4 Ft. --- -- 7/8 inches

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

guides, at every other support point.

1. Refer to Section 230529, “Hangers and Supports for HVAC Piping and Equipment”, and

coordinate. Most stringent requirement applies.

a. Do not exceed hanger rod loading indicated in Section MSS SP-58, Table 3 or the

table given in this Section, paragraph .3.4.D.

b. See Structural for other applicable requirements.

3.5 PIPE JOINT CONSTRUCTION

A. Refer to Division 23 Section "Basic Mechanical Materials and Methods" for joint construction

requirements for soldered and brazed joints in copper tubing and threaded, welded, and flanged

joints in steel piping.

3.6 HYDRONIC SPECIALTIES INSTALLATION

A. Install manual air vents at high points in piping, at all heat-transfer coils and heat exchangers,

top of risers, and elsewhere as required for system air venting.





B. Install automatic air vents in mechanical equipment room’s at all high points of system piping,

at supply side of heat-transfer coils, and elsewhere as required for system air venting.

C. Install combination tangential air separator with strainer in pump suction lines. Install piping to

compression tank with a 2 percent upward slope toward tank. Install manual blowdown piping

with ball valve; extend to nearest drain. Install with adequate clearance to allow removal and

inspection of integral strainer assembly.

D. Install bypass chemical feeders in each closed piping hydronic system, in upright position with

top of funnel not more than 48 inches (1200 mm) above floor. Install feeder in bypass line, off

main, using globe valves on each side of feeder and in the main between bypass connections.

Pipe drain, with ball valve, to nearest equipment drain.

E. Install hot water diaphragm expansion tank supported on floor with sufficient strength to carry

weight of tank, piping connections, and fittings, plus weight of a full tank of water. Do not

overload building components and structural members.

F. Install calibrated balancing valves for each piece of mechanical equipment with a hot water,

connection.

1. Install one (1) balancing valve for each chiller supply side piping, and each secondary

CHW return from the zone.

3.7 TERMINAL EQUIPMENT CONNECTIONS

A. Size for supply and return piping connections shall be as indicated on plan general notes for

actual water flow for each runout.

B. Install control valves in return water piping in accessible locations close to connected

equipment. Provide unions to allow easy removal of control valves for maintenance and

inspection.

C. Install bypass piping with ball valve around control valve. If multiple, parallel control valves

are installed, only one bypass is required.

D. Install ports for pressure and temperature gages at coil inlet connections.

3.8 CHEMICAL TREATMENT

A. Perform an analysis of supply water to determine the type and quantities of chemical treatment

needed to keep system free of scale, corrosion, and fouling, and to sustain the water

characteristics indicated in Section 232500:

B. Fill system and perform initial chemical treatment.


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 system with clean water. Clean strainers.

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 trapped air.

Use drains installed at low points for complete draining of liquid.

3. Check expansion tanks to determine that they are not air bound and that system is full of

water.

4. Subject piping system to hydrostatic test pressure that is not less than 1.5 times the design

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 either 90 percent of specified minimum yield strength or 1.7

times "SE" value in Appendix A of 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.

3.10 ADJUSTING

A. Mark calibrated nameplates of pump discharge valves after hydronic system balancing has been

completed, to permanently indicate final balanced position.

B. Perform these adjustments before operating the system:

1. Open valves to fully open position. Close coil bypass valves.

2. Check pump for proper direction of rotation.

3. Set automatic fill valves for required system pressure.

4. Check 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. Check operation of automatic bypass valves.

7. Check and set operating temperatures of boilers to design requirements.

8. Lubricate motors and bearings.

3.11 CLEANING





A. Flush hydronic piping systems with clean water. Remove and clean or replace strainer screens.

After cleaning and flushing hydronic piping systems, but before balancing, remove disposable

fine-mesh strainers in pump suction diffusers.

1. Piping systems shall be flushed continuously until all weld slag, dirt, rust, etc. is removed

and the water is clear. The contractor is responsible for any and all damage to the

equipment. The contractor shall thoroughly chemically clean all heat-transfer coils and

surface prior to project substantial completion.

2. Contractor shall supply all HVAC water treatment chemicals, and shall measure, test and

adjust the chemical water treatment to protect all piping systems in accordance with

Section 232500.

END OF SECTION




HYDRONIC PUMPS 232123 - 1

SECTION 232123

HYDRONIC PUMPS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes the following categories of hydronic pumps for hydronic systems:

1. End-suction pumps for chilled water systems.

1.2 SUBMITTALS

A. Product Data: Include certified performance curves and rated capacities; shipping, installed,

and operating weights; furnished specialties; final impeller dimensions; and accessories for each

type of product indicated. Indicate pump's operating point on curves.

B. Shop Drawings: Show pump layout and connections. Include Setting Drawings with templates

for installing foundation and anchor bolts and other anchorages.

1. Wiring Diagrams: Detail wiring for power, signal, and control systems and differentiate

between manufacturer-installed and field-installed wiring.

C. Maintenance Data: For pumps to include in maintenance manuals as specified.


A. UL Compliance: Fabricate and label pumps to comply with UL 778, "Motor-Operated Water

Pumps," for construction requirements.

B. Product Options: Drawings indicate size, profiles, connections, and dimensional requirements

of pumps and are based on the specific types and models indicated. Other manufacturers'

pumps with equal performance characteristics may be considered.

C. Regulatory Requirements: Fabricate and test pumps to comply with HI 1.1-1.5, "Centrifugal

Pumps for Nomenclature, Definitions, Application and Operation," and HI 1.6, "Centrifugal

Pump Tests."

D. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70,

Article 100, by a testing agency acceptable to authorities having jurisdiction.






A. Manufacturer's Preparation for Shipping: Clean flanges and exposed machined metal surfaces

and treat with anticorrosion compound after assembly and testing. Protect flanges, pipe

openings, and nozzles with wooden flange covers or with screwed-in plugs.

B. Store pumps in dry location.

C. Retain protective covers for flanges and protective coatings during storage.

D. Protect bearings and couplings against damage from sand, grit, and other foreign matter.

E. Comply with pump manufacturer's written rigging instructions.

1.5 COORDINATION

A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases.

B. Each pump shall be provided with fitting to connect different pressure status switches to be

installed by EMS.

1.6 EXTRA MATERIALS

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 and coupling for each pump, including variable

speed duty couplings for pumps with adjustable frequency drives (AFD).

2. Shafts, seals, couplings, motors: One (1) year.

1.7 WARRANTY

A. Warranty: One (1) year from date of Substantial Completion for defects in material and

workmanship.

B. Warranty

1. The warranty period shall be a non-prorated period of 24 months from date of

installation, not to exceed 30 months from date of manufacture. Warranty shall cover

pump, motor and terminal box as a complete unit.





PART 2 - PRODUCTS

2.1 MANUFACTURERS


of the following.

1. Supported-Volute, Flexible-Coupled, End-Suction Pumps:

a. Basis of Design: Bell & Gossett ITT; Div. of ITT Fluid Technology Corp.


c. Ingersoll-Dresser Pump Co.

d. Taco; Fabricated Products Div.

2.2 GENERAL PUMP REQUIREMENTS

A. Pump Units: Factory assembled and tested.

B. Motors: Comply with requirements in Division 230513 Section "Motors."

1. All motors shall be premium efficiency in accordance with NEMA MG1. Refer to

section 230513 for table of minimum efficiencies.

2.3 FLEXIBLE-COUPLED, END-SUCTION PUMPS

A. Description: Base-mounted, centrifugal, flexible-coupled, end-suction, single-stage, bronze-

fitted, back-pull-out, radically split case design; rated for 175-psig (1200-kPa) minimum

working pressure and a continuous water temperature of 225 deg F (107 deg C).

1. Casing: Cast iron, with flanged piping connections, drain plug at low point of volute,

threaded gage tappings at inlet and outlet connections, and integral feet or other means on

volute to support weight of casing and attached piping. Casing shall allow removal and

replacement of impeller without disconnecting piping.

2. Impeller: ASTM B 584, cast bronze, statically and dynamically balanced, closed

overhung, single suction, keyed to shaft, and secured by locking cap screw.

3. Wear Rings: Replaceable, bronze casing ring.

4. Shaft and Sleeve: Steel shaft with bronze sleeve.

5. Seals: Mechanical, with carbon-steel rotating ring, stainless-steel spring, ceramic seat,

and flexible bellows and gasket.

6. Coupling: Flexible-spacer type, capable of absorbing torsional vibration and shaft

misalignment; with flange and sleeve section that can be disassembled and removed

without removing pump or motor.

a. Couplings for adjustable frequency drive (AFD) pumps shall be designed for

variable speed duty.

7. Coupling Guard: Steel, removable, and attached to mounting frame.





8. Mounting Frame: Welded-steel frame and cross members, factory fabricated from

ASTM A 36/A 36M channels and angles. Fabricate for mounting pump casing, coupling

guard, and motor. Field-drill motor-mounting holes for field-installed motors.

9. Motor: Secured to mounting frame, with adjustable alignment.

10. Provide differential pressure fittings for pressure switches across pump suction and

discharge.

B. Coordination: Pump supplies shall coordinate with suction diffuser supplier to match the flange

sizes for diffuser inlet and pump suction.

2.4 PUMP SPECIALTY FITTINGS

A. Suction Diffuser: Angle pattern, 175-psig (1200-kPa) pressure rating, cast-iron body and end

cap, pump-inlet fitting; with bronze startup and bronze or stainless-steel permanent strainers;

bronze or stainless-steel straightening vanes; drain plug; and factory- or field-fabricated support.

1. Contractor is responsible to match pump flange (suction) connection size and diffuser

inlet (system) piping connection sizes actual pumps provided.

2. Pump Suction Diffuser Schedule:

PUMP

TAG

FLANGED ANGLE TYPE MODEL

#

FLANGE

SIZE

RATED GPM

PIPE PUMP

PCHWP-1 Bell & Gossett GF-1 6” 4” 420

PCHWP -2 Bell & Gossett GF-3 6” 4” 420

SCHWP-1 Bell & Gossett EE-3 4” 4” 210

SCHWP-2 Bell & Gossett EE-3 4” 4” 210

B. Triple-Duty Valve: Straight pattern, 175-psig (1200-kPa) pressure rating, cast-iron body,

pump-discharge fitting; with drain plug and bronze-fitted shutoff, balancing, and check valve

features. Provide flow meter readout kit with pressure gauges and calculator

1. “Triple Duty” Pump Discharge Valve Schedule:

PUMP TAG FLANGED STRAIGHT

VALVE MODEL #

FLANGE

SIZE

RATED GPM

PCHWP -1 3DS-4S 4” 420

PCHWP -2 3DS-4S 4” 420

SCHWP-1 3DS-3S 3” 210

SCHWP-2 3DS-3S 3” 210





PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine equipment foundations and anchor-bolt locations for compliance with requirements for

installation.

1. Examine roughing-in for piping systems to verify actual locations of piping connections

before pump installation.

2. Examine foundations and inertia bases for suitable conditions where pumps are to be

installed.


3.2 PUMP INSTALLATION

A. Install pumps according to manufacturer's written instructions.

1. Install pumps according to HI 1.1-1.5, "Centrifugal Pumps for Nomenclature,

Definitions, Application and Operation."

B. Install pumps to provide access for periodic maintenance, including removing motors,

impellers, couplings, and accessories.

C. Support pumps and piping separately so piping is not supported by pumps.

D. Suspend in-line pumps using continuous-thread hanger rod and vibration-isolation hangers.

Install seismic bracing as required by authorities having jurisdiction.

E. Set EMSe-mounted pumps on concrete foundation. Disconnect coupling halves before setting.

Do not reconnect couplings until alignment operations have been completed.

1. Support pump base plate on rectangular metal blocks and shims, or on metal wedges with

small taper, at points near foundation bolts to provide a gap of 3/4 to 1-1/2 inches (19 to

38 mm) between pump base and foundation for grouting.

2. Adjust metal supports or wedges until pump and driver shafts are level. Check coupling

faces and suction and discharge flanges of pump to verify that they are level and plumb.

3.3 ALIGNMENT

A. Align pump and motor shafts and piping connections after setting them on foundations, after

grout has been set and foundation bolts have been tightened, and after piping connections have

been made.

B. Comply with pump and coupling manufacturers' written instructions.

C. Adjust pump and motor shafts for angular and offset alignment by methods specified in HI 1.1-

1.5, "Centrifugal Pumps for Nomenclature, Definitions, Application and Operation."





D. After alignment is correct, tighten foundation bolts evenly but not too firmly. Completely fill

Base plate with nonshrink, nonmetallic grout while metal blocks and shims or wedges are in

place. After grout has cured, fully tighten foundation bolts.

3.4 CONNECTIONS

A. Piping installation requirements are specified in other Division 23 Sections. Drawings indicate

general arrangement of piping, fittings, and specialties.

B. Install piping adjacent to machine to allow service and maintenance.

C. Connect piping to pumps. Install ball valves that are the same size as piping connected to

pumps.

D. Install concentric reducer at pump discharge nozzles.

E. Install suction pipe sizes to suction diffuser inlet as indicated. Suction diffuser inlet shall match

inlet pipe size indicated on schedule.

F. Install isolation (throttling) valve on discharge side of in-line circulators, and install, y-strainer

and isolation valve on suction side. Install pressure indicator(s) across pump discharge and

suction piping.

G. Install flexible connector, non-slam check valve (or triple duty valve for constant speed pumps)

and ball valve on discharge side of end-suction pumps, and install suction diffuser, flexible

connector, y-strainer and ball valve on suction side.

1. Except install triple-duty valve in place of non-slam check valve for pumps without

adjustable frequency drive (AFD’s) on discharge side of vertical in-line pumps.

H. Install suction diffuser on suction side of base mounted pumps.

I. Install pressure gages on pump suction and discharge, chiller entering and leaving water piping,

and boiler leaving water piping in field fabricated spool piece in flanged piping.

J. Install temperature wells and digital thermometers in pump suction piping, chiller leaving water

piping, and heat exchanger entering and leaving water piping, boiler leaving water temperature,

and storage tank leaving water temperature.

1. Install ½-inch ball valves for gauges.

K. Install two (2) 1-inch brass test plug connections on entering and leaving side of each chiller

piping connection.

L. Extend 3/8-inch brass tubing to chiller pressure transducers with ball valve per manufacturers’

recommendations.

M. Install flow measuring stations with five (5) pipe diameters unobstructed straight pipe on inlet

side and three (3) pipe diameters on outlet side. If the flow measuring stations do not indicate





properly due to improper placement in the piping system, the contractor shall re-work the piping

system at their own cost until functioning properly as determined by the Engineer.

N. Install calibrated balancing valves at the outlet side of each boiler, chiller, and all cooling and

heating coils, including all air handlers and air terminal units (VAV boxes). Install additional

balancing valve for each preheat circulating pump at all air handlers with preheat coils.

O. Install union, drain, automatic air vent, flexible connector, y-strainer and ball valve on the inlet

water side of each hydronic coil and union, drain, manual air vent, flexible connector, automatic

modulating temperature control valve, calibrated balancing valve and ball valve on the leaving

water side of each hydronic coil.

1. Install manual vents and drains at all hydronic coils.

P. Install temperature, pressure transducer, and flow measuring station wells for EMS as required

by the EMS contractor.

Q. Install differential pressure transducers in building chilled water and service hot water system

piping (approx. ¾ way down stream) as required by the EMS contractor for adjustable

frequency drive (AFD) pumping control.

1. Provide four (4) differential pressure systems per piping loop per floor.

R. Install differential pressure relief valve(s) across service hot water heating pumps

(suction/discharge).

S. Install stainless steel braided flexible connector and ball valve on boiler inlet piping and

stainless steel braided flexible connector, calibrated balancing valve and ball valve on outlet

piping.

T. Install ball (isolation) valve, and calibrated balancing valve on closed-loop drycooler inlet and

ball (isolation) valve on outlet piping. Install three-way bypass control valve in basement

chiller room as indicated for temperature control.

U. Install electrical connections for power, controls, and devices.

V. Electrical power and control wiring and connections are specified in Division 26 Sections.

W. Ground equipment.

1. Tighten electrical connectors and terminals according to manufacturer's published torque-

tightening values. If manufacturer's torque values are not indicated, use those specified

in UL 486A and UL 486B.

3.5 START UP PROCEDURES

A. Verify that pumps are installed and connected according to the Contract Documents.

B. Verify that electrical wiring installation complies with manufacturer's written instructions and

the Contract Documents.





C. Verify that EMS control wiring installation is complete and affects a complete operating system

in accordance with the sequence of operation specified.

D. Perform the following preventive maintenance operations and checks before starting:

1. Lubricate bearings.

2. Remove grease-lubricated bearing covers, flush bearings with kerosene, and clean

thoroughly. Fill with new lubricant according to manufacturer's written instructions.

3. Disconnect coupling and check motor for proper rotation that matches direction marked

on pump casing. Verify that variable speed pump couplings are designed for variable

speed variable torque applications up to maximum operating RPM of pump motor.

4. Verify that pumps are free to rotate by hand and that pumps for handling hot liquids are

free to rotate with pumps hot and cold. Do not operate pumps if they are bound or drag,

until cause of trouble is determined and corrected.

5. Check suction piping connections for tightness to avoid drawing air into pumps.

6. Clean strainers.

7. Verify that pump controls are correct for required application.

E. Starting procedure for pumps with shutoff power not exceeding safe motor power is as follows:

1. Prime pumps by opening suction valves and closing drains, and prepare pumps for

operation.

2. Open cooling water-supply valves in cooling water supply to bearings, where applicable.

3. Open sealing liquid-supply valves if pumps are so fitted.

4. Open warm-up valves of pumps handling hot liquids if pumps are not normally kept at

operating temperature.

5. Open circulating line valves if pumps should not be operated against dead shutoff.

6. Start motors.

7. Open discharge valves slowly.

8. Observe leakage from stuffing boxes and adjust sealing liquid valve for proper flow to

ensure lubrication of packing. Let packing "run in" before reducing leakage through

stuffing boxes; then tighten glands.

9. Check general mechanical operation of pumps and motors.

10. Close circulating line valves once there is sufficient flow through pumps to prevent

overheating.

F. When pumps are to be started against closed check valves with discharge shutoff valves open,

steps are the same, except open discharge valves before starting motors.

3.6 DEMONSTRATION


adjust, operate, and maintain hydronic pumps as specified below:

1. Train Owner’s maintenance personnel on procedures and schedules for starting and

stopping, troubleshooting, servicing, and maintaining pumps.

2. Review data in maintenance manuals. act Closeout."

3. Review data in maintenance manuals.





4. Schedule training with Owner, through Engineer, with at least seven days' advance

notice.

END OF SECTION




HVAC WATER TREATMENT 232500 - 1

SECTION 232500

HVAC WATER TREATMENT

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes water-treatment systems for the following:

1. Chilled water (closed-loop system).

1.2 CHEMICAL FEED SYSTEM DESCRIPTION

A. Closed-Loop Systems: One make-up water assembly on the system with isolating and drain

valves downstream from circulating pumps, unless otherwise indicated.

1. Closed-loop systems include, dual temperature chilled water (heating) (cooling) system.

2. Introduce chemical treatment through bypass feeder when required or indicated by test.

a. The existing bypass feeder shall be removed replaced with new and reinstalled as

necessary to complete the work.


A. Maintain water quality for HVAC systems that controls corrosion and build-up of scale and

biological growth for maximum efficiency of installed equipment without posing a hazard to

operating personnel or the environment.

B. Base chemical treatment performance requirements on quality of water available at Project site,

HVAC system equipment material characteristics and functional performance characteristics,

operating personnel capabilities, and requirements and guidelines of authorities having

jurisdiction. Contractor is responsible for obtaining latest quality analysis from Facquier

County Sanitation Authority for the projects site.

C. There shall be no chromates, polyphosphates, or heavy metals in the chemical formulation.

D. Water treatment shall not in any way affect the life of any part of the water cooling equipment,

pipe, valves, fittings, and other appurtenances.

E. Water treatment system shall introduce chemicals into each system only when the system is

operating.

F. Open cooling systems shall maintain these conditions:

1. Scale and corrosion inhibitor: 0.4 to 0.8 ppm as molybdate tracer with other chemicals

used as corrosion inhibitor.

2. pH: 7 to 8.5.

3. Organic growths: 10,000 bacteria/ml.





4. Cycles of concentration: 6 maximum.

G. Chilled water shall maintain these conditions:

1. pH: 8 to 10.5

2. Corrosion inhibitor: 50 to 100 ppm as molybdate or 500 to 1000 ppm sodium nitrite.

3. Closed System: Maintain system essentially free of scale, corrosion, and fouling to

sustain the following water characteristics:

a. pH: 8.0 to 10.0.

b. Corrosion Inhibitor: 1000-1200 PPM (as Nitrite/Borate), or 50 to 100 ppm (as

Molybdate).

1.4 SUBMITTALS

A. Product Data: Include rated capacities; water-pressure drops; shipping, installed, and operating

weights; and furnished products listed below:

1. Test equipment.

2. Chemicals.

3. Chemical feeders.

B. Shop Drawings: Detail equipment assemblies indicating dimensions, weights, loads, required

clearances, method of field assembly, components, and location and size of each field

connection.

1. Wiring Diagrams: Detail power and control wiring and differentiate between

manufacturer-installed and field-installed wiring. Submit both Fairfax Fauquier County

water analysis and contractor’s analysis for review.

2. Chemicals proposed for each treated system, with calculations showing that treatment

will produce the levels required in “Performance Requirements” above.

3. Pretreatment and chemical treatment equipment showing tanks, maintenance space

required, and piping connections to HVAC systems. Include plans, elevations, sections,

details, and attachments to other work.

C. Water Analysis: Perform testing and submit a copy of the water analysis to illustrate water

quality available at Project site. Submit both Fauquier County Sanitation Authority water

analysis and contractor’s independent analysis for review.

D. Field Test Reports: Indicate and interpret monthly test results for compliance with performance

requirements.

E. Maintenance Data: For meters, pumps, agitators, filters, system controls and controllers and

accessories to include in maintenance manuals as specified.

F. Product Data:





1. Chemicals and concentrations proposed for system cleaning.

2. Each item of equipment.

G. Certifications: Qualifications of water treatment supplier, including:

1. Names and qualifications of staff proposed to be assigned to the project.

2. List of at least five projects meeting the requirements described in the article “Quality

Assurance: below, each with name, address, and telephone number of contact person who

can confirm satisfactory installation and operation of the system.


A. Installer Qualifications: The contractor shall engage a reputable water treatment contractor

experienced installer who is an authorized representative of the HVAC treatment manufacturer

for installation and initial start-up of chemical treatment equipment required for this Project.

B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70,

Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for

intended use.

C. Water Treatment subcontractor shall supervise the cleaning of the piping systems and submit a

certificate of compliance with the specification.

1.6 MAINTENANCE

A. Scope of Service: Provide chemicals and service program for maintaining optimum conditions

in the circulating water for inhibiting corrosion, scale, and organic growths in the chilled water

(cooling), closed-loop piping, and equipment. Services and chemicals shall be provided for a

period of one (1) year from date of Acceptance, including the following:

1. Initial water analysis and recommendations.

2. Startup assistance.

3. Periodic field service and consultation.

4. Customer report charts and log sheets.

5. Laboratory technical assistance.

6. Analyses and reports of all chemical items concerning safety and compliance with

government regulations.

1.7 EXTRA MATERIALS

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. Chemicals: Furnish quantity for all systems equal to as required for one (year) operation.

1.9 WARRANTY

A. One (1) year from date of Acceptance for defects in material and workmanship.





1.8 QUALIFICATIONS OF WATER TREATMENT SUBCONTRACTOR

A. Contractor shall engage and the Architect shall approve an independent water treatment

subcontractor, who shall provide the water treatments specified in this section.

B. Is located in the Baltimore/Washington D.C., metropolitan area within 100 miles of the project

site.

C. Is regularly engaged in providing and servicing systems of similar type and capacity to that

installed on this project.

D. Has a record of at least five projects similar to this project in type and size, which have been in

place and operating satisfactorily for at least 5 years.

E. Offers 24-hour emergency service.

F. Maintains locally an adequate stock of parts and supplies to service this system and equipment.

G. Has service contract available.


A. Obtain water analysis from the local agency supplying water to the site, or by a test.

B. The chilled water system will be operational when the weather is cool.

1.10 MAINTENANCE SERVICE

A. For 1 year after Substantial Completion, test and maintain systems with bimonthly site visits.

Additional intermittent site visits shall be performed if conditions deem so and will be

performed at no cost to Fauquier County Public Schools (FCPS).

B. Perform an analysis at the time of each visit, or within 72 hours at the firm’s laboratory, and

submit report as required in “Submittals”.

C. Closed systems: During the final 30 days of the project 1-year service period, water treatment

supplier’s representatives shall test each closed system.

1. Make minor adjustments if required to correct chemical balance.

2. If system conditions indicate significant leaks, notify Contractor. After piping

corrections or repairs, adjust system chemical balance.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Acceptable Manufacturers : Subject to compliance with requirements, provide products by one

of the following:





1. HVAC Water-Treatment Products:

a. See-Metrics.

b. Badger.

c. Master Meter.

d. Tate.

e. Neptune.

f. Liquid-Metronics, Inc. (L.M.I.)

g. Pulsafeeder.

h. Amsco.

i. Taylor.

j. Bonar.

k. Arcwater Treatment Co., Inc.

l. GF Morin Co., Inc.

m. Intermatic.

n. Ives/ASCO.

o. Shelco.

p. Wingert.

2. HVAC Water Treatment Contractors:

a. Basis of Design: ARC Water Treatment Co., Inc.

b. Tricon, Inc.

c. Diversery Water Technologies (Mogul).

2.1 ACCEPTABLE SUPPLIERS AND MANUFACTURERS

A. Water treatment system subcontractors:

1. ARC Water Treatment Company, Inc.

2. Bond Water Technologies

3. Ecolab (Ro-Co Corp.)

4. Water Chemical Service, Inc.

5. Olin Water Services

2.2 MANUAL CHEMICAL-FEED EQUIPMENT

A. Bypass Feeders: Steel, with corrosion-resistant exterior coating, minimum 3-1/2-inch fill

opening in the top, and NPS 3/4 bottom inlet and top side outlet. Quarter turn or threaded fill

cap with gasket seal and diaphragm to lock the top on the feeder when exposed to system

pressure in the vessel.

1. Capacity: 5 gal..

2. Minimum Working Pressure: 125 psig.

2.3 MATERIALS





A. For cleaning heating and cooling piping systems: Detergent, dispersant, and other required

chemicals, in accordance with approved product data.

B. For each system’s chemical treatment: Chemicals in accordance with approved product data, to

maintain the conditions specified in “Performance Requirements” above.

2.4 CHEMICAL TREATMENT TEST EQUIPMENT

A. Test Kit: Manufacturer recommended equipment and chemicals, in a carrying case, for testing

pH, total dissolved solids, dissolved oxygen, phosphonate, biocount, chloride, and total

alkalinity and for calcium hardness field tests.

B. Corrosion Test Coupon Assembly: Constructed of corrosion material, complete with piping,

valves, and mild steel and copper coupons. Locate copper coupon downstream from mild steel

coupon in the test coupon assembly.

1. One (1) holder station rack for the closed service hot chilled water (heating) (cooling)

system.

2. Basis of Design (Dual Temperature): Wingart Model CSCR-2-007/09 with Dole Valve

Two Station Rack.

2.5 CHEMICALS

A. Furnish chemicals recommended by water-treatment system manufacturer that are compatible

with piping system components and connected equipment.

PART 3 - EXECUTION

3.1 WATER ANALYSIS

A. Perform an analysis of supply water to determine the type and quantities of chemical treatment

needed to maintain the water quality as specified in "Performance Requirements" Article.

3.2 INSTALLATION

A. Install treatment equipment level and plumb.

B. Add cleaning chemicals as recommended by manufacturer.

3.3 CONNECTIONS

A. Piping installation requirements are specified in other Division 23 Sections. Drawings indicate

general arrangement of piping, fittings, and specialties.

B. Install piping adjacent to equipment to allow service and maintenance.





C. Confirm applicable electrical requirements in Division 26 Sections for connecting electrical

equipment.

D. Ground equipment.


tightening values. If manufacturer's torque values are not indicated, use those specified

in UL 486A and UL 486B.

3.4 CLEANING PIPING SYSTEMS

A. Before adding chemicals to the system, isolate coils of heating and cooling equipment, and open

bypasses.

B. Flushing portions of the system:

1. After a piping loop has been completed and prior to the installation of strainer baskets,

flush that portion of the system. Connections shall be same size as piping being flushed,

or one size smaller.

2. When a major section of the building has been completed, repeat the same procedure,

except that pipe connections shall be limited to NPS 1.5 (DN 40).

3. Flushing shall remove sediment, scale, rust and other foreign substances.

4. After flushing, install strainers and pressure-test system and repair leaks.

C. Flushing building system: After various portions of the piping system have been tested and

flushed and system is substantially completed, fill the system completely with water, venting all

trapped air, and operating the pump.

1. Open a drain at the system low point while replacing the water at the same rate.

2. Continue flushing until clean water shows at the drain, but for not less than two hours.

3. After flusing, remove strainers and clean and replace them. Remove the by-pass around

the heat pump condensers and install control valves.

D. Chemical cleaning: Fill system with sufficient detergent and dispersant to remove dirt, oil, and

grease.

1. Circulate for at least 48-hours.

2. Open a drain valve at the lowest point and bleed while system continues to circulate.

Assure that the automatic makeup valve is operating.

3. Continue until water runs clear and all chemicals are removed. Sample and test the water

until pH is the same as pH of makeup water.

4. After chemical cleaning, remove strainers and clean and reinstall them.

5. Close bypasses and open valves to coils.

E. Submit certificate and test results.

3.5 INSTALLING CHEMICAL TREATMENT FOR CLOSED SYSTEM

A. Perform water analysis and submit recommended chemicals for treatment.

B. Install chemicals.





C. At the end of the project correction period, test the closed system and correct concentration of

chemicals if required. Submit test and adjustment report.


A. Engage a factory-authorized service representative to perform startup service.

1. Inspect field-assembled components and equipment installation, including piping and

electrical connections. Report results in writing.

2. Inspect piping and equipment to determine that systems and equipment have been

cleaned, flushed, and filled with water, and are fully operational before introducing

chemicals for water-treatment system.

B. Test chemical feed piping as follows:

1. Do not enclose, cover, or put piping into operation until it is tested and satisfactory test

results are achieved.

2. Test for leaks and defects. If testing is performed in segments, submit separate report for

each test, complete with diagram of portion of piping tested.

3. Leave uncovered and unconcealed new, altered, extended, and replaced water piping until

it has been tested and approved. Expose work that has been covered or concealed before

it has been tested and approved.

4. Cap and subject piping to static water pressure of 50 psig (345 kPa) above operating

pressure, without exceeding pressure rating of piping system materials. Isolate test

source and allow test pressure to stand for four hours. Leaks and loss in test pressure

constitute defects.

5. Repair leaks and defects with new materials and retest piping until satisfactory results are

obtained.

6. Prepare test reports, including required corrective action.

3.7 ADJUSTING

A. Occupancy Adjustments: Within 12 months of Substantial Completion, perform four (4)

separate water analyses and submit to Architect for review to prove that manual chemical feed

systems are maintaining water quality within performance requirements specified in this

Section. Perform analyses at least 60 days apart. Submit written reports of water analysis.

3.8 DEMONSTRATION

A. Engage a factory-authorized service representative to train Architect's maintenance personnel to

adjust, operate, and maintain HVAC water-treatment systems and equipment.

1. Train Owner’s maintenance personnel on procedures and schedules for starting and

stopping, troubleshooting, servicing, and maintaining equipment and schedules.

B. Review manufacturer's safety data sheets for handling of chemicals.





C. Review data in maintenance manuals, especially data on recommended parts inventory and

supply sources and on availability of parts and service.

D. Review data in maintenance manuals, especially data on recommended parts inventory and

supply sources and on availability of parts and service.

E. Schedule at least four (4) hours of training with FCPS, through Engineer, with at least seven

days' advance notice.

3.9 OPERATING INSTRUCTIONS

A. Treatment representative shall start up equipment and instruct Owner’s representative on its

operation.

END OF SECTION




AIR-COOLED VARIABLE SPEED COMPRESSOR HELICAL ROTARY SCREW CHILLERS (ALT. A) 236426.1-1

SECTION 236426.1-1

AIR-COOLED VARIABLE SPEED COMPRESSOR HELICAL ROTARY SCREW CHILLERS

(ALT - A)

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes packaged, air-cooled, variable speed compressor, electric-motor driven,

dual independent refrigerant circuit, multiple helical rotary screw compressor, multiple circuit,

water chiller with the following features.

1. Motor Controller (variable speed drive compressor).

2. Microprocessor-based EMS Building controls by Owner’s EMS Vendor.

3. BACNET card shall be included with chiller from factory.

B. The contractor is responsible for fully coordinating with the EMS (DDC) controls contractor

and provide all technical information and data required to ensure that all functions and

sequence of operations specified are provided.

C. The contractor is responsible for installing the chiller in the facility with manufacturer and code

required service clearances for electrical panels, motor service access, compressor removal and

replacement and piping connections on one end.

D. Provide multiple independent refrigerant circuits for operational redundancy.

E. Hail Guards: Provide hail guards to protect all condenser coils.

F. Any chiller submitted for this contract shall meet all the following criteria:

1. Meet or exceed specified capacity at scheduled conditions.

2. Not exceed maximum allowable water pressure loses through chiller at scheduled water

flow rate.

3 . Not exceed maximum allowable sound pressure level, dBA.

4. Not exceed maximum allowable weight in pounds.

5. Not exceed maximum allowable power requirements in MCA and MOCP.

6. Meet or exceed ARI rated efficiency in IPLV.

1.2 DEFINITIONS

A. EER: Energy-efficiency Ratio.

B. IPLV: Integrated part-loaded value at Standard ARI conditions.

C. CCP: Chiller control panel.





1.3 SUBMITTALS

A. Product Data: Include chiller refrigerant; rated capacity; full load and part load efficiencies,

cooler pressure drop, (shipping, installed and operating weights; furnished specialties;

accessories and electrical characteristic with complete wiring diagrams.

1. Provide computer selection data with ARI 550/590-98 certified performance.

2. Statement from manufacturer detailing minimum and maximum ambient outdoor

temperature for safe operation, with continuous operation at load point from 10-100

percent.

a. Air-cooled water chiller shall be designed to operate continuously from 40°F to

110°F entering air temperature with individual compressor operation from 20 to

100 percent load.

3. Product data for each chiller including the following:

a. Refrigerant.

b. Capacity.

c. Cooler pressure drop.

e. Weights (shipping, installed, and operating).

f. Furnished accessories.

g. Installation and startup instructions.

h. ARI Rated IPLV.

B. Shop Drawings: Showing fabrication and installation of chiller, including plans, elevations,

sections, details of components, attachments, and other construction elements. Include the

following:

1. Assembled unit dimensions.

2. Operating weight loadings and distribution.

3. Required clearances for maintenance and operation.

4. Size and location of piping and field wiring connections. The vendor is responsible to

size refrigerant piping and select refrigerant specialties for a complete operating system.

5. Full coordination with EMS Controls Contractor to ensure that controls interface will to

provide Sequence of Operation Specified. Include points list, chiller plant Sequence of

Operation and wiring controls diagram with EMS (DDC) wiring connections.

6. Manufacturer’s installation instructions, including machine and all features, options and

accessories.

7. Full coordination with EMS contractor to provide local area network (LAN) controls

interface to provide Sequence of Operation Specified. Include points list, chiller plant

Sequence of Operation and wiring controls diagram with EMS (DDC) wiring

connections.

C. Wiring Diagrams: Detail wiring for power, signal, and control systems and differentiate


1. Provide Nameplate Data: Full load amps, maximum circuit amps, and maximum over

current protection amps.





F. Product Certificates: Certification of performance, factory tested, according to ARI 550/590-

98, and those chillers has been started and function properly. Provide in accordance with this

Section “Source Quality Control”.

G. Maintenance Data: For each chiller to include in the operation and maintenance manuals.

1. Operating and Maintenance Data.

2. Owner’s instruction report.

3. Test reports.

4. Sound test reports. Sound test per ARI 575-87 at 100%, 75%, 50% and 25% loads.

H. Source quality-control test reports.

I. Startup service reports.

J. Operation and Maintenance Data: For each water chiller to include in emergency, operation

and maintenance manual.

K. Warranties: General, Warranty, and Special warranties specified in this Section.


A. ARI Certification: Signed by manufacturer certifying compliance with requirements in ARI

550/590, “Water Chilling Packages Using the Vapor Compression Cycle.”

1. Evaporator fouling factor: 0.0001.



C. ASHRAE Certification: Signed by manufacturer certifying compliance with ASHRAE 15 for

safety code for mechanical refrigeration that the system is not required to have refrigerant leak

detection and automatic mechanical exhaust controls due to the limited amount of refrigerant in

each individual refrigeration circuit. Comply with ASHRAE Guideline 3 for refrigerant leaks,

recovery, and handling and storage requirements.

D. ASME Compliance: Comply with ASME Boiler and Pressure Vessel Code: Section VIII,

Division 1, "Pressure Vessels," for constructing and testing evaporator and condenser pressure

vessels. Label evaporator and condenser with ASME Label.

E. UL Compliance: Comply with UL 1995.

F. NEC Compliance: Comply with all applicable NFPA 70 requirements for electrical power and

control wiring and components.

G. Chiller shall be capable of capacity reduction to 20 percent of scheduled value without surging.

1. Reduction shall be based on condenser water temperature drop per ARI 550/590-98.

H. Refrigerant: Chiller manufacturer shall meet design criteria with HFC-134a refrigerant.





I. Green Seal Certification: Signed by manufacturer or Green Seal certifying compliance with

Green Seal’s GS-31.

J. ASHRAE Compliance: Conform to ASHRAE 15 for chiller design, construction, leak testing,

and installation.


A. Deliver modular water chiller with protective crating and covering. Ship water chillers from

factory fully charged with refrigerant or nitrogen. If nitrogen, charge chiller by factory

authorized and trained technicians.

B. Store chiller to prevent damage and protect from weather, dirt, fumes, water, and construction

debris in clean dry space.

C. Handle chillers according to manufacturer's written rigging and installation instructions for

unloading, transporting, and setting in final location.

1.6 WARRANTY

A. General: Warranties specified in this Article shall not deprive Owner of other rights Owner

may have under other provisions of the Contract Documents and shall be in addition to, and

run concurrent with, other warranties made by Contractor under requirements of the Contract

Documents.

1. Full Service: Includes all labor and replacement material and labor and service work, and

4-hour mandatory response time upon warranty notification for five (5) years from date

of acceptance.

2. Limited Service: Includes all manufacturer’s defects in materials and workmanship for

parts and labor, and 4 hour mandatory response upon warranty notification for five (5)

years from date of acceptance.

B. Warranty: Include coverage for helical rotary compressors, water-cooled condensers,

refrigerant head pressure control valves, refrigerant metering system, automatic condenser

water blow-down system, digital control systems (including BACnet controller), starter, and

power metering and monitoring, and replacement of refrigerant as manufactured and delivered

to site.

1. Full and limited service: Period of five (5) years from date of acceptance.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with requirements, provide Chiller Option 1, Chiller Option 2, or

approved equal.





1. Basis of Design (Option 1): Trane Model RTAE. (dual HRS Compressor); Stealth Ultra

Low Noise Version.

2. Or Approved Equivalent.

2.2 MANUFACTURED UNIT

A. Description: One factory-assembled, and wired and tested multiple screw air-cooled chiller.

Chiller consists of a minimum of ( independently circuited compressor matching with single

circuit evaporator and air-cooled condensers, factory installed and tested safety controls and

DDC electronic chiller plant control systems.

1. Provide integral disconnect switch to open all ungrounded conductors with lock-out

capability as required per code.

2.3 EQUIPMENT DESCRIPTION

A. Air-Cooled Chiller: Chiller shall incorporate helical rotary screw (HRS) type compressors and

consist of multiple independent refrigerant circuits. Each refrigerant circuit shall consist of an

individual compressor, air-cooled condenser, thermal expansion valve, and control system. The

dual circuit evaporator shall be piped to each refrigerant circuit through the tubes and the

chilled water shall be piped in a common loop through the shell. The circuiting can be reversed

depending on the manufacturer. Each circuit shall be constructed to be independent of other

circuits from a refrigeration and electrical stand-point. The multi-circuit chiller must be able to

produce chilled water even in the event of a failure of one refrigerant circuits.

1. Chiller Modules shall be listed in accordance with UL Standard 465, CSA certified per

Standard C22.2#119, and bear the ASME UM stamp on all heat exchangers.

2. The chiller and evaporator shall ship wired and charged with refrigerant. The chiller shall

be factory run tested prior to shipment.

3. Compressors, heat exchangers, piping and controls shall be mounted on a heavy gauge

steel frame. Electrical controls, contactors, and relays shall be mounted within the unit

control panel.

B. Noise criteria: 63 dBa maximum. Contractor shall be responsible to provide whatever sound

attenuation is needed to achieve 63 dBa sound pressure level at three-feet from unit enclosure

in any direction.

1. Contractor responsible to provide additional sound attenuation (i.e. walls, ceilings,

enclosure, etc.), where noise level exceeds 63 dBa with machine running at full load in

chiller enclosure.

C. Chiller compressors: Industrial grade helical rotary screw (HRS) compressors.

1. Each module shall contain a minimum of two (2) HRS independently circuited and with

internal spring isolation mounted to the module with rubber-in-shear isolators. Each

circuit system shall also include high discharge pressure and low suction pressure manual

reset safety cut-outs.





D. Compressor motor:

1. Hermetic or semi-hermetic refrigerant-cooled helical rotary compressor.

a. Scroll compressor not allowed.

2. Motors:

a. Provide over-temperature winding sensor (one per phase) to prevent burnout.

b. Motor shall be permanent magnet motor design.

c. Compressor motor shall be modulated by matched factory-installed variable

frequency drive.

3. Motor efficiency: Premium Efficiency.

E. Evaporator:

1. Evaporator: The evaporator shall be shell and tube constructed or carbon steel with

copper tubes; designed, tested, and stamped in accordance with ASME code for 300 psig

working pressure on the evaporator and 360 psig working pressure on the condenser.

The evaporator heat exchanger shall be factory mounted on the unit.

2. Refrigeration Specialties: Provide each release, schradder valves, for changing and

maintenance, in addition, provide all filter drivers, receivers, solenoid valve, pressure

sensors, accumulators, thermostatic expansion valve, slide valves for capacity control,

pressure sensors, etc., as required for a complete operating system.

F. Condenser:

1. Provide fin and tube type condenser coils.

2. Condenser shall be designed for use with R-134A.

3. Micro-channel coil condenser coils are not acceptable.

4. Coils shall be factory pressure tested.

2.4 CHILLER CONTROL PANEL (CCP)

A. Chiller Control Panel (CCP) – general:

1. Factory manufactured and installed and wired microcomputer panel.

a. Program and display operating parameters.

b. Protect chiller with integral safety logic from damaging malfunctions.

c. Interface with building automation system as specified.

B. Operating controls:

1. Scheduling of the various compressors shall be performed by a microprocessor based

control system (Chiller Control Panel). A new lead compressor is selected every 24 hours

to assure even distribution of compressor run time.

2. The CCP shall monitor and report the following on each refrigeration system:





a. Discharge Pressure Fault.

b. Suction Pressure Fault.

c. Compressor Temperature

d. Suction Temperature

e. Evaporator Leaving Chilled Water Temp.

3. The CCP shall monitor and report the following system parameters:

a. Chilled Water Entering and Leaving Temperature.

b. Chilled Water and Condenser Water Flow Rate.

c. Condensing Temperature.

d. Evaporator Temperature.

e. Condensing Pressure.

f. Evaporator Pressure.

4. An out of tolerance indication from these controls or sensors shall cause a “fault”

indication at the CCP and shutdown on that compressor with the transfer of load

requirements to the next available compressor. In the case of a System Fault the entire

chiller will be shut down. When a fault occurs, the CCP shall record conditions at the

time of the fault and store the data for recall. This information shall be capable of being

recalled through the keypad of the CCP’s and displayed on the CCP’s 2 line by 40

character back-lit LCD. A history of faults shall be maintained including date and time of

day of each fault (up to the last 20 occurrences).

5. Individual monitoring of leaving chilled water temperatures from each refrigeration

system shall be programmed to protect against freeze-up.

6. The control system shall monitor entering and leaving chilled water temperatures to

determine system load and modulate compressor circuits in sequence as required to

maintain leaving water temperature setpoint (44 deg F, adj.). Response times and set

points shall be adjustable. The system shall provide for variable time between compressor

sequencing and temperature sensing, so as to fine tune the chiller to different existing

building conditions. The CCP shall be equipped with a connection for BACnet

communications with the Energy Management System (EMS).

C. Safety controls: Display complete safety annunciation for each shutdown occurrence including

day, time and reason for shutdown, temperature and pressure.

1. Chiller safety controls system shall be provided with the unit (minimum) as follows:

a. Low evaporator refrigerant pressure.

b. Loss of flow through the evaporator.

c. High condenser refrigerant pressure.

d. High compressor motor temperature.

e. Low suction gas temperature.

f. Low leaving evaporator water temperature.

2. Failure of chiller to start or chiller shutdown due to any of the above safety cutouts shall

be enunciated by display of the appropriate diagnostic description at the unit control

panel. This annunciation will be in plain English. Alphanumeric codes shall be

unacceptable.





3. The chiller shall be furnished with a CCP as an integral portion of the chiller control

circuitry to provide the following functions:

a. Provide automatic chiller shutdown during periods when the load level decreases

below the normal operating requirements of the chiller. Upon an increase in load,

the chiller shall automatically restart.

b. Provisions for connection to automatically enable and disable the chiller from the

Energy Management System (EMS).

c. The control panel shall provide alphanumeric display showing all system

parameters in the English language with numeric data in English units.

4. Normal Chiller Operation

a. When chiller is enabled, the factory supplied CCP modulates the chiller capacity

from minimum to maximum as required by building load.

b. The Chiller control system shall respond to Entering Water Temperature and will

have an integral reset based on entering water temperature to provide for efficient

operation at part-load conditions.

5. Power Phase Monitor

a. Provide a Power Phase Monitor on the incoming power supply to the chiller. This

device shall prevent the chiller from operating during periods when the incoming

power is unsuitable for proper operation.

b. The power phase Monitor shall provide protection against the following

conditions:

1) Low Voltage (Brown-Out)

2) Phase Rotation

3) Loss of Phase

4) Phase Imbalance

6. Current Sensing shall be solid state with electronic three-phase overloads with three

current transformers. The UL 1995 sized electronic motor protection shall monitor and

protect against the following:

a. Three phase overload protection.

b. Start-up overload protection.

c. Short circuit protection.

d. Ground-fault protection.

e. Phase imbalance.

f. Phase Loss.

g. Phase reversal.

h. Under-voltage.

i. Phase-to-phase fault detection.

j. kW transducer for demand monitoring at EMS.

k. Chiller soft start.

D. Interface controls:

1. Remote current limit reset.

2. Remote temperature control reset.





3. Remote start/stop.

4. Energy Management System (EMS):

a. Provide BACnet compatible controller (ASHRAE 135-2000) necessary to interface

directly with building automation system including wiring between interface panel,

chiller control panel and associated sensors.

b. Operating parameters: Provide all functions and information available at the local

chiller panel. The following list is an example of points available with most chiller

panels.

1) Entering and leaving chilled water temperatures.

2) Condenser refrigerant pressure and temperatures.

3) Evaporator refrigerant pressures and temperatures.

4) Oil pressure.

5) Purge pressure.

6) Percent of motor current.

7) Chiller status.

8) Communications between CH-1 and EMS.

9) Chiller enable/disable.

10) Chilled water setpoint.

11) Demand limit setpoint.

c. Safety and cycling shutdowns/warnings: Provide all functions and information

available at the local chiller panel. The following list is an example of points

available with most chiller panels.

1) Low water temperature.

2) Power fault.

3) High compressor discharge refrigerant temperature.

4) High oil temperature.

5) High oil pressure.

6) Low oil pressure.

7) Low evaporator pressure.

8) High condenser pressure.

9) Motor starter failure.

10) Water flow interrupt of evaporator and condenser.

11) Remote stop from EMS.

12) High condenser pressure limit (when in effect).

13) Low evaporator pressure limit (when in effect).

14) Relief disc rupture.

15) Manual and auto reset alarm.

16) Other data points as indicated on the points list.

2.5 ELECTRICAL

A. Chiller CH-1 shall have single point power connections and remote field installed disconnect

switches. The switch shall open all ungrounded conductors. All external inputs and outputs

shall be compatible with the Energy Management System (EMS). Inputs/Outputs include:





1. Remote Start/Stop

2. Cooling Alarm

3. All wiring shall be copper.

4. Provide disconnects, VFD’s, controls and circuiting for chiller auxiliaries including

pumps, heaters, controls, monitors, etc.

5. All components shall withstand and/or interrupt a fault current of 65,000 AMPS.

2.6 REFRIGERANTS

A. Chiller manufacturer shall meet design criteria with HFC-134a refrigerant.

B. Provide full operating charge of refrigerant and oil or oil separator and return system designed

to insure oil is adequately returned to the compressor and does not collect in heat exchangers.

2.7 INSULATION

A. Cold Surfaces: Closed-cell, flexible elastomeric, thermal insulation complying with ASTM C

534, Type II, for sheet materials.

1. Thickness: 1 inch (50 mm).

2. Adhesive: As recommended by insulation manufacturer.

3. Factory apply insulation over entire surfaces of water chiller components.

a. Apply adhesive to 100 percent of insulation contact surface.

b. Seal seams and joints.

c. After adhesive has fully cured, apply two coats of protective coating to insulation.

B. Provide factory insulation to cover all low temperature surfaces with 1 inch insulation. Include

evaporator, water boxes, and suction elbow.

1. Provide insulation for all factory provided field installed accessories.

2.8 ACCESSORIES

A. Differential pressure switch:

1. Adjustable cut-in and cut-out points.

2. 120V rating.

3. 100 mm face.

4. Orange Research Inc., Series 1203 with dial indicator.

B. Low Ambient Refrigerant Head Pressure Control:

1. Integral condenser air flow control dampers to control air flow through the condenser as

required to maintain refrigerant differential pressure through a range of varying entering

outdoor air temperatures.





2.9 WATER HEADERS

A. The evaporator inlet water piping shall incorporate a 30-mesh in-line strainer system to prevent

heat exchanger fouling.

2.10 VIBRATION CONTROL

A. Provide min 6-inch high housekeeping pad with vibration isolator types as referenced in

Chapter 42 of the 1991 ASHRAE “Handbook-Heating, Ventilating, and Air-Conditioning

Applications”:

1. Compressor Vibration Isolators: Rubber mounts (ASHRAE Type 2), minimum

deflection of 0.25 inch.

2. Evaporators: Steel Springs on rubber mounts with snubbers to restrain movement

(ASHRAE Type 4), minimum deflectors 1-inch.

3. Chiller Vibration Isolation: Rubber pads (ASHRAE Type 1), minimum deflection of

0.25-inch.


A. Factory test and rate water chillers, before shipping, according to ARI 550/590, “Water

Chilling Packages Using the Vapor Compression Cycle.” Stamp with ARI label.

B. Factory test heat exchangers hydrostatically at 1.50 times the design pressure.

C. Factory test and inspect evaporator and air-cooled condenser according to ASME Boiler and

Pressure Vessel Code: Section VIII, Division 1. Stamp with ASME label.

D. Factory test and inspect water boxes at 150 percent of working pressure.

E. Rate sound power level according to ARI 575 procedure.

F. Rate sound power level according to ARI 370 procedure.

G. Allow Owner access to places where water chillers are being source quality-control tested.

Notify Engineer 14 days in advance of testing.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Before water chiller installation, examine roughing-in for concrete equipment bases, anchor-

bolt sizes and locations, piping, and electrical to verify actual locations, sizes, and other

conditions affecting water chiller performance, maintenance, and operations.

1. Final water chiller locations indicated on Drawings are approximate. Determine exact

locations before roughing-in for piping and electrical connections.






C. Access and rigging will be restrictive. Examine areas to receive chillers for compliance with

installation tolerances and other conditions affecting performance and maintenance of chillers.

D. Examine proposed route of moving chillers into place and verify in writing with submittal

rigging procedure.

E. Verify piping roughing-in locations.

F. Verify branch circuit wiring suitability. Do not proceed with installation until unsatisfactory

conditions have been corrected.

3.2 INSTALLATION

A. Install chillers according to manufacturer's written instructions.

B. Provide all control and power circuits to control devices and chiller auxiliaries per

manufacturer’s instructions and in accordance with Division 26.

C. Install chillers plumb and level, and anchor. Anchor housekeeping pads to slab on grade.

Anchor chiller, evaporator and vibration isolator pads to outdoor concrete housekeeping pads.

1. Install dowel rods to connect concrete base to concrete floor. Unless otherwise indicated,

install dowel rods on 18-inch (450-mm) centers around the full perimeter of concrete

base.

2. For supported equipment, install epoxy-coated anchor bolts that extend through concrete

base and anchor into structural concrete floor.

3. Place and secure anchorage devices. Use setting drawings, templates, diagrams,

instructions, and directions furnished with items to be embedded.

4. Install anchor bolts to elevations required for proper attachment to supported equipment.

5. Cast-in-place concrete materials and placement requirements are specified in Division 3.

D. Install vibration isolators according to isolator manufacturer's written instructions.

1. Chiller Vibration Isolation: Rubber pads with a minimum deflection of 0.25 inch (6.35

mm).

2. Compressor Vibration Isolation: Rubber mounts with a minimum deflection of 0.25

inches.

E. Maintain manufacturer's recommended clearances for service and maintenance.

F. Install piping connections maintaining clearances for service and maintenance of chillers.

G. Install flange connections at remote evaporator.

H. Install flexible pipe connectors for refrigerant piping and chilled water piping connections.

I. Install shutoff valves at remote evaporator inlet and outlet connections as indicated.





J. Install remote control panel inside mechanical room. Route rigid galvanized steel conduit

between chiller and remote control panel as recommended by manufacturer. Provide all work

including, but not limited to, additional branch circuit wiring, panel installation and

coordination with all trades work at no additional cost to owner.

K. Install and test refrigerant monitoring, control and alarm panel until installation meets the

requirements of the Engineer and local building officials and inspectors.

L. Follow ASHRAE Standard 15 “Safety Code for Mechanical Refrigeration”, latest edition.

1. Extend safety-relief valves or rupture disc discharge piping from chiller and purge to

exterior of chiller enclosure.

M. Charge water chiller with refrigerant if not factory charged.

N. Install separate devices furnished by manufacturer.

3.3 CONNECTIONS

A. Chilled water piping installation requirements are specified in Division 23 Section “Hydronic

Piping.” Drawings indicate general arrangement of piping, fittings, and specialties.

B Install piping adjacent to chiller to allow service and maintenance.

C. Evaporator Connections: Connect inlet to evaporator with controller-bulb well, shutoff valve,

thermometer, strainer, pressure gage, and union or flange. Connect outlet to evaporator with

shutoff valve, flow switch, balancing valve, thermometer, pressure gage, and union or flange.

D Refrigerant Pressure Relief Valve Connections: Extend vent piping to the outside without

valves or restrictions.

E. Ground water chillers according to Division 26 Section “Grounding and Bonding.”

F. Connect wiring according to Division 26 Section “Conductors and Cables.”

G. Ground equipment.

1. Tighten electrical connectors and terminals, including grounding connections, according

to manufacturer's published torque-tightening values. Where manufacturer's torque

values are not indicated, use those specified in UL 486A and UL 486B.

3.4 PIPING SYSTEM FLUSHING PROCEDURE

A. Prior to connecting the chiller to the chilled water loop, the piping loop shall be flushed with a

detergent and hot water (110-130°F) mixture to remove previously accumulated dirt and other

organic. In old piping systems with heavy encrustation of inorganic materials consult a water

treatment specialist for proper passivation and/or removal of these contaminants.





B. During the flushing 30 mesh (max.) Y-strainers (or acceptable equivalent) shall be in place in

the system piping and examined periodically as necessary to remove collected residue. The

flushing process shall take no less than 6 hours or until the strainers, when examined after each

flushing, are clean. Old systems with heavy encrustation shall be flushed for a minimum of 24

hours and may take as long as 48 hours before the filters run clean. Detergent and acid

concentrations shall be used in strict accordance with the respective chemical manufacturer’s

instructions. After flushing with the detergent and/or dilute acid concentrations the system loop

shall be purged with clean water for at least on hour to ensure that all residual cleaning

chemicals have been flushed out.

C. Prior to supplying water to the chiller the Water Treatment Specification shall be consulted for

requirements regarding the water quality during chiller operation. The appropriate chiller

manufacturer’s service literature shall be available to the operator and/or service contractor and

consulted for guidelines concerning preventative maintenance and off-season shutdown

procedures.


A. Manufacturer's Field Service: Provide services of a factory-authorized service representative

to disassemble and reassemble components for installation of chillers, including piping and

electrical connections, and report results in writing.


equipment.

2. Eleven (11) months after start-up the contractor shall return to chiller plant retest and

adjust controls and safeties, replace damaged and malfunctioning controls and equipment.

The contractors shall return and perform this work, upon request by Owners

Representative and/or the Engineer.

3.6 CLEANING

A. Clean equipment and finishes weekly to remove dust and dirt.

B. Touch up scratches in unfinished surfaces weekly to restore corrosion resistance.

C. Touch up scratches in finished surfaces weekly to restore finish.

D. After completing installation, including outlet fittings and devices, inspect unit components.

Remove paint splatters and other spots, dirt, and debris. Repair damaged finish to match

original finish.

3.7 PRE-FUNCTIONAL TESTING AND START-UPS


B. Inspect field-assembled components, equipment installation, and piping and electrical

connections for proper assemblies, installations, and connections.





C. Complete installation and startup checks according to manufacturer's written instructions and

check for the following items:

1. No physical damage to unit.

2. Unit is level.

3. Chiller vibration isolation and flexible pipe connections are installed.

4. Clearances have been maintained and piping is installed for easy removal for service and

tube cleaning.

5. Chilled pipes have been connected to correct ports.

6. Labels and safety instructions are clearly visible.

7. Oil levels are as recommended by manufacturer.

8. Shipping skids, blocks, and straps are removed.

9. Verify that refrigerant charge is sufficient and water chiller has been leak tested.

10. Verify that pumps are installed and functional.

11. Verify that thermometers and gages are installed.

12. Operate water chiller form run-in period according to manufacturer’s written instructions.

13. Check bearing lubrication and oil levels.

14. Verify that refrigerant pressure relief is vented outside.


16. Verify static deflection of vibration isolators, including deflection during water chiller

startup and shutdown.

17. Verify and record performance of chilled water flow and low-temperature interlocks.

18. Verify and record performance of water chiller protection devices.

19. Test and adjust controls and safeties. Replace damaged or malfunctioning controls and

equipment.

D. Prepare a written startup report that records results of tests and inspections.

3.8 DEMONSTRATION

A. Startup Services: Engage a factory-authorized service representative to demonstrate and train

Owner's maintenance personnel as specified below.

1. Train Owner's maintenance personnel on procedures and schedules related to startup,

shutdown, and troubleshooting, servicing, and preventive maintenance.

2. Review data in the operation and maintenance manuals.

3. Schedule training with Owner, through Engineer, with at least 7 days' advance notice.

4. Charging chiller with refrigerant and oil.

5. Leak testing.

6. Start-up service.

7. Provide man-hours as required to work with the Energy Management System (EMS)

contractor to ensure that all monitoring points are available at the operator workstation.

8. Provide the EMS contractor with technical information and onsite assistance until the

EMS contractor has successfully demonstrated the system to the Owner until final punch

list work is completed to the satisfaction of the Engineer.

END OF SECTION




AIR-COOLED VARIABLE SPEED CONDENSOR FAN MULTIPLE SCROLL CHILLER (ALT. B) 236426.2-1

SECTION 236426.2

AIR-COOLED VARIABLE SPEED CONDENSER FAN MULTIPLE SCROLL CHILLER (ALT-B)

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes packaged, air-cooled, variable speed condenser fan electric-motor driven,

dual independent refrigerant circuit, multiple scroll compressors, water chiller with the

following features.

1. Motor Controller (variable speed condenser fans).

2. Microprocessor-based EMS Building controls by Owner’s EMS Vendor.

3. BACNET card shall be included with chiller from factory.

B. The contractor is responsible for fully coordinating with the EMS (DDC) controls contractor

and provide all technical information and data required to ensure that all functions and

sequence of operations specified are provided.

C. The contractor is responsible for installing the chiller in the facility with manufacturer and code

required service clearances for electrical panels, motor service access, compressor removal and

replacement and piping connections on one end.

D. Provide multiple independent refrigerant circuits for operational redundancy.

E. Hail Guards: Provide hail guards to protect all condenser coils.

F. Any chiller submitted for this contract shall meet all the following criteria:

1. Meet or exceed specified capacity at scheduled conditions.

2. Not exceed maximum allowable water pressure loses through chiller at scheduled water

flow rate.

3 Not exceed maximum allowable sound pressure level, dBA.

4. Not exceed maximum allowable weight in pounds.

5. Not exceed maximum allowable power requirements in MCA and MOCP.

6. Meet or exceed ARI rated efficiency in IPLV.

1.2 DEFINITIONS

A. EER: Energy-efficiency Ratio.

B. IPLV: Integrated part-loaded value at Standard ARI conditions.

C. CCP: Chiller control panel.





1.3 SUBMITTALS

A. Product Data: Include chiller refrigerant; rated capacity; full load and part load efficiencies,

cooler pressure drop, (shipping, installed and operating weights; furnished specialties;

accessories and electrical characteristic with complete wiring diagrams.

1. Provide computer selection data with ARI 550/590-98 certified performance.

2. Statement from manufacturer detailing minimum and maximum ambient outdoor

temperature for safe operation, with continuous operation at load point from 14-100

percent.

a. Air-cooled water chiller shall be designed to operate continuously from 32°F to

125°F entering air temperature.

3. Product data for each chiller including the following:

a. Refrigerant.

b. Capacity.

c. Cooler pressure drop.

e. Weights (shipping, installed, and operating).

f. Furnished accessories.

g. Installation and startup instructions.

B. Shop Drawings: Showing fabrication and installation of chiller, including plans, elevations,

sections, details of components, attachments, and other construction elements. Include the

following:

1. Assembled unit dimensions.

2. Operating weight loadings and distribution.

3. Required clearances for maintenance and operation.

4. Size and location of piping and field wiring connections. The vendor is responsible to

size refrigerant piping and select refrigerant specialties for a complete operating system.

5. Full coordination with EMS Controls Contractor to ensure that controls interface will to

provide Sequence of Operation Specified. Include points list, chiller plant Sequence of

Operation and wiring controls diagram with EMS (DDC) wiring connections.

6. Manufacturer’s installation instructions, including machine and all features, options and

accessories.

7. Full coordination with EMS contractor to provide local area network (LAN) controls

interface to provide Sequence of Operation Specified. Include points list, chiller plant

Sequence of Operation and wiring controls diagram with EMS (DDC) wiring

connections.

C. Wiring Diagrams: Detail wiring for power, signal, and control systems and differentiate


1. Provide Nameplate Data: Full load amps, maximum circuit amps, and maximum over

current protection amps.





D. Product Certificates: Certification of performance, according to ARI 550/590-98. Start and

functionally test chillers at the factory before shipment. Provide in accordance with this

Section “Source Quality Control”.

E. Maintenance Data: For each chiller to include in the operation and maintenance manuals.

1. Operating and Maintenance Data.

2. Owner’s instruction report.

3. Test reports.

F. Source quality-control test reports.

G. Startup service reports.

H. Operation and Maintenance Data: For each water chiller to include in emergency, operation

and maintenance manual.

I. Warranties: General, Warranty, and Special warranties specified in this Section.


A. ARI Certification: Signed by manufacturer certifying compliance with requirements in ARI

550/590, “Water Chilling Packages Using the Vapor Compression Cycle.”

1. Evaporator fouling factor: 0.0001.



C. ASME Compliance: Comply with ASME Boiler and Pressure Vessel Code: Section VIII,

Division 1, "Pressure Vessels," for constructing and testing evaporator and condenser pressure

vessels. Label evaporator and condenser with ASME Label.

D. UL Compliance: Comply with UL 1995.

E. NEC Compliance: Comply with all applicable NFPA 70 requirements for electrical power and

control wiring and components.

F. Refrigerant: Chiller manufacturer shall meet design criteria with HFC-134a refrigerant.

G. ASHRAE Compliance: Conform to ASHRAE 15 for chiller design, construction, leak testing,

and installation.


A. Deliver water chiller with protective and covering. Ship water chillers from factory fully

charged with refrigerant or nitrogen. If nitrogen, charge chiller by factory authorized and

trained technicians.





B. Store chiller to prevent damage and protect from weather, dirt, fumes, water, and construction

debris in clean, dry space.

C. Handle chillers according to manufacturer's written rigging and installation instructions for

unloading, transporting, and setting in final location.

1.6 WARRANTY

A. General: Warranties specified in this Article shall not deprive Owner of other rights Owner

may have under other provisions of the Contract Documents and shall be in addition to, and

run concurrent with, other warranties made by Contractor under requirements of the Contract

Documents.

1. Full Service: Includes all labor and replacement material and labor and service work, and

4-hour mandatory response time upon warranty notification for five (5) years from date

of acceptance.

2. Limited Service: Includes all manufacturer’s defects in materials and workmanship for

parts and labor, and 4 hour mandatory response upon warranty notification for five (5)

years from date of acceptance.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with requirements, provide chiller Option B by one of the following, or

Provide Chiller Option A on the Bid Form..

1. Basis of Design: Carrier, Model 30RB (single point power only).

2. Or approved equal.

2.2 MANUFACTURED UNIT

A. Description: One microprocessor controlled, air-cooled liquid chiller for outdoor installation,

utilizing scroll compressors and low sound fans controlled with variable speed fan drive

motors. Chiller software shall be specifically developed to coordinate optimal fan speed for

application conditions and provide refrigerant circuit optimization, resulting in higher part-load

efficiency and reduced acoustic levels.

1. Provide integral disconnect switch to open all ungrounded conductors with lock-out

capability as required per code.

2.3 EQUIPMENT DESCRIPTION

A. Air-Cooled Chiller: Chiller shall incorporate scroll type compressors and consist of multiple

independent refrigerant circuits. Each refrigerant circuit shall consist of scroll compressor (s),





air-cooled condenser, thermal expansion valve, and control system. The dual circuit evaporator

shall be piped to each refrigerant circuit through the tubes and the chilled water shall be piped

in a common loop through the shell. The circuiting can be reversed depending on the

manufacturer. Each circuit shall be constructed to be independent of other circuits from a

refrigeration and electrical stand-point. The multi-circuit chiller must be able to produce chilled

water even in the event of a failure of one refrigerant circuit.

1. The chiller and evaporator shall ship wired and charged with refrigerant. The chiller shall

be factory run tested prior to shipment.

2. Compressors, heat exchangers, piping and controls shall be mounted on a heavy gauge

steel frame. Electrical controls, contactors, and relays shall be mounted within the unit

control panel.

B. Noise criteria: 73 dBa maximum. Contractor shall be responsible to provide whatever sound

attenuation is needed to achieve 73 dBa sound pressure level at three-feet from unit enclosure

in any direction.

1. Contractor responsible to provide additional sound attenuation (i.e. walls, ceilings,

enclosure, etc.), where noise level exceeds 73 dBa with machine running at full load in

chiller enclosure.

C. Chiller compressors:

1. Fully hermetic scroll type compressors.

2. Direct drive, 3500 rpm (60 Hz), protected by motor temperature sensors, suction gas

cooled motor.

3. External vibration isolation rubber-in-shear.

4. Each compressor shall be equipped with crankcase heaters to minimize oil dilution.

D. Evaporator:

1. Shall-and-tube type, direct expansion.

2. Tubes shall be internally enhanced seamless-copper type rolled into tube sheets.

3. Shall be equipped with Victaulic-type water connections.

4. Shell shall be insulated with ¾-in. (19-mm) PVC foam (closed-cell) with a maximum K

factor of 0.28.

5. Design shall incorporate a minimum of 2 independent direct-expansion refrigerant

circuits.

6. Cooler shall be tested and stamped in accordance with ASME Code for a refrigerant

working side pressure of 445 psig (3068 kPa). Cooler shall have a maximum water-side

pressure of 300 psig (2068 kPa)

7. Cooler shall be provided with a factory-installed flow switch.

8. Refrigeration Components: Refrigerant circuit components shall include replaceable-core

filter drier, moisture indicating sight glass, electronic expansion device, discharge service

valve and liquid line service valves, and complete operating charge of both refrigerant R-

410A and compressor oil.

E. Condenser:





1. Coil shall be air-cooled Novation® heat exchanger technology with microchannel

(MCHX) coils and shall have a series of flat tubes containing a series of multiple, parallel

flow microchannels layered between the refrigerant manifolds. Coils shall consist of a

two-pass arrangement. Coil construction shall consist of aluminum alloys for fins, tubes,

and manifolds in combination with a corrosion-resistant coating.

2. Tubes shall be cleaned, dehydrated, and sealed.

3. Assembled condenser coils shall be leak tested and pressure tested at 656 psig (4522

kPa).

2.4 CHILLER CONTROL PANEL (CCP)

A. Chiller Control Panel (CCP) – general:

1. Factory manufactured and installed and wired microcomputer panel.

a. Program and display operating parameters.

b. Protect chiller with integral safety logic from damaging malfunctions.

c. Interface with building automation system as specified.

B. Operating controls:

1. Scheduling of the various compressors shall be performed by a microprocessor based

control system (Chiller Control Panel). A new lead compressor is selected every 24 hours

to assure even distribution of compressor run time.

2. The CCP shall monitor and report the following on each refrigeration system:

a. Discharge Pressure Fault.

b. Suction Pressure Fault.

c. Compressor Temperature

d. Suction Temperature

e. Evaporator Leaving Chilled Water Temp.

3. The CCP shall monitor and report the following system parameters:

a. Chilled Water Entering and Leaving Temperature.

b. Chilled Water and Condenser Water Flow Rate.

c. Condensing Temperature.

d. Evaporator Temperature.

e. Condensing Pressure.

f. Evaporator Pressure.

4. An out of tolerance indication from these controls or sensors shall cause a “fault”

indication at the CCP and shutdown on that compressor with the transfer of load

requirements to the next available compressor. In the case of a System Fault the entire

chiller will be shut down. When a fault occurs, the CCP shall record conditions at the

time of the fault and store the data for recall. This information shall be capable of being

recalled through the keypad of the CCP’s and displayed on the CCP’s 2 line by 40





character back-lit LCD. A history of faults shall be maintained including date and time of

day of each fault (up to the last 20 occurrences).

5. Individual monitoring of leaving chilled water temperatures from each refrigeration

system shall be programmed to protect against freeze-up.

6. The control system shall monitor entering and leaving chilled water temperatures to

determine system load and modulate compressor circuits in sequence as required to

maintain leaving water temperature setpoint (44 deg F, adj.). Response times and set

points shall be adjustable. The system shall provide for variable time between compressor

sequencing and temperature sensing, so as to fine tune the chiller to different existing

building conditions. The CCP shall be equipped with a connection for BACnet

communications with the Energy Management System (EMS).

C. Safety controls: Display complete safety annunciation for each shutdown occurrence including

day, time and reason for shutdown, temperature and pressure.

1. Chiller safety controls system shall be provided with the unit (minimum) as follows:

a. Low evaporator refrigerant pressure.

b. Loss of flow through the evaporator.

c. High condenser refrigerant pressure.

d. High compressor motor temperature.

e. Low suction gas temperature.

f. Low leaving evaporator water temperature.

2. Failure of chiller to start or chiller shutdown due to any of the above safety cutouts shall

be enunciated by display of the appropriate diagnostic description at the unit control

panel. This annunciation will be in plain English. Alphanumeric codes shall be

unacceptable.

3. The chiller shall be furnished with a CCP as an integral portion of the chiller control

circuitry to provide the following functions:

a. Provide automatic chiller shutdown during periods when the load level decreases

below the normal operating requirements of the chiller. Upon an increase in load,

the chiller shall automatically restart.

b. Provisions for connection to automatically enable the chiller from the Energy

Management System (EMS).

c. The control panel shall provide alphanumeric display showing all system

parameters in the English language with numeric data in English units.

4. Normal Chiller Operation

a. When chiller is enabled, the factory supplied CCP modulates the chiller capacity

from minimum to maximum as required by building load.

b. The Chiller control system shall respond to Entering Water Temperature and will

have an integral reset based on entering water temperature to provide for efficient

operation at part-load conditions.

5. Power Phase Monitor





a. Provide a Power Phase Monitor on the incoming power supply to the chiller. This

device shall prevent the chiller from operating during periods when the incoming

power is unsuitable for proper operation.

b. The power phase Monitor shall provide protection against the following

conditions:

1) Low Voltage (Brown-Out)

2) Phase Rotation

3) Loss of Phase

4) Phase Imbalance

6. Current Sensing shall be solid state with electronic three-phase overloads with three

current transformers. The UL 1995 sized electronic motor protection shall monitor and

protect against the following:

a. Three phase overload protection.

b. Start-up overload protection.

c. Short circuit protection.

d. Ground-fault protection.

e. Phase imbalance.

f. Phase Loss.

g. Phase reversal.

h. Under-voltage.

i. Phase-to-phase fault detection.

j. kW transducer for demand monitoring at EMS.

k. Chiller soft start.

D. Interface controls:

1. Remote current limit reset.

2. Remote temperature control reset.

3. Remote start/stop.

4. Energy Management System (EMS):

a. Provide BACnet compatible controller (ASHRAE 135-2000) necessary to interface

directly with building automation system including wiring between interface panel,

chiller control panel and associated sensors.

b. Operating parameters: Provide all functions and information available at the local

chiller panel. The following list is an example of points available with most chiller

panels.

1) Entering and leaving chilled water temperatures.

2) Condenser refrigerant pressure and temperatures.

3) Evaporator refrigerant pressures and temperatures.

4) Oil pressure.

5) Purge pressure.

6) Percent of motor current.

7) Chiller status.

8) Communications between CH-1 and EMS.

9) Chiller enable/disable.

10) Chilled water setpoint.





11) Demand limit setpoint.

c. Safety and cycling shutdowns/warnings: Provide all functions and information

available at the local chiller panel. The following list is an example of points

available with most chiller panels.

1) Low water temperature.

2) Power fault.

3) High compressor discharge refrigerant temperature.

4) High oil temperature.

5) High oil pressure.

6) Low oil pressure.

7) Low evaporator pressure.

8) High condenser pressure.

9) Motor starter failure.

10) Water flow interrupt of evaporator and condenser.

11) Remote stop from EMS.

12) High condenser pressure limit (when in effect).

13) Low evaporator pressure limit (when in effect).

14) Relief disc rupture.

15) Manual and auto reset alarm.

16) Other data points as indicated on the points list.

2.5 ELECTRICAL

A. Chiller CH-1 shall have single point power connections and remote field installed disconnect

switches. The switch shall open all ungrounded conductors. All external inputs and outputs

shall be compatible with the Energy Management System (EMS). Inputs/Outputs include:

1. Remote Start/Stop

2. Cooling Alarm

3. All wiring shall be copper.

4. Provide disconnects, VFD’s, controls and circuiting for chiller auxiliaries including

pumps, heaters, controls, monitors, etc.

5. All components shall withstand and/or interrupt a fault current of 65,000 AMPS.

2.6 REFRIGERANTS

A. Chiller manufacturer shall meet design criteria with HFC-410A refrigerant.

B. Provide full operating charge of refrigerant and oil or oil separator and return system designed

to insure oil is adequately returned to the compressor and does not collect in heat exchangers.

2.7 INSULATION

A. Cold Surfaces: Closed-cell, flexible elastomeric, thermal insulation complying with ASTM C

534, Type II, for sheet materials.





1. Thickness: 3/4 inch (19 mm).

2. Adhesive: As recommended by insulation manufacturer.

B. Provide factory insulation to cover all low temperature surfaces with 3/4 inch insulation.

Include evaporator, water boxes, and suction line.

2.8 ACCESSORIES

A. High-efficiency variable condenser fans: All fans on the unit shall have variable speed fan

motors to provide higher part load efficiency and reduced acoustic levels. Each fan circuit shall

have a factory-installed, independent variable speed drive with display. Variable speed drives

are rated IP-55 enclosures and UL Listed. The use of this option, with the addition of antifreeze

in the cooler circuit and wind baffles, shall allow running with outdoor ambient temperatures

down to –20 F (–28.9 C).

B. Minimum Load Control: Unit shall be equipped with factory (or field) installed,

microprocessor-controlled, minimum load control that shall permit unit operation down to a

minimum of 6% capacity (varies with unit size). This option/accessory is not available on

applications with leaving fluid temperature less than 38 F (3.3 C).

C. Condenser Coil Trim Panels: Unit shall be supplied with factory-installed coil covers to protect

the condenser coil from physical damage.

D. BACnet Communication: Shall provide pre-programmed factory-installed communication

capability with a BACnet MS/TP network. Allows integration with i-Vu® Open control system

or a third-party BACnet building automation system.

E. Compressor Suction Service Valve: Standard refrigerant discharge isolation and liquid valves

shall enable service personnel to store the refrigerant charge in the cooler or condenser during

servicing. This factory-installed option (one valve per refrigerant circuit) shall allow for further

isolation of the compressor from the cooler vessel.

F. Suction Line Insulation: Insulation shall be tubular closed-cell insulation. This option shall be

required on applications with leaving fluid temperatures below 30 F (–1.1 C) and

recommended for areas of high dewpoints where condensation may be a concern.

G. Freeze Protection Cooler Heaters: Cooler heaters shall provide protection from cooler freeze-

up to –20 F (–29 C).

H. Compressor Sound Reduction: Shall provide sound reduction for the scroll compressors. Unit

shall be equipped with factory-installed compressor sound reduction enclosure which provides

an enclosure to encase each compressor that is covered with an acoustic blanket.

2.9 WATER HEADERS

A. The evaporator inlet water piping shall incorporate a 30-mesh in-line strainer system to prevent

heat exchanger fouling.





2.10 VIBRATION CONTROL

A. Provide galvanized steel support platform. Provide associated water-proofing and roofing as

necessary to maintain the existing roof warranty. Refer to Division 7 for Roofing and other

applicable requirements.

1. Chiller Vibration Isolation: ASHRAE Type 4 restrained spring isolation minimum

deflection of 1.0 inch (24.5 mm).

2. Compressor Vibration Isolation: Rubber mounts with a minimum deflection of 0.25

inches internally isolated.


A. Factory run test water chillers before shipping. Stamp with ARI label.

B. Factory test heat exchangers hydrostatically at 1.50 times the design pressure.

C. Factory test and inspect evaporator and air-cooled condenser according to ASME Boiler and

Pressure Vessel Code: Section VIII, Division 1. Stamp with ASME label.

D. Factory test and inspect water boxes at 150 percent of working pressure.

E. Rate sound power level according to ARI 575 procedure.

F. Rate sound power level according to ARI 370 procedure.

G. Allow Owner access to places where water chillers are being source quality-control tested.

Notify Engineer 14 days in advance of testing.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Before water chiller installation, examine roughing-in for concrete equipment bases, anchor-

bolt sizes and locations, piping, and electrical to verify actual locations, sizes, and other

conditions affecting water chiller performance, maintenance, and operations.

1. Final water chiller locations indicated on Drawings are approximate. Determine exact

locations before roughing-in for piping and electrical connections.


C. Access and rigging will be restrictive. Examine areas to receive chillers for compliance with

installation tolerances and other conditions affecting performance and maintenance of chillers.

D. Examine proposed route of moving chillers into place and verify in writing with submittal

rigging procedure.





E. Verify piping roughing-in locations.

F. Verify branch circuit wiring suitability. Do not proceed with installation until unsatisfactory

conditions have been corrected.

3.2 INSTALLATION

A. Install chillers according to manufacturer's written instructions.

B. Provide all control and power circuits to control devices and chiller auxiliaries per

manufacturer’s instructions and in accordance with Division 26.

C. Install chillers plumb and level, and anchor. Anchor air-cooled chiller to outdoor structural

steel support platform.

1. Bolt chiller to steel framing securely.

D. Maintain manufacturer's recommended clearances for service and maintenance.

E. Install piping connections maintaining clearances for service and maintenance of chillers.

F. Install flange connections at remote evaporator.

G. Install flexible pipe connectors for refrigerant piping and chilled water piping connections.

H. Install shutoff valves at remote evaporator inlet and outlet connections as indicated.

I. Install remote control panel inside mechanical room. Route rigid galvanized steel conduit

between chiller and remote control panel as recommended by manufacturer. Provide all work

including, but not limited to, additional branch circuit wiring, panel installation and

coordination with all trades work at no additional cost to owner.

J. Install and test refrigerant monitoring, control and alarm panel until installation meets the

requirements of the Engineer and local building officials and inspectors.

K. Follow ASHRAE Standard 15 “Safety Code for Mechanical Refrigeration”, latest edition.

1. Extend safety-relief valves or rupture disc discharge piping from chiller and purge to

exterior of chiller enclosure.

L. Charge water chiller with refrigerant if not factory charged.

M. Install separate devices furnished by manufacturer.

3.3 CONNECTIONS

A. Chilled water piping installation requirements are specified in Division 23 Section “Hydronic

Piping.” Drawings indicate general arrangement of piping, fittings, and specialties.

B Install piping adjacent to chiller to allow service and maintenance.





C. Evaporator Connections: Connect inlet to evaporator with controller-bulb well, shutoff valve,

thermometer, strainer, pressure gage, and union or flange. Connect outlet to evaporator with

shutoff valve, flow switch, balancing valve, thermometer, pressure gage, and union or flange.

D Refrigerant Pressure Relief Valve Connections: Extend vent piping to the outside without

valves or restrictions.

E. Ground water chillers according to Division 26 Section “Grounding and Bonding.”

F. Connect wiring according to Division 26 Section “Conductors and Cables.”

G. Ground equipment.

1. Tighten electrical connectors and terminals, including grounding connections, according

to manufacturer's published torque-tightening values. Where manufacturer's torque

values are not indicated, use those specified in UL 486A and UL 486B.


A. Manufacturer's Field Service: Provide services of a factory-authorized service representative

to assemble components for installation of chillers, including piping and electrical connections,

and report results in writing.


equipment.

2. Eleven (11) months after start-up the contractor shall return to chiller plant retest and

adjust controls and safeties, replace damaged and malfunctioning controls and equipment.

The contractors shall return and perform this work, upon request by FCPS Representative

and/or the Engineer.

3.5 CLEANING

A. Clean equipment and finishes weekly to remove dust and dirt.

B. Touch up scratches in unfinished surfaces weekly to restore corrosion resistance.

C. Touch up scratches in finished surfaces weekly to restore finish.

D. After completing installation, including outlet fittings and devices, inspect unit components.

Remove paint splatters and other spots, dirt, and debris. Repair damaged finish to match

original finish.

3.6 PRE-FUNCTIONAL TESTING AND START-UPS






B. Inspect field-assembled components, equipment installation, and piping and electrical

connections for proper assemblies, installations, and connections.

C. Complete installation and startup checks according to manufacturer's written instructions and

check for the following items:

1. No physical damage to unit.

2. Unit is level.

3. Chiller vibration isolation and flexible pipe connections are installed.

4. Clearances have been maintained and piping is installed for easy removal for service and

tube cleaning.

5. Chilled pipes have been connected to correct ports.

6. Labels and safety instructions are clearly visible.

7. Oil levels are as recommended by manufacturer.

8. Shipping skids, blocks, and straps are removed.

9. Verify that refrigerant charge is sufficient and water chiller has been leak tested.

10. Verify that pumps are installed and functional.

11. Verify that thermometers and gages are installed.

12. Operate water chiller form run-in period according to manufacturer’s written instructions.

13. Check bearing lubrication and oil levels.

14. Verify that refrigerant pressure relief is vented outside.


16. Verify static deflection of vibration isolators, including deflection during water chiller

startup and shutdown.

17. Verify and record performance of chilled water flow and low-temperature interlocks.

18. Verify and record performance of water chiller protection devices.

19. Test and adjust controls and safeties. Replace damaged or malfunctioning controls and

equipment.

D. Prepare a written startup report that records results of tests and inspections.

E. Occupancy Adjustments: When requested within 12 months of date Substantial Completion,

provide on-site assistance in adjusting system to suit actual occupied conditions. Provide up to

two visits to site outside normal occupancy hours for this purpose.

3.7 DEMONSTRATION

A. Startup Services: Engage a factory-authorized service representative to demonstrate and train

Owner's maintenance personnel as specified below.

1. Train Owner's maintenance personnel on procedures and schedules related to startup,

shutdown, and troubleshooting, servicing, and preventive maintenance.

2. Review data in the operation and maintenance manuals.

3. Schedule training with Owner, through Engineer, with at least 7 days' advance notice.

4. Charging chiller with refrigerant and oil.

5. Leak testing.

6. Start-up service.

7. Provide man-hours as required to work with the Energy Management System (EMS)

contractor to ensure that all monitoring points are available at the operator workstation.





8. Provide the EMS contractor with technical information and onsite assistance until the

EMS contractor has successfully demonstrated the system to the Owner until final punch

list work is completed to the satisfaction of the Engineer.

9. Contractor shall provide all materials and labor necessary to demonstrate system

operation to Owner/Engineer. The contractor shall repeatedly make site visits,

demonstrate and make revisions to system at their own expense until all systems are

accepted by the Owner and Engineer.

END OF SECTION




GENERAL ELECTRICAL REQUIREMENTS 260100 - 1

SECTION 260100

GENERAL ELECTRICAL REQUIREMENTS

PART 1 - GENERAL

1.1 SPECIAL ELECTRICAL REQUIREMENTS

A. Drawing use and interpretation:

1. Drawings are diagrammatic and indicate general arrangement of systems and

equipment, except when specifically dimensioned or detailed.

2. For locations of building elements, refer to structural, mechanical and electrical

drawings.

3. Field measurements take precedence over drawings.

4. Electrical plans are intended to indicate size, capacity, approximate location, direction

and general relationship of the work, but not exact detail or arrangement. The

contractor is responsible for indicating detailed arrangements for procured equipment

and layouts on all shop drawings required in all Div. 26 Specifications.

5. Field verify locations and arrangement of existing systems and equipment.

6. The design engineer b2E will submit the plans to Fauquier County Department of

Community Development for approval. The Contractor will obtain the permit and pay

permit fees, and shall include the cost of permits and inspections in the bid price.

7. Areas will be made available to the Contractor as shown in the project manual. Days

and times for access and vehicle/equipment travel on site must be approved in advance

by FCPS. All equipment and materials must be appropriately marked off and

barricaded and attended when in use so as to present no hazard to the public at any

time.

8. The Contractor must at no time create any hazard to any member of the public or to

any property.

9. When school is in session, the contractor may not block any walking or vehicle

pathways, except temporarily and with specific advance approval by FCPS.

10. The contractor must protect all existing facilities and repair at no additional cost to the

Owner any damage caused by the contractor.

11. The Contractor is responsible to remove the existing chiller; neither the Owner nor the

Engineer are prescribing means and methods. The contractor may disassemble the

chiller, or may remove part of the existing building structure and replace/repair the

structure to the equivalent of its pre-existing condition, or may use other method

within the conditions of the contract. The contractor may remove part of the existing

MER wall and restore it to equivalent of pre-existing condition. These are suggestions

only, neither the Owner nor the Engineer are prescribing particular means and

methods. The contractor is responsible to survey the site and bid the project

accordingly.

12. The contract award will be based on either design alternative A or alternative B,

whichever serves in the Owner’s best interest, based upon first cost, estimated energy

cost, and project budget. The Owner will indicate which method of bid evaluation was

utilized to reach final award.





B. Installation of systems and equipment:

1. Installation is subject to clarification as indicated in reviewed Shop and Field

Coordination Drawings.

a. Generally, lay out piping requiring gravity drainage first; then lay out large pipe

mains, ductwork and electrical conduit.

b. This procedure is intended to promote orderly installation, but not to establish

trade precedence.

c. Dimensions indicated are limiting dimensions.

d. Do not use equipment exceeding dimensions required by manufacturer for

service access, and applicable codes reduce required clearances.

e. In electrical equipment room corridors and aisle ways, maintain clear head room

between floor and underside of conduit, switches, controllers, panelboards,

transformers and equipment to allow for future replacing of equipment and

major components.

f. Coordinate connections to all equipment, and penetrations of conduit through

floors, walls and roof with actual field conditions and dimensions. Contractors

shall thoroughly familiarize themselves with the project requirements prior to

submitting bid price.

g. Measure and coordinate the connections and the installations between trades

prior to submitting shop drawings.

h. Under no circumstances shall any electrical equipment be hung, supported or

suspended from the building suspended ceilings. Ductwork, piping, etc., shall

be hung directly from the building structure (i.e. steel bar joist or truss system).

i. Crane lifts, hot work, and work which transmits disruptive noise into the

occupied areas of the school must be not be performed between 6:30 a.m. and

5:00 p.m. on days when school is in session. School is not in session weekends,

December 21, 2015 through January 1, 2016, January 18, 2016, and February

15, 2016.

1.2 SUMMARY


1. Raceways.

2. Building wire and connectors.

3. Supporting devices for electrical components.

4. Electrical identification.

5. Concrete equipment bases.

6. Electrical demolition.

7. Cutting and patching for electrical construction.

8. Touchup painting.

9. Misc. Electrical Equipment Connectors.

10. Chiller: Evaporator Heater Connection (Freeze Protection)





1.3 DEFINITIONS

A. RMC: Rigid metal conduit.

B. EMT: Electrical metallic tubing.

C. FMC: Flexible metal conduit.

D. IMC: Intermediate metal conduit.

E. LFMC: Liquid tight flexible metal conduit.

F. Scheduled: As scheduled on drawing equipment schedules or as called out by model

number/designation in the specification.

G. Acceptance: With respect to initiation of warranty, the date when the Engineer signs the

Contractor’s Application for Final Payment for release of retainage.

H. EMS: Energy Management System.

J. Notice-to-Proceed: The date, which the building owner or authorized agent authorizes

Notice–to-Proceed by Letter.

K. Scheduled: As scheduled on drawing equipment schedules or as called-out by

manufacturer/model number/designation in the specification.

N. Basis of Design: Equipment specifically designated with the term “Basis of Design” as

indicated in the specifications or as scheduled on drawings.

1. The Contractor shall provide the “Basis of Design” or one of the “Acceptable

Manufacturers” listed in the specification. Where “Acceptable Manufacturer’s”

equipment other than the “Basis of Design” is provided, the contractor is responsible

to fully coordinate and provide design changes to structural steel, electrical power to

match nameplate data, controls, ductwork connections, piping connections, unit

efficiency, compatibility with controls, for a complete operating system in

accordance with the plans and specifications.

1.4 SUBMITTALS

A. Shop Drawings: Dimensioned plans and sections or elevation layouts of electricity-

metering equipment.

1. Locations of any ceiling or wall mounted access doors required to access serviceable

equipment.

B. Field Test Reports: Indicate and interpret test results for compliance with performance

requirements.






A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in

NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction,

and marked for intended use.

B. Equipment Selection: Mechanical equipment by “Acceptable Manufacturer” of higher

electrical characteristics other than as indicated as “Basis of Design” on drawings may be

furnished provided electrical services, circuit breakers, conduit, starters, adjustable

frequency drives, panelboards, motor control cabinets are increased. The contractor is

responsible to coordinate between trades prior to submitting bid price. Additional costs to

the Owner shall not be considered for such modifications, and shall remain the

responsibility of the contractor.

C. Perform work in accordance with the following codes:

1. State and local building electrical and fire alarm codes.

2. National Electric Code (NFPA 70).

3. National Fire Alarm Code (NFAP 72).

4. National Fire Protection Association (Applicable Codes).

5. Underwriter Laboratories (Comply with or exceed all provisions of specific equipment

listings or classifications).

6. National Electrical Manufacturers Association (NEMA).

7. Virginia Uniform Statewide Building Code (latest amendments).

8. Fire alarm testing criteria as may published by the Chief Fire Code Inspector for

Fauquier County, Virginia.

9. ASHRAE Energy Code – 90.1 - 2010.

D. Conductors: All equipment, branch circuit wiring, bus, lugs terminations, connectors, etc.

shall be copper (98 percent conductivity). Use of aluminum is not permitted conducting

materials shall be copper only. This includes but is not limited to all panels, disconnects,

enclosed breakers, lugs, splices, terminals, etc.

1.6 DELIVERY, STORAGE AND HANDLING

A. Deliver conduit with factory-applied end caps. Maintain end caps through shipping,

storage, and handling to prevent conduit end damage and prevent entrance of dirt, debris,

and moisture.

B. Protect stored conduit from moisture and dirt. Elevate above grade. Do not exceed

structural capacity of floor or roof, if stored inside or on the roof.

1. Do not store heavy equipment or materials inside or on the roof.

C. Protect couplings, fittings and specialties from moisture and dirt.

D. Provide covering and shielding for equipment to protect from damage.

E. Protect existing building and building components.





F. Repair, restore, and replace damaged existing and new building components and

equipment.

G. Protect nameplates on electrical panelboards, motor controllers, control centers,

transformers, circuit breakers and other equipment.

1.7 SEQUENCING AND SCHEDULING

A. Coordinate electrical equipment installation with other building components.

B. Arrange for conduit spaces, chases, slots, and openings in existing building structure and

shaft during progress of construction to allow for electrical installations.

C. Coordinate installation of required supporting devices and set sleeves in poured-in-place

concrete and other structural components, as they are constructed.

D. Sequence, coordinate, and integrate installations of electrical materials and equipment for

efficient flow of the Work. Coordinate installation of large equipment requiring

positioning, re-assembly before closing in chiller room, electric room, shaft, etc.

E. Coordinate lifting and rigging and connection of electrical systems with exterior

underground and overhead utilities and services. Comply with requirements of governing

regulations, franchised service companies, and controlling agencies for setting or moving

large equipment. Perform work in accordance with all applicable codes and local

authorities having jurisdiction and obtain and pay for all permits and other costs.

F. Coordinate requirements for access panels and doors if electrical items requiring access are


G. Coordinate installation of identifying devices and panel schedules after completing

covering and painting, if devices are applied to surfaces. Install identifying devices before

installing acoustical ceilings and similar concealment.

H. Coordinate lifting and rigging and connection of electrical systems with interior space

limitations and finishes. Remove and replace as necessary existing architectural,

mechanical, electrical, plumbing, etc., building components as required to install large

and/or heavy equipment.

1.8 JOB CONDITIONS

A. Cause as little interference or interruption of existing utilities and services as possible.

1. Schedule work which will cause interference or interruption in advance with Owner

Authorities having jurisdiction, and affected contractors.

B. Keep roads clear of materials and debris.

C. Examine Contract Documents to determine how other work will affect execution of

electrical work.





D. Examine site and become familiar with existing local conditions affecting work.

E. Determine and verify locations of existing conduit and equipment in building where work

is being performed.

F. Make arrangements and pay for necessary permits, licenses, and inspections.

G. Record drawings:

1. Keep a complete set of electrical drawings in job site office for indicating actual

installation of electrical systems and equipment.

2. Use this set of drawings for no other purpose.

3. Where material, equipment, or systems components are installed differently from that

indicated, show such differences clearly and neatly.

4. At project completion, submit record set of drawings.

1.9 SUBSTANTIAL COMPLETION AND ACCEPTANCE

A. Acceptance: The electrical and fire alarm systems shall not be Accepted by the Owner and

Engineer until all systems are installed, fully operational, and systems demonstrations for

HVAC systems and low voltage electrical systems are completed, the mechanical systems

are completed and the EMS is completed and fully functional to the satisfaction of the

Owner.

1.10 THREE-PHASE MOTOR PROTECTORS

A. Provide all labor and materials for provision, installation, setup and testing motor protectors

which will shut-down and protect all three-phase motors upon detecting overvoltage, under-

voltage, loss of phase, phase reversal, phase imbalance, etc.

B. Provide motor protectors for each 3-phase motor or including AFDS for pumps whether

provided as a factory mounted or field installed motor. Provide for built-up and for factory

fabricated equipment. Provide whether or not equipment is provided with internal motor

protection (i.e. AFD) or not. Provide all motor protectors with auto reset.

C. Basis of Design: ICM 450 or approved equal.

1.11 HEAT TRACING CABLE

A. The Contractor shall provide heat trace cable for all chilled water piping exposed to the

outdoors and in the equipment curbs and HVAC units on the roof. Heat trace shall be provided

whether or not heat transfer fluid is water or glycol solution.


a. Chromalox.

b. Raychem.

c. Markel.





B. Heat tracing cable shall consist of flat, flexible, low heat density strip of parallel circuit

construction.

1. 16 AWG bus bars and a continuous inner core of self-regulating conductive material.

2. Insulate core with a radiation crosslinked polyolefin jacket.

C. Design system with integral thermostat to automatically maintain minimum water temperature

of 40 deg. F to an ambient of 0 deg. F.

1. Interlock electrical power to operate whenever circuit breaker is energized and

temperature is below 40 deg. F.

D. Cable shall be self-regulating and thermostatically controlled.

1. Cable shall respond to varying localized temperature conditions along the pipe by self-

regulating its heat output at each point along its length.

E. Provide power connection kit, splices, end seal kits, glass cloth adhesive tape, and other

components required for a complete installation.

F. Provide adjustable high limit thermostat for outdoor mounting to prevent pipe temperature from

exceeding 50 deg. F.

G. Power: 120/60/1 or 208/60/1 or 277/60/1 as indicated on the Division 26 contract documents

and for the available power in the building.

1. Refer to Section 260100 for coordination requirements between trades work.

2. Heat trace cable shall be provided by Div. 23; installed by Div. 23, Powered by Div. 26.

H. Systems Protected: The following piping systems shall be protected. The contractor is

responsible to provide calculations indicating the length of cable and quantity of power circuits

needed for each system based on the actual piping length, diameter, insulation thickness, etc.

The contractor is responsible to coordinate the quantity and location of power circuits with

Division 26 and provide weatherproof power circuits as necessary to affect a complete

operating system.

1. Water piping exposed to outdoors shall be on commercial power.

2. CH-1 all piping and equipment exposed to outdoors for CHWS and CHWR.

1.12 CHILLER FREEZE PROTECTION CIRCUIT BY DIV 26

A. Provide power connection kit, splices, end seal kits, glass cloth adhesive tape, and other

components required for a complete installation.

B. Provide power from nearest emergency power panel for required voltage. Size and provide

conduit and cable for full load of heater in outdoor chiller enclosure and compensate for voltage

drop not to exceed 2%.





C. Provide Power: 120/60/1 or 208/60/1 or 277/60/1 to match the nameplate data for the

evaporator heater (freeze protection) at the chiller. Coordinate with the Div 23 contractor for the

available voltages in the building.

PART 2 - PRODUCTS

2.1 SUPPORTING DEVICES

A. Material: Cold-formed steel, with corrosion-resistant coating acceptable to authorities

having jurisdiction.

D. Metal Items for Use Outdoors or in Damp Locations: Hot-dip galvanized steel.

E. Slotted-Steel Channel Supports: Flange edges turned toward web, and 9/16-inch- diameter

slotted holes at a maximum of 2 inches o.c., in webs.

F. Slotted-Steel Channel Supports: Comply with Division 5 Section "Metal Fabrications" for

slotted channel framing.

1. Channel Thickness: Selected to suit structural loading.

2. Fittings and Accessories: Products of the same manufacturer as channel supports.

G. Raceway and Cable Supports: Manufactured clevis hangers, “J” hooks, riser clamps,

straps, threaded C-clamps with retainers, ceiling trapeze hangers, wall brackets, and spring-

steel clamps or click-type hangers.

H. Pipe Sleeves: ASTM A 53, Type E, Grade A, Schedule 40, galvanized steel, plain ends.

I. Cable Supports for Vertical Conduit: Factory-fabricated assembly consisting of threaded

body and insulating wedging plug for nonarmored electrical cables in riser conduits. Plugs

have number and size of conductor gripping holes as required to suit individual risers.

Body constructed of malleable-iron casting with hot-dip galvanized finish.

J. Expansion Anchors: Carbon-steel wedge or sleeve type.

K. Toggle Bolts: All-steel springhead type.

L. Powder-Driven Threaded Studs: Heat-treated steel (obtain approval from Structural

Engineer).

2.2 WARRANTIES

A. The Contractor shall warrant for period of two years all work provided under the contract

to include, but not necessarily limited to, all systems, equipment, materials, and





workmanship. This shall not be construed to limit any extended warranty periods of longer

than one year for specific items or systems specified elsewhere in the Contract Documents.

B. The warranty period shall commence on the date of acceptance by the Owner and shall

cover all parts and labor as required to fulfill the warranty at no cost to the Owner.

C. Information on all warranties shall be included in the O&M Manuals specified herein to be

provided by the Owner.

2.3 ASBESTOS

A. Asbestos Free Materials: The intention of these drawings and specifications is that there

be no asbestos containing materials installed on this project. The best of Engineer’s

knowledge, none of the material or equipment specified herein or shown on the drawings

contains asbestos. The Contractor shall make every effort to prevent any asbestos

materials from being installed in or used on construction of the project. At the completion

of the project, the Contractor shall certify by letter that to the best of his knowledge, no

asbestos containing materials were used for or in the construction of this project.

2.4 GRAPHICS DATABASE

A. This project’s Computer Aided Design & Drafting (CADD) drawings and files may be

purchased directly from the Engineer for use in preparing computer graphics specific to

this project upon signing a “Letter of Indemnification”.

2.5 TOUCHUP PAINT

A. For Equipment: Equipment manufacturer's paint selected to match installed equipment

finish.

B. Galvanized Surfaces: Zinc-rich paint recommended by item manufacturer.

2.6 PENETRATIONS

A. Maintain fire ratings and provide U.L. Listed firestopping system where electrical items

penetrate fire rated building elements (See Architectural). Include in written warranty of

work, a guarantee of the weatherproof integrity of penetrations where such penetrations

occur at exterior envelope.

PART 3 - EXECUTION

3.1 ELECTRICAL EQUIPMENT INSTALLATION

A. Headroom Maintenance: If mounting heights or other location criteria are not indicated,

arrange and install components and equipment to provide the maximum possible headroom.





B. Materials and Components: Install level, plumb, and parallel and perpendicular to other

building systems and components, unless otherwise indicated.

C. Equipment: Install to facilitate service, maintenance, and repair or replacement of

components. Connect for ease of disconnecting, with minimum interference with other

installations.

D. Conduit Raceway Right of Way: Give to raceways and piping systems installed at a

required slope.

E. The contractor shall not install any raceway in a manner that creates moisture traps.

3.2 RACEWAY APPLICATION

A. Use the following raceways for outdoor installations:

1. Exposed: RMC (galvanized).

2. Concealed: RMC (galvanized) or IMC (galvanized).

3. Connection to Vibrating Equipment: LFMC.

4. Boxes and Enclosures: NEMA 250, Type 3R or Type 4.

B. Use the following raceways for indoor installations:

5. Exposed: EMT.

6. Concealed: EMT.

7. Connection to Vibrating Equipment: LFMC.

8. Damp or Wet Locations: RMC (galvanized).

9. Boxes and Enclosures: NEMA 250, Type 1, unless otherwise indicated.

3.3 RACEWAY AND CABLE INSTALLATION

A. Conceal raceways and cables, unless otherwise indicated, within finished walls, ceilings,

and floors.

B. Install raceways and cables at least 6 inches away from parallel runs of flues and steam or

hot-water pipes. Locate horizontal raceway runs above water and steam piping.

C. Use temporary raceway caps to prevent foreign matter from entering.

D. Make conduit bends and offsets so ID is not reduced. Keep legs of bends in the same plane

and straight legs of offsets parallel, unless otherwise indicated.

E. Use raceway and cable fittings compatible with raceways and cables and suitable for use

and location.

F. Install raceways below concrete slabs and leave at least 6-inch concrete cover.

1. Secure raceways to reinforcing rods to prevent sagging or shifting during concrete

placement.





2. Space raceways laterally to prevent voids in concrete.

3. Install conduit larger than 1-inch trade size parallel to or at right angles to main

reinforcement. Where conduit is at right angles to reinforcement, place conduit close

to slab support.

4. Transition from nonmetallic tubing to Schedule 80 nonmetallic conduit, rigid steel

conduit, or IMC before rising above floor.

5. Make bends in exposed parallel or banked runs from same centerline to make bends

parallel. Use factory elbows only where elbows can be installed parallel; otherwise,

provide field bends for exposed parallel raceways.

G. Without exception, install pull wires in empty raceways. Use No. 14 AWG zinc-coated

steel or monofilament plastic line with not less than 200-lb tensile strength. Leave at least

12 inches of slack at each end of the pull wire.

H. Install telephone and signal system raceways, 2-inch trade size and smaller, in maximum

lengths of 150 feet and with a maximum of two 90-degree bends or equivalent. Separate

lengths with pull or junction boxes where necessary to comply with these requirements, in

addition to requirements above.

I. Connect motors and equipment subject to vibration, noise transmission, or movement with

a maximum of 72-inch flexible conduit. Install LFMC in wet or damp locations. Install

separate ground conductor across flexible connections.

3.4 WIRING METHODS FOR POWER, LIGHTING, AND CONTROL CIRCUITS

A. Feeders: Type THHN/THWN insulated conductors in raceway.

B. Branch Circuits: Type THHN/THWN insulated copper conductors in raceway, #12 AWG

and larger.

1. Do not use less than ¾-inch diameter conduit for any branch circuit.

2. Do not install more than three (3) current carrying conductors in any conduit.

3. Do not install smaller than #12 awg. wire size for any power distribution circuits.

4. AC and MC-flexible raceway not allowed.

C. Remote-Control Signaling and Power-Limited Circuits: Type THHN/THWN insulated

conductors in raceway for Classes 1, 2, and 3, unless otherwise indicated.

3.5 WIRING INSTALLATION

A. Install splices and taps that are compatible with conductor material and that possess

equivalent or better mechanical strength and insulation ratings than unspliced conductors.

B. Install wiring at outlets with at least 6 inches of slack conductor at each outlet.

C. Connect outlet and component connections to wiring systems and to ground. Tighten

electrical connectors and terminals, according to manufacturer's published torque-

tightening values. If manufacturer's torque values are not indicated, use those specified in

UL 486A.





3.6 ELECTRICAL SUPPORTING DEVICE APPLICATION

A. Damp Locations and Outdoors: Hot-dip galvanized materials or nonmetallic, U-channel

system components.

B. Dry Locations: Steel materials.

C. Selection of Supports: Comply with manufacturer's written instructions, (See Structural).

D. Strength of Supports: Adequate to carry present and future loads, times a safety factor of

at least four; minimum of 200-lb design load.

3.7 SUPPORT INSTALLATION

A. Install support devices to securely and permanently fasten and support electrical

components.

B. Install individual and multiple raceway hangers and riser clamps to support raceways.

Provide U-bolts, clamps, attachments, and other hardware necessary for hanger assemblies

and for securing hanger rods and conduits.

C. Support parallel runs of horizontal raceways together on trapeze- or bracket-type hangers.

D. Size supports for multiple raceway installations so capacity can be increased by a 25

percent minimum in the future.

E. Support individual horizontal raceways with separate, malleable-iron pipe hangers or

clamps.

F. Install 1/4-inch- diameter or larger threaded steel hanger rods, unless otherwise indicated.

G. Spring-steel fasteners specifically designed for supporting single conduits or tubing may be

used instead of malleable-iron hangers for 1-1/2-inch and smaller raceways serving

lighting and receptacle branch circuits above suspended ceilings and for fastening

raceways to slotted channel and angle supports.

H. Arrange supports in vertical runs so the weight of raceways and enclosed conductors is

carried entirely by raceway supports, with no weight load on raceway terminals.

I. Simultaneously install vertical conductor supports with conductors.

J. Install metal channel racks for mounting cabinets, panelboards, disconnect switches,

control enclosures, pull and junction boxes, transformers, and other devices unless

components are mounted directly to structural elements of adequate strength.

K. Install sleeves for cable and raceway penetrations of concrete slabs and walls unless core-

drilled holes are used. Install sleeves for cable and raceway penetrations of masonry and

fire-rated gypsum walls and of all other fire-rated floor and wall assemblies. Install sleeves

during erection of concrete and masonry walls.





L. Securely fasten electrical items and their supports to the building structure, unless

otherwise indicated. Perform fastening according to the following unless other fastening

methods are indicated:

1. Wood: Fasten with wood screws or screw-type nails.

2. Masonry: Toggle bolts on hollow masonry units and expansion bolts on solid

masonry units.

3. Concrete: Expansion bolts.

a. Instead of expansion bolts, threaded studs driven by a powder charge and provided

with lock washers may be used in existing concrete deck construction where

approved by the project structural engineer in writing.

4. Steel: Welded threaded studs or spring-tension clamps on steel.

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

5. Welding to steel structure may be used only for threaded studs, not for conduits, pipe

straps, or other items.

6. Light Steel: Sheet-metal screws.

7. Fasteners: Select so the load applied to each fastener does not exceed 25 percent of its

proof-test load.

3.8 FIRESTOPPING

A. Apply firestopping to cable and raceway penetrations of fire-rated floor and wall

assemblies to achieve fire-resistance rating of the assembly.

3.9 CUTTING AND PATCHING

A. The installed floors, walls and roofs contain electric conduit and piping either under or in

the floor/roof and walls. The contractor is responsible for locating previously installed

equipment under or in the floor/roof or walls. The contractor is responsible for repairing

previously installed equipment damaged due to cutting the floors, walls and roof.

B. Perform or pay for cutting, fitting, repairing, patching and finishing of work of other

sections where it is necessary to disturb such work to permit installation of mechanical

work.

C. Avoid cutting, where possible, by setting sleeves or frames, and by requesting openings in

advance.

Coordinate locations with work of other sections.

D. Before cutting of structural elements, obtain written approval of Structural Engineer.

1. Use only approved methods.

2. Neatly cut holes as small as possible to admit work.

3. Do not weaken walls or floors; locate holes in concrete to miss structural.

E. Locate openings and sleeves to permit neat installation of piping, ductwork and equipment.





F. Do not remove or damage fireproofing materials.

Install hangers, inserts, supports, and anchors prior to installation of fireproofing.

Repair or replace fireproofing removed or damaged, at no extra cost.

G. Cut channel, chase and drill floors, walls, partitions, ceilings and other surfaces necessary

for mechanical installations. Perform cutting by skilled mechanics of trades involved.

H. Repair cut surfaces to match adjacent surfaces.

I. Cut, channel, chase, and drill floors, walls, partitions, ceilings, and other surfaces required

to permit electrical installations. Perform cutting by skilled mechanics of trades involved.

J. Repair and refinish disturbed finish materials and other surfaces to match adjacent

undisturbed surfaces. Install new fireproofing where existing firestopping has been

disturbed. Repair and refinish materials and other surfaces by skilled mechanics of trades

involved.

3.10 ACCESS DOORS IN INACCESSIBLE CEILING CONSTRUCTION

A. Layout junction and pull boxes outside of areas with drywall or inaccessible ceiling

construction.

B. Do not provide access panels in drywall ceilings for access to junction or pull boxes.

C. Rework any conduit and wiring as necessary to eliminate ceiling or wall mounted access

panels in finished spaces.

D. Provide submittal to the Engineer indicating any access panels needed in drywall or

inaccessible ceilings where the serviceable device could not be installed any other way

prior to installation for review and approval by the Engineer.


A. Inspect installed components for damage and faulty work, including the following:

1. Raceways.

2. Building wire and connectors.

3. Supporting devices for electrical components.

4. Electrical identification.

5. Concrete bases.

6. Electrical demolition.

7. Cutting and patching for electrical construction.

8. Touchup painting.

3.12 REFINISHING AND TOUCHUP PAINTING

A. Refinish and touch up paint. Paint materials and application requirements as specified.





1. Clean damaged and disturbed areas and apply primer, intermediate, and finish coats to

suit the degree of damage at each location.

2. Follow paint manufacturer's written instructions for surface preparation and for timing

and application of successive coats.

3. Repair damage to galvanized finishes with zinc-rich paint recommended by

manufacturer.

4. Repair damage to PVC or paint finishes with matching touchup coating recommended

by manufacturer.

3.13 CLEANING AND PROTECTION

A. On completion of installation, including outlets, fittings, and devices, inspect exposed

finish. Remove burrs, dirt, paint spots, and construction debris.

B. Protect equipment and installations and maintain conditions to ensure that coatings,

finishes, and cabinets are without damage or deterioration at time of Substantial

Completion.

C. Thoroughly clean work area no less than weekly.

3.14 DIV. 26 CONTRACTOR SUPPORT FOR SYSTEMS IN OPERATION-START-UP

The Div. 26 contractor shall provide all labor and materials to fully support Div. 23 HVAC

systems start up and field quality control. The Div. 26 contractor shall perform all required

electrical portions of the Div. 23 startup. Assist in performing the following:

A. Prior to substantial completion, at time agreed to by Owner, put systems into satisfactory

operation.

1. Assist with Systems Demonstration after the TAB balancing report is submitted and

approved, and prior to Substantial Completion.

B. Miscellaneous Electrical Equipment Connections: Provide power for the following

equipment.

1. Motor Controllers: All combination disconnect/starters shall be provided with panel

mounted hand-off-auto (H.O.A.) switches. The H.O.A. switches shall be provided

with indicator lights, and control power transformers.

2. Motor Protectors: Provide motor protectors for all three-phase motors.

a. Provide ICM-45 motor protectors.

b. Mount in NEMA 1 enclosure adjacent motor controller, or inside control panel

of equipment served.

3. Heat Trace Cable: Provide heat trace cables designed to maintain the pipe water

temperature at 40 degF when ambient OAT is 0 degF.





a. Interlock cable with EMS to monitor heat trace status, and issue an alarm if

failure occurs.

b. Provide one separate electrical power circuit for each outdoor pipe run.

END OF SECTION




COMMON WORK RESULTS FOR ELECTRICAL 260200 - 1

SECTION 260200

COMMON WORK RESULTS FOR ELECTRICAL

PART 1 - GENERAL

1.1 SUMMARY


1. Electrical equipment coordination and installation. 2. Sleeves for raceways and cables. 3. Sleeve seals. 4. Grout. 5. Common electrical installation requirements.

1.2 DEFINITIONS

A. EPDM: Ethylene-propylene-diene terpolymer rubber.

B. NBR: Acrylonitrile-butadiene rubber.

1.3 SUBMITTALS

A. Submit shop drawings, product data and samples for all items as specified in related sections of

these specifications. All submittal data shall be correctly identified to show project name, and

the exact model, style or size of item being submitted. Improperly identified submittals will not

be reviewed by the Engineer. Each item submitted for review shall bear the Subcontractor’s

stamp which states that they have reviewed submission, that is complete, and that in their

opinion it meets the contract requirements. Contractor’s stamp shall identify the paragraph and

page number for which the submittal is being made. Any submission which has not been

reviewed and stamped by the Electrical Trade will not be reviewed by the Engineer.

B. Shop drawings, samples, diagrams, catalog data and such other data necessary to fully describe

and substantiate compliance with these contract documents shall be submitted as follows:

1. Samples, in good working order, shall be complete with all installation and service

drawings and instructions. All samples will be returned at the submitter’s expense unless

otherwise indicated. Samples may be subject to destructive testing by Owner/Engineer.

C. Operation and Maintenance manual(s) shall include a complete product index, a copy of all

accepted shop drawings, installation and maintenance data, sequence of controls, parts lists, and

the name, address and telephone of supplier or nearest representative. All electrical devices,

equipment and systems in these specifications shall be included and all other such electrical

items which will require servicing before the duration of its useful life has been reached. The

manual(s) shall be presented to the Engineer for review and transmitted to the Owner before the

final payment is recommended.





D. Equivalents: Manufacturers, trade names and model numbers indicated herein and on drawings

shall be interpreted as establishing a standard of quality and shall not be construed as limiting

competition. The Contractor may propose to use any article which, in his judgment, is equal to

that specified. The use of such proposed articles is subject to acceptance by the Engineer.

Where three or more manufacturers are named in the specifications or on the drawings for any

item, the Contractor shall use one of the manufacturers. No others shall be reviewed or

accepted. Manufacturers listed first in these specifications and on drawings were used as a basis

of design. It will be the responsibility of the Contractor to verify all connections, physical sizes

and capacities of all other manufacturer’s items, both items named herein, or items proposed. If

the equipment necessitates changes in power distribution, conduit, wiring, lighting, ductwork,

piping, or any other building systems from that indicated on the drawings, the Contractor shall

be responsible for all additional costs included and notify other trades of the changes. Where

such changes are required, detail drawings indicating all required changed shall be submitted for

review at the same time the manufacturer’s drawings are submitted for approval.

E. Guarantee: Electrical equipment, materials and labor required by these specifications and

accompanying drawings shall be guaranteed to be free from defective materials or workmanship

for a period of one year after final acceptance of the project except extended warranties as

specified elsewhere in these documents on specific items of equipment will be furnished by the

Trade providing the equipment. Defects in material or workmanship occurring during this

period shall corrected with new material and equipment or additional labor at no cost to the

Owner. Manufacturer’s certificates of warranty shall be transmitted to the Owner before final

payment is recommended.


A. Equipment and materials used in the project shall be new and undamaged. The electrical

installation shall fit into the space allotted and shall allow adequate, acceptable, clearances for

entry, servicing, safety, and maintenance. The Contractor shall coordinate the work to ensure

that the equipment may be moved into place without altering building components or other

installations. All electrical work shall be performed by a Commonwealth of Virginia Class-A

licensed Electrical Contractor whose technicians, mechanics, or tradesmen shall be skilled in the

trade involved. All electrical work shall be performed under the direct supervision of an

electrician with locally recognized and accepted master license.

1.5 REFERENCES

A. The complete installation and all materials and equipment under Division 26 shall conform to

the Virginia Uniform Statewide Building Code, current issue, including all applicable portions

of the National Fire Protection Association Codes and all other governing codes and

regulations.

B. All equipment used shall bear the Underwriters Laboratory (U.L.) label for the intended

application, or other organizations label if acceptable to the Authority having jurisdiction and

concern with product evaluation.





1.6 PERMITS, LICENSES, TAXES AND INSPECTION CERTIFICATES

A. All permits, bonds, licenses, electrical connection fees, inspection fees and taxes required for

the execution of the work shall be obtained and paid for by the Contractor. Under each phase of

the electrical work the Contractor shall furnish three copies of certificates of final acceptance to

the Engineer from any inspection authority having jurisdiction.

B. At the completion of the job, provide the Engineer with three (3) copies of an electrical

inspection certificate from the local Electrical Inspector, if such inspection is provided and/or

required by the locality.

1.7 COORDINATION

A. Coordinate arrangement, mounting, and support of electrical equipment:

1. To allow maximum possible headroom unless specific mounting heights that reduce

headroom are indicated.

2. To provide for ease of disconnecting the equipment with minimum interference to other

installations.

3. To allow right of way for piping and conduit installed at required slope.

4. So connecting raceways, cables, wireways, cable trays, and busways will be clear of

obstructions and of the working and access space of other equipment.

B. Coordinate installation of required supporting devices and set sleeves in cast-in-place concrete,

masonry walls, and other structural components as they are constructed.

C. Coordinate location of access panels and doors for electrical items that are behind finished

surfaces or otherwise concealed.

D. Coordinate sleeve selection and application with selection and application of firestopping.

E. The contract documents indicate the extent and general arrangement of the electrical systems.

The Contractor shall be responsible for the coordination and proper relation of the electrical

work to the building structure and to the work of other trades. No additional compensation or

extension of completion time will be granted for extra work caused by the lack of coordination.

F. Cooperation: The Contractor shall provide dimensions and locations of all openings, shafts and

similar items to the proper trades and install work as required so as not to interfere with, or

delay, the building construction.

G. Location of lines and equipment shall be determined from actual field measurements. The

outlines of the building shown on the electrical drawings are intended only as a guide to indicate

relative locations of the electrical work. Refer to architectural and structural drawings for

building construction details. If conflicts prevent installation of electrical work at the locations

indicated, minor deviations shall be made subject to acceptance by the Engineer, and without

additional compensation.

H. Roughing-In: Receptacles, switches, and other similar items shall align vertically or

horizontally with each other, hose bibs, thermostats, the building structure and features thereof

when it appears obvious and logical that they should.





I. Damage to Other Work: The Electrical Trade is responsible for damage to other work caused

by his work or workmen. Repairing of damage work shall be done by the Trade who installed

the work, and as directed by the Engineer; the cost of which shall be paid for by the Electrical

Trade.

J. Where conduit, equipment, devices and other electrical appurtenances are shown on the

drawings, the general arrangement of such items on the electrical drawings shall be followed as

closely as actual building construction and the work of other trades will permit. Because of the

small scale of the electrical drawings, it is not feasible to indicate all offsets, fittings and

accessories which may be required. The Contractor shall investigate the construction conditions

affecting the work and provide fittings and accessories as required to meet actual conditions.

PART 2 - PRODUCTS

2.1 SLEEVES FOR RACEWAYS AND CABLES

A. Steel Pipe Sleeves: ASTM A 53/A 53M, Type E, Grade B, Schedule 40, galvanized steel, plain

ends.

B. Cast-Iron Pipe Sleeves: Cast or fabricated "wall pipe," equivalent to ductile-iron pressure pipe,

with plain ends and integral waterstop, unless otherwise indicated.

C. Sleeves for Rectangular Openings: Galvanized sheet steel.

1. Minimum Metal Thickness:

a. For sleeve cross-section rectangle perimeter less than 50 inches (1270 mm) and no

side more than 16 inches (400 mm), thickness shall be 0.052 inch (1.3 mm).

b. For sleeve cross-section rectangle perimeter equal to, or more than, 50 inches

(1270 mm) and 1 or more sides equal to, or more than, 16 inches (400 mm),

thickness shall be 0.138 inch (3.5 mm).

2.2 SLEEVE SEALS

A. Acceptable Description: Modular sealing device, designed for field assembly, to fill annular

space between sleeve and raceway or cable.

1. Manufacturers: Subject to compliance with requirements, available manufacturers

offering products that may be incorporated into the Work include, but are not limited to,

the following:


b. Calpico, Inc.

c. Metraflex Co.


2. Sealing Elements: EPDM interlocking links shaped to fit surface of cable or conduit.

Include type and number required for material and size of raceway or cable.





3. Pressure Plates: Stainless steel. Include two for each sealing element.

4. Connecting Bolts and Nuts: Stainless steel of length required to secure pressure plates to

sealing elements. Include one for each sealing element.

2.3 GROUT

A. Nonmetallic, Shrinkage-Resistant Grout: ASTM C 1107, factory-packaged, nonmetallic

aggregate grout, noncorrosive, nonstaining, mixed with water to consistency suitable for

application and a 30-minute working time.

PART 3 - EXECUTION

3.1 COMMON REQUIREMENTS FOR ELECTRICAL INSTALLATION

A. Comply with NECA 1.

B. Measure indicated mounting heights to bottom of unit for suspended items and to center of unit

for wall-mounting items.

C. Headroom Maintenance: If mounting heights or other location criteria are not indicated,

arrange and install components and equipment to provide maximum possible headroom

consistent with these requirements.

D. Equipment: Install to facilitate service, maintenance, and repair or replacement of components

of both electrical equipment and other nearby installations. Connect in such a way as to

facilitate future disconnecting with minimum interference with other items in the vicinity.

E. Right of Way: Give to piping systems installed at a required slope.

3.2 SLEEVE INSTALLATION FOR ELECTRICAL PENETRATIONS

A. Electrical penetrations occur when raceways, cables, wireways, cable trays, or busways

penetrate concrete slabs, concrete or masonry walls, or fire-rated floor and wall assemblies.

B. Provide sleeves for all conduits passing through concrete or masonry walls, partitions, concrete

slabs or beams installed during construction of the wall, partition, slab or beam. Sleeves placed

horizontally in walls or in any position in beams shall be standard weight ASTM A53 steel pipe

of length equal to thickness of wall or beam. Those placed vertically in non-waterproof floors

shall be 20 gauge galvanized sheet steel of length equal to thickness of slab, flared and nailed to

the form, or fastened to reinforcing fabric and filled with sand during pouring to prevent

deformation. Sleeves occurring in floors of rooms where hose bibs or floor drains provided

under Division 23 occur, and in pipe spaces, shall be standard weight steel pipe projecting ½”

above the finished floor except in Equipment Rooms they shall project four (4) inches above

floor. Sleeves in floors with waterproof membrane shall be provided with flanges or flashing

rings and shall be clamped or flashed into membrane. All sleeves shall be of sufficient diameter

to allow installation of conduit except sleeves on lines subject to movement, which shall clear

the conduit at least one inch all around. Conduits through exterior walls, or floors, below grade





shall have seals specified herein between the conduit and wall sleeve. Sleeve shall have anchor

and water stop plate. The entire assembly shall be tightened and adjusted to make watertight.

C. Fire-Rated Assemblies: Install sleeves for penetrations of fire-rated floor and wall assemblies

unless openings compatible with firestop system used are fabricated during construction of floor

or wall. Sleeves for insulated wiring and conduit, penetrating fire (and smoke) rated partitions,

walls and floors shall have seals as specified herein and shall be sealed in accordance with the

terms of U.L. Listed Through-Penetration Firestop Systems (XHEZ) as published in the U.L.

Fire Resistance Directory. Penetrations shall exactly conform to details of the Firestop System

indicated for the type of partition, wall and floor construction encountered. All firestopping of

sleeves for electrical work shall be provided under Division 26.

D. Cut sleeves to length for mounting flush with both surfaces of walls.

E. Extend sleeves installed in floors 2 inches (50 mm) above finished floor level.

F. Size pipe sleeves to provide 1/4-inch (6.4-mm) annular clear space between sleeve and raceway

or cable, unless indicated otherwise.

G. Seal space outside of sleeves with grout for penetrations of concrete and masonry

1. Promptly pack grout solidly between sleeve and wall so no voids remain. Tool exposed

surfaces smooth; protect grout while curing.

H. Interior Penetrations of Non-Fire-Rated Walls and Floors: Seal annular space between sleeve

and raceway or cable, using joint sealant appropriate for size, depth, and location of joint.

I. Fire-Rated-Assembly Penetrations: Maintain indicated fire rating of walls, partitions, ceilings,

and floors at raceway and cable penetrations. Install sleeves and seal raceway and cable

penetration sleeves with firestop materials.

J. Roof-Penetration Sleeves: Seal penetration of individual raceways and cables with flexible

boot-type flashing units applied in coordination with roofing work.

K. Aboveground, Exterior-Wall Penetrations: Seal penetrations using steel pipe sleeves and

mechanical sleeve seals. Select sleeve size to allow for 1-inch (25-mm) annular clear space

between pipe and sleeve for installing mechanical sleeve seals.

L. Underground, Exterior-Wall Penetrations: Install cast-iron pipe sleeves. Size sleeves to allow

for 1-inch (25-mm) annular clear space between raceway or cable and sleeve for installing

mechanical sleeve seals.

3.3 SLEEVE-SEAL INSTALLATION

A. Install to seal exterior wall penetrations.

B. Use type and number of sealing elements recommended by manufacturer for raceway or cable

material and size. Position raceway or cable in center of sleeve. Assemble mechanical sleeve

seals and install in annular space between raceway or cable and sleeve. Tighten bolts against

pressure plates that cause sealing elements to expand and make watertight seal.





3.4 FIRESTOPPING

A. Apply firestopping to penetrations of fire-rated floor and wall assemblies for electrical

installations to restore original fire-resistance rating of assembly.


A. System Readings: Certain system voltage and current readings shall be taken, the values

recorded and submitted in triplicate to the Engineer. Two complete sets of readings are

required, one under no load and one under maximum available load. The current and voltage

shall be recorded on each phase (plus voltage between all phases) at main panelboard and at

each branch circuit panelboard. Additional spot readings shall be made if required. Resistance

of grounding system shall be tested and recorded. Forms for submitting this report may be

obtained from the Engineer’s office. A sample form is bound in section 260502.

B. Equipment Readings: Voltage and amperage readings on each phase of each motor circuit an

each resistance heater circuit installed under this contract shall be measured, the values

recorded, and submitted in triplicate to the Engineer. Also record motor nameplate data, actual

motor heater protective ratings and all other data necessary for selection of heater device.

C. Verification: Upon completion of the project, the Contractor shall submit a separate letter of

certification (or compliance) to the Owner/Engineer that each of the following systems or

equipment functions properly, conforms to all requirements of these specifications and all

requirements of the manufacturer of the systems:

3.6 INSTRUCTION OF OWNER’S REPRESENTATIVE

A. The Electrical Trade shall instruct the representative of the Owner in the proper operation and

maintenance of all elements of the electrical systems. Competent representatives of the

Contractor shall spend such time as necessary to fully prepare the Owner to operate and

maintain the electrical systems.

3.7 RECORD OF UNDERGROUND LINES

A. On completion of the project, the Contractor shall prepare and submit to the Owner/Engineer a

drawing on tracing paper and one full-size print to show the location of any underground lines

installed in locations different from those on the Engineer’s drawings. The locations and the

distance from the building to outside lines and manholes shall be dimensioned.

3.8 MANUFACTURER’S ASSISTANCE

A. Qualified technical representatives of manufacturers shall be available to visit the project and

provide required assistance for any problems or trouble areas of any systems, material or

equipment used in the project. Manufacturer’s engineering assistance shall also be available for

above problems or trouble areas. The Contractor shall purchase all materials, equipment or

systems with these services included in the purchase price or otherwise be prepared to have the

above service provided when needed or requested by the Engineer without additional





compensation. Where on manufacturer’s equipment constitutes the majority of the components

or devices to make a system, the manufacturer’s equipment constitutes the majority of

components or devices to make a system, the manufacturer’s technically qualified

representative shall inspect and accept the completed installation whether or not especially

requested by the Engineer.

3.9 TRANSFORMER TAP SETTING

A. The contractor shall coordinate the selected tap setting of the local utility company’s pad

mounted transformer to prevent excessive secondary under/over voltage at the main service

disconnecting means.

3.10 INSTALLATION

A. General: Division 26 shall provide the installation methods specified hereinafter for the

following equipment:

1. All electrical work for receptacles or connections to the above equipment shall be made

by the Electrical Trade. Do no roughing-in or other electrical work in these areas until

roughing-in drawings reviewed by the Engineer are received. The presumed location of

all presently envisioned equipment having electrical connections is shown on the

drawings and specified herein, but this is for estimating purposes only and the Contractor

shall prepare his bid to allow for any possible rearrangement of the equipment listed, or

as indicated. Provide permanent liquid-tight flexible metal conduit connections to the

equipment from the outlet boxes or conduit stubbed up above the floor or conduit stubbed

down from the ceiling for all equipment indicated, except where receptacles are

indicated. These connections shall include but not be limited to: disconnect switches,

service switches, combination motor starters, motor protective switches and other wiring

devices as required per the manufacturer’s drawings, the NEC and the Contract

Documents.

B. Equipment Wiring: Shall be in accordance with equipment manufacturer’s drawings and

instructions, and the equipment installing Trades’ written instructions.

C. Contactors and Relays: Install all contactors and relays in accordance with NEC as required.

3.11 TESTING OF ELECTRICAL SYSTEMS

A. All manufacturers recommend check list and testing shall be completed prior to performing all

functional testing and startups for each component of a system shall be successfully completed

by the Subcontractor responsible for the purchase of the equipment or system and shall be

conducted prior to formal NETA testing of equipment or subsystems of the given system.

B. The Contractor and each Subcontractor shall provide skilled tradesmen/technicians, with

specific knowledge of the equipment and systems installed on this project, to provide and

support the functional performance testing of individual systems.

END OF SECTION




CONDUCTORS AND CABLES 260519 - 1

SECTION 260519

CONDUCTORS AND CABLES

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes building wires and cables and associated connectors, splices, and

terminations for wiring systems rated 600 V and less.

B. Provide all conductors rated for up to 600 volt.

1.2 SUBMITTALS


B. Qualification Data: For testing agency.


A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70,

Article 100, by a testing agency acceptable to the County of Fauquier, Virginia and marked for

intended use.

B. Comply with NFPA 70.

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 CONDUCTORS AND CABLES


1. A.F.C.

2. American Insulated Wire Corp.; a Leviton Company.





3. General Cable Corporation.

4. Senator Wire & Cable Company.

5. Southwire Company.

B. Refer to Part 3 "Conductor and Insulation Applications" Article for insulation type, cable

construction, and ratings.

C. Conductor Material: Copper solid conductor for No. 10 AWG and smaller, stranded for No. 8

AWG and larger. Use of aluminum conductors is prohibited and shall not be used on this

project.

D. Conductor Insulation Types: Type THW, THHN-THWN, XHHW complying with NEMA WC.

E. Multiconductor Cable: Type MC and AC cable is not allowed.

2.3 CONNECTORS AND SPLICES


1. AFC Cable Systems, Inc.

2. AMP Incorporated/Tyco International.

3. Hubbell/Anderson.

4. O-Z/Gedney; EGS Electrical Group LLC.

5. 3M Company; Electrical Products Division.

B. Description: Factory-fabricated connectors and splices of size, ampacity rating, material, type,

and class for application and service indicated.

PART 3 - EXECUTION

3.1 CONDUCTOR AND INSULATION APPLICATIONS

A. Service Entrance: Type XHHW, single conductors in raceway.

B. Exposed Feeders: Type THHN-THWN, single conductors in raceway.

C. Feeders Concealed in Ceilings, Walls, and Partitions: Type THHN-THWN, single conductors

in EMT or rigid steel raceway

D. Feeders Concealed in Concrete, below Slabs-on-Grade, and Below Grade: Type -THWN,

single conductors in raceway.

E. Exposed Branch Circuits: Type THHN-THWN, single conductors in raceway.

F. Branch Circuits or Feeders Concealed in existing Ceilings, Walls, and Partitions: Type THHN-

THWN, single conductors in rigid steel or EMT raceway. Where it I not practical to install

conduit in existing walls. Provide metal surfaces mounded warranty; wire mold V400 or equal.





1. AC and MC flexible raceway not allowed.

G. Branch Circuits or Feeders concealed or embedded in concrete structure are not allowed.

H. Class 1 Control Circuits: Type THHN-THWN, in raceway or U.L. Listed for use, plenum rated

ceilings.

I. Class 2 Control Circuits: Power-limited cable, concealed in building finishes.

3.2 INSTALLATION

A. Conceal cables in finished walls, ceilings, and floors, unless otherwise indicated.

B. Use manufacturer-approved pulling compound or lubricant where necessary; compound used

must not deteriorate conductor or insulation. Do not exceed manufacturer's recommended

maximum pulling tensions and sidewall pressure values.

C. Use pulling means; including fish tape, cable, rope, and basket-weave wire/cable grips that will

not damage cables or raceway.

D. Install all cables (exposed and concealed) parallel and perpendicular to surfaces of exposed

structural members, and follow surface contours where possible.

E. Support cables according to Division 26 Section "Basic Electrical Materials and Methods."

F. Seal around cables penetrating fire-rated elements according to Division 7 Section "Through-

Penetration Firestop Systems."

G. Identify and color-code conductors and cables according to Division 26 Section Electrical

Identification."

3.3 CONNECTIONS

A. Tighten electrical connectors and terminals according to manufacturer's published torque-


UL 486A and UL 486B.

B. Make splices and taps that are compatible with conductor material and that possess equivalent

or better mechanical strength and insulation ratings than unspliced conductors.

1. Use oxide inhibitor in each splice and tap conductor for aluminum conductors.

C. Wiring at Outlets: Install conductor at each outlet, with at least 6 inches of slack.


A. Testing: Perform the following field quality-control testing:





1. After installing conductors and cables and before electrical circuitry has been energized,

test for compliance with requirements.

2. Perform each electrical test and visual and mechanical inspection stated in NETA ATS,

Section 7.3.1. Certify compliance with test parameters.

B. Test Reports: Prepare a written report to record the following:



3. Test results that do not comply with requirements and corrective action taken to achieve


END OF SECTION




GROUNDING AND BONDING 260526 - 1

SECTION 260526

GROUNDING AND BONDING

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes grounding of electrical systems and equipment. Grounding requirements

specified in this Section may be supplemented by special requirements of systems described in

other Sections.

1.2 SUBMITTALS


B. Product Data: For the following:

1. Ground rods.

2. Exothermic weld materials

C. Qualification Data: For firms and persons specified in "Quality Assurance" Article.

D. Field Test Reports: Submit written test reports to include the following:



3. Results of failed tests and corrective action taken to achieve test results that comply with

requirements.


A. Testing Agency Qualifications: Testing agency as defined by OSHA in 29 CFR 1910.7 or a

member company of the InterNational Electrical Testing Association and that is acceptable to


1. Testing Agency's Field Supervisor: Person currently certified by the InterNational

Electrical Testing Association to supervise on-site testing specified in Part 3.



intended use.

1. Comply with UL 467.





C. Comply with NFPA 70; for overhead-line construction and medium-voltage underground

construction, comply with IEEE C2.

D. Comply with NFPA 780 and UL 96 when interconnecting with lightning protection system.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

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

following:

1. Grounding Conductors, Cables, Connectors, and Rods:

a. Chance/Hubbell.

b. Copperweld Corp.

c. Erico Inc.; Electrical Products Group.

d. Framatome Connectors/Burndy Electrical.

e. Harger Lightning Protection, Inc.

f. Heary Brothers Lightning Protection Co.

g. Ideal Industries, Inc.

h. ILSCO.

i. Kearney/Cooper Power Systems.

j. Korns: C. C. Korns Co.; Division of Robroy Industries.

k. O-Z/Gedney Co.; a business of the EGS Electrical Group.

l. Raco, Inc.; Division of Hubbell.

m. Robbins Lightning, Inc.

n. Superior Grounding Systems, Inc.

o. Thomas & Betts, Electrical.

2.2 GROUNDING CONDUCTORS

A. For insulated conductors, comply with Division 16 Section "Conductors and Cables."

B. Material: Copper.

C. Equipment Grounding Conductors: Insulated with green-colored insulation.

D. Isolated Ground Conductors: Insulated with green-colored insulation with yellow stripe. On

feeders with isolated ground, use colored tape, alternating bands of green and yellow tape to

provide a minimum of three bands of green and two bands of yellow.

E. Grounding Electrode Conductors: Stranded cable.

F. Underground Conductors: Bare, tinned, stranded, unless otherwise indicated.

G. Bare Copper Conductors: Comply with the following:





1. Solid Conductors: ASTM B 3.

2. Assembly of Stranded Conductors: ASTM B 8.

3. Tinned Conductors: ASTM B 33.

H. Copper Bonding Conductors: As follows:

1. Bonding Cable: 28 kcmil, 14 strands of No. 17 AWG copper conductor, in diameter.

2. Bonding Conductor: No. 4 or No. 6 AWG, stranded copper conductor.

3. Bonding Jumper: Bare copper tape, braided bare copper conductors, terminated with

copper ferrules; 1-5/8 inches wide and 1/16 inch thick.

4. Tinned Bonding Jumper: Tinned-copper tape, braided copper conductors, terminated

with copper ferrules; 1-5/8 inches wide and 1/16 inch thick.

2.3 CONNECTOR PRODUCTS

A. Comply with IEEE 837 and UL 467; listed for use for specific types, sizes, and combinations of

conductors and connected items.

B. Bolted Connectors: Bolted-pressure-type connectors, or compression type.

C. Welded Connectors: Exothermic-welded type, in kit form, and selected per manufacturer's

written instructions.

PART 3 - EXECUTION

3.1 APPLICATION

A. Use only copper conductors for both insulated and bare grounding conductors in direct contact

with earth, concrete, masonry, crushed stone and similar materials.

B. In raceways, use insulated equipment grounding conductors.

C. Exothermic-Welded Connections: Use for connections to structural steel and for underground

connections, except those at test wells.

D. Equipment Grounding Conductor Terminations: Use bolted pressure clamps.

E. Underground Grounding Conductors: Use tinned copper conductor, No. 2/0 AWG minimum.

Bury at least 24 inches below grade or bury 12 inches above duct bank when installed as part of

the duct bank.

F. Provide grounding of utility company transformer equipment as required by PEPCO published

guidelines.

3.2 EQUIPMENT GROUNDING CONDUCTORS





A. Comply with NFPA 70, Article 250, for types, sizes, and quantities of equipment grounding

conductors, unless specific types, larger sizes, or more conductors than required by NFPA 70

are indicated.

B. Install equipment grounding conductors in all feeders and circuits.

C. Install insulated equipment grounding conductor with circuit conductors for the following items,

in addition to those required by NEC:

1. Feeders and branch circuits.

2. Receptacle circuits.

3. Single-phase motor and appliance branch circuits.

4. Three-phase motor and appliance branch circuits.

5. Flexible raceway runs.

6. Metal-clad cable runs.

D. Isolated Equipment Enclosure Circuits: For designated equipment supplied by a branch circuit

or feeder, isolate equipment enclosure from supply raceway with a nonmetallic raceway fitting

listed for the purpose. Install fitting where raceway enters enclosure, and install a separate

equipment grounding conductor. Isolate equipment grounding conductor from raceway and

from panelboard grounding terminals. Terminate at equipment grounding conductor terminal of

the applicable derived system or service, unless otherwise indicated.

E. Nonmetallic Raceways: Install an equipment grounding conductor in nonmetallic raceways

unless they are designated for telephone or data cables.

F. Air-Duct Equipment Circuits: Install an equipment grounding conductor to duct-mounted

electrical devices operating at 120 V and more, including air cleaners and heaters. Bond

conductor to each unit and to air duct.

3.3 INSTALLATION

A. Grounding Conductors: Route along shortest and straightest paths possible, unless otherwise

indicated. Avoid obstructing access or placing conductors where they may be subjected to

strain, impact, or damage.

B. Bonding Straps and Jumpers: Install so vibration by equipment mounted on vibration isolation

hangers and supports is not transmitted to rigidly mounted equipment. Use exothermic-welded

connectors for outdoor locations, unless a disconnect-type connection is required; then, use a

bolted clamp. Bond straps directly to the basic structure taking care not to penetrate any

adjacent parts. Install straps only in locations accessible for maintenance.

3.4 CONNECTIONS

A. General: Make connections so galvanic action or electrolysis possibility is minimized. Select

connectors, connection hardware, conductors, and connection methods so metals in direct

contact will be galvanically compatible.





1. Use electroplated or hot-tin-coated materials to ensure high conductivity and to make

contact points closer to order of galvanic series.

2. Make connections with clean, bare metal at points of contact.

3. Make aluminum-to-steel connections with stainless-steel separators and mechanical

clamps.

4. Make aluminum-to-galvanized steel connections with tin-plated copper jumpers and

mechanical clamps.

5. Coat and seal connections having dissimilar metals with inert material to prevent future

penetration of moisture to contact surfaces.

B. Exothermic-Welded Connections: Comply with manufacturer's written instructions. Welds that

are puffed up or that show convex surfaces indicating improper cleaning are not acceptable.

C. Equipment Grounding Conductor Terminations: For No. 8 AWG and larger, use pressure-type

grounding lugs. No. 10 AWG and smaller grounding conductors may be terminated with

winged pressure-type connectors.

D. Noncontact Metal Raceway Terminations: If metallic raceways terminate at metal housings

without mechanical and electrical connection to housing, terminate each conduit with a

grounding bushing. Connect grounding bushings with a bare grounding conductor to grounding

bus or terminal in housing. Bond electrically noncontinuous conduits at entrances and exits

with grounding bushings and bare grounding conductors, unless otherwise indicated.

E. Tighten screws and bolts for grounding and bonding connectors and terminals according to

manufacturer's published torque-tightening values. If manufacturer's torque values are not

indicated, use those specified in UL 486A and UL 486B.

F. Compression-Type Connections: Use hydraulic compression tools to provide correct

circumferential pressure for compression connectors. Use tools and dies recommended by

connector manufacturer. Provide embossing die code or other standard method to make a

visible indication that a connector has been adequately compressed on grounding conductor.

G. Moisture Protection: If insulated grounding conductors are connected to ground rods or

grounding buses, insulate entire area of connection and seal against moisture penetration of

insulation and cable.


A. Testing: Engage a qualified testing agency acceptable to the County of Fauquier County,

Virginia to perform the following field quality-control testing:

1. After installing grounding system but before permanent electrical circuitry has been

energized, test for compliance with requirements.

2. Test completed grounding system at each location where a maximum ground-resistance

level is specified, at service disconnect enclosure grounding terminal, and at ground test

wells. Measure ground resistance not less than two full days after the last trace of

precipitation, and without the soil being moistened by any means other than natural

drainage or seepage and without chemical treatment or other artificial means of reducing





natural ground resistance. Perform tests, by the fall-of-potential method according to

IEEE 81.

3. Provide drawings locating each ground rod and ground rod assembly and other grounding

electrodes, identify each by letter in alphabetical order, and key to the record of tests and

observations. Include the number of rods driven and their depth at each location and

include observations of weather and other phenomena that may affect test results.

Describe measures taken to improve test results.

4. Excessive Ground Resistance: If resistance to ground exceeds specified values, notify

Engineer promptly and include recommendations to reduce ground resistance.

5. Test all bonding of all raised floor stanchions and pedestals.

END OF SECTION




RACEWAYS AND BOXES 260533 - 1

SECTION 260533

RACEWAYS AND BOXES

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes raceways, fittings, boxes, enclosures, and cabinets for electrical wiring.

1.2 DEFINITIONS

A. EMT: Electrical metallic tubing.

B. IMC: Intermediate metal conduit.

C. LFMC: Liquidtight flexible metal conduit.

D. LFNC: Liquidtight flexible nonmetallic conduit.

E. RNC (PVC): Rigid nonmetallic conduit.

1.3 SUBMITTALS

A. Product Data: For surface raceways, wireways and fittings, floor boxes, hinged-cover

enclosures, cabinets, and duct bank rack/spacers.

B. Shop Drawings: Show fabrication and installation details of components for raceways, fittings,

boxes, enclosures, and cabinets.


A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70,


intended use.

B. Comply with NFPA 70.

1.5 COORDINATION

A. Coordinate layout and installation of raceways, boxes, enclosures, cabinets, and suspension

system with other construction that penetrates ceilings or is supported by them, including light

fixtures, HVAC equipment, fire-suppression system, and partition assemblies.





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:


by the manufacturers specified. “No Substitutions Allowed.”

2.2 CONDUIT AND TUBING

A. Manufacturers:

1. AFC Cable Systems, Inc.

2. Alflex Inc.

3. Thomas & Betts, Steel City.

4. Grinnell Co./Tyco International; Allied Tube and Conduit Div.

5. LTV Steel Tubular Products Company.

6. Manhattan/CDT/Cole-Flex.

7. O-Z Gedney; Unit of General Signal.

8. Wheatland Tube Co.

B. Rigid Steel Conduit: ANSI C80.1.

C. Aluminum Rigid Conduit: ANSI C80.5.

D. IMC: ANSI C80.6.

E. Plastic-Coated Steel Conduit and Fittings: NEMA RN 1.

F. Plastic-Coated IMC and Fittings: NEMA RN 1.

G. EMT and Fittings: ANSI C80.3.

1. All Steel Fittings: Use compression fittings. Use of alloy fittings and screws, “pot

metal”, or “white metal” is not allowed.

H. LFMC: Liquidtight Flexible metal Conduit.

I. LFNMC: Liquidtight Flexible Non-Metallic Conduit steel (with PVC jacket).

J. Fittings: NEMA FB 1; compatible with conduit and tubing materials.

K. RNC: PVC schedule 40.

2.3 METAL WIREWAYS






1. Hoffman.

2. Square D.

3. Thomas & Betts, Steel City.

B. Material and Construction: Sheet metal sized and shaped as indicated.

1. Indoor Standard Area: NEMA 1.

2. Outdoors: NEMA 4.

C. Fittings and Accessories: Include couplings, offsets, elbows, expansion joints, adapters, hold-

down straps, end caps, and other fittings to match and mate with wireways as required for

complete system.

D. Select features, unless otherwise indicated, as required to complete wiring system and to

comply with NFPA 70.

E. Wireway Covers: Hinged type or Screw-cover type.

F. Finish: Manufacturer's standard enamel finish.

2.4 BOXES, ENCLOSURES, AND CABINETS


1. Cooper Crouse-Hinds; Div. of Cooper Industries, Inc.

2. Emerson/General Signal; Appleton Electric Company.

3. Erickson Electrical Equipment Co.

4. Hoffman.

5. Hubbell, Inc.; Killark Electric Manufacturing Co.

6. O-Z/Gedney; Unit of General Signal.

7. RACO; Division of Hubbell, Inc.

8. Scott Fetzer Co.; Adalet-PLM Division.

9. Spring City Electrical Manufacturing Co.

10. Thomas & Betts Corporation, Steel City.

11. Walker Systems, Inc.; Wiremold Company (The).

B. Sheet Metal Outlet and Device Boxes: NEMA OS 1.

C. Cast-Metal Outlet and Device Boxes: NEMA FB 1, Type FD, with gasketed cover.

D. Small Sheet Metal Pull and Junction Boxes: NEMA OS 1.

E. Cast-Metal Pull and Junction Boxes: NEMA FB 1, cast aluminum with gasketed cover.

F. Hinged-Cover Enclosures: NEMA 250, Type 1, with continuous hinge cover and flush latch.

1. Metal Enclosures: Steel, finished inside and out with manufacturer's standard enamel.





G. Cabinets: NEMA 250, Type 1, galvanized steel box with removable interior panel and

removable front, finished inside and out with manufacturer's standard enamel. Hinged door in

front cover with flush latch and concealed hinge. Key latch to match panelboards. Include

metal barriers to separate wiring of different systems and voltage and include accessory feet

where required for freestanding equipment.

2.5 FACTORY FINISHES

A. Finish: For raceway, enclosure, or cabinet components, provide manufacturer's standard Gray

paint applied to factory-assembled surface raceways, enclosures, and cabinets before shipping.

PART 3 - EXECUTION

3.1 RACEWAY APPLICATION

A. Outdoors:

1. Exposed: Rigid galvanized steel.

2. Concealed: Rigid galvanized steel.

3. Underground, Single Run: RNC, with waterproof fittings.

4. Underground, Grouped: RNC, with waterproof fittings.

5. Connection to Vibrating Equipment (Including Hydraulic, Pneumatic, Electric Solenoid,

or Motor-Driven Equipment): LFMC.

6. Boxes and Enclosures: NEMA 250, Type 4.

B. Indoors:

1. Exposed: EMT.

2. Concealed: EMT.

3. Connection to Vibrating Equipment (Including Transformers and Hydraulic, Pneumatic,

Electric Solenoid, or Motor-Driven Equipment): FMC; except use LFMC in damp or wet

locations.

4. Damp or Wet Locations: Rigid steel conduit.

5. Boxes and Enclosures: NEMA 250, Type 1, except as follows:

C. Minimum Raceway Size: 3/4-inch trade size.

D. Raceway Fittings: Compatible with raceways and suitable for use and location.

1. Intermediate Steel Conduit: Use threaded rigid steel conduit fittings, unless otherwise

indicated.

E. Install nonferrous conduit or tubing for circuits operating above 60 Hz. Where aluminum

raceways are installed for such circuits and pass through concrete, install in nonmetallic sleeve.

F. Do not install aluminum conduits embedded in or in contact with concrete.





3.2 INSTALLATION

A. Keep raceways at least 6 inches away from parallel runs of flues and steam or hot-water pipes.

Install horizontal raceway runs above water and steam piping.

B. Complete raceway installation before starting conductor installation.

C. Support raceways as specified in Division 16 Section "Basic Electrical Materials and Methods."

D. Install temporary closures to prevent foreign matter from entering raceways.

E. Protect stub-ups from damage where conduits rise through floor slabs. Arrange so curved

portions of bends are not visible above the finished slab.

F. Make bends and offsets so ID is not reduced. Keep legs of bends in the same plane and keep

straight legs of offsets parallel, unless otherwise indicated.

G. Conceal conduit and EMT within finished walls, ceilings, and floors, unless otherwise

indicated.

1. Install concealed raceways with a minimum of bends in the shortest practical distance,

considering type of building construction and obstructions, unless otherwise indicated.

H. Raceways below Slab on Grade and Below Grade:

1. Change from nonmetallic tubing to Schedule 40 nonmetallic conduit, rigid steel conduit,

or IMC before rising above the floor.

2. For conduits below grade provide U.L. Listed water-tight fittings. Contractor is

responsible for protecting installed conduits from both incidental construction damage

and water infiltration.

I. Install all raceways parallel or at right angles to nearby surfaces or structural members and

follow surface contours as much as possible. The Owner reserves the right to have conduits

reinstalled at no additional cost where installation is judged by the Owner to be disorganized,

non-uniform, or not parallel/perpendicular to structure.

1. Run parallel or banked raceways together on common supports.

2. Make parallel bends in parallel or banked runs. Use factory elbows only where elbows

can be installed parallel; otherwise, provide field bends for parallel raceways.

J. Join raceways with fittings designed and approved for that purpose and make joints tight.

1. Use insulating bushings to protect conductors.

K. Tighten compression fittings with suitable tools.

L. Terminations:

1. Where raceways are terminated with locknuts and bushings, align raceways to enter

squarely and install locknuts with dished part against box. Use two locknuts, one inside

and one outside box.





2. Where raceways are terminated with threaded hubs, screw raceways or fittings tightly

into hub so end bears against wire protection shoulder. Where chase nipples are used,

align raceways so coupling is square to box; tighten chase nipple so no threads are

exposed.

M. Without exception, install pull wires in empty raceways. Use polypropylene or monofilament

plastic line with not less than 200-lb tensile strength. Leave at least 12 inches of slack at each

end of pull wire.

N. Install raceway sealing fittings at suitable, approved, and accessible locations and fill them with

UL-listed sealing compound. For concealed raceways, install each fitting in a flush steel box

with a blank cover plate having a finish similar to that of adjacent plates or surfaces. Install

raceway sealing fittings at the following points:

1. Where conduits pass from warm to cold locations, such as building exterior.

2. Where otherwise required by NFPA 70.

O. Stub-up Connections: Extend conduits through concrete floor for connection to freestanding

equipment. Install with an adjustable top or coupling threaded inside for plugs set flush with

finished floor. Extend conductors to equipment with rigid steel conduit; FMC may be used

6 inches above the floor. Install screwdriver-operated, threaded plugs flush with floor for future

equipment connections.

P. Flexible Connections: Use maximum of 72 inches of flexible conduit for recessed and

semirecessed lighting fixtures; for equipment subject to vibration, noise transmission, or

movement; and for all motors. Use LFMC in damp or wet locations. Install separate ground

conductor across flexible connections.

Q. Surface Raceways: Install a separate, green, ground conductor in raceways from junction box

supplying raceways to receptacle or fixture ground terminals.

R. Verify floor box as an assembly matches or exceeds fire rating of floor.

S. Set floor boxes level. Trim after installation to fit flush with finished floor surface.

T. Install hinged-cover enclosures and cabinets plumb. Support at each corner.

U. Use of any PVC (RNM conduit) above slab on grade is not allowed.

3.3 PROTECTION

A. Provide final protection and maintain conditions that ensure coatings, finishes, and cabinets are

without damage or deterioration at time of Substantial Completion.

1. Repair damage to galvanized finishes with zinc-rich paint recommended by

manufacturer.

2. Repair damage to PVC or paint finishes with matching touchup coating recommended by

manufacturer.

3.4 CLEANING





A. After completing installation of exposed, factory-finished raceways and boxes, inspect exposed

finishes and repair damaged finishes.

END OF SECTION




ENCLOSED CONTROLLERS 260915 - 1

SECTION 260915

ENCLOSED CONTROLLERS

PART 1 - GENERAL

1.1 SUMMARY

A. Section includes the following enclosed controllers rated 600 V and less:

1. Full-voltage magnetic.

2. Reduced-voltage magnetic.

3. Multispeed.

1.2 DEFINITIONS

A. CPT: Control power transformer.

B. MCCB: Molded-case circuit breaker.

C. MCP: Motor circuit protector.

D. N.C.: Normally closed.

E. N.O.: Normally open.

F. OCPD: Overcurrent protective device.

G. SCR: Silicon-controlled rectifier.

1.3 SUBMITTALS

A. Product Data: For each type of enclosed controller. Include manufacturer's technical data on

features, performance, electrical characteristics, ratings, and enclosure types and finishes.

B. Shop Drawings: For each enclosed controller. Include dimensioned plans, elevations, sections,

details, and required clearances and service spaces around controller enclosures.

1. Show tabulations of the following:

a. Each installed unit's type and details.

b. Factory-installed devices.

c. Nameplate legends.

d. Short-circuit current rating of integrated unit.





e. Listed and labeled for integrated short-circuit current (withstand) rating of OCPDs

in combination controllers by an NRTL acceptable to authorities having

jurisdiction.

f. Features, characteristics, ratings, and factory settings of individual OCPDs in

combination controllers.

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

C. Qualification Data: For qualified testing agency.

D. Field quality-control reports.

E. Operation and Maintenance Data: For enclosed controllers to include in emergency, operation,

and maintenance manuals. In addition to items specified in Division 01 Section "Operation and

Maintenance Data," include the following:

1. Routine maintenance requirements for enclosed controllers and installed components.

2. Manufacturer's written instructions for testing and adjusting circuit breaker and MCP trip

settings.

3. Manufacturer's written instructions for setting field-adjustable overload relays.

4. Manufacturer's written instructions for testing, adjusting, and reprogramming reduced-

voltage solid-state controllers.

F. Load-Current and Overload-Relay Heater List: Compile after motors have been installed, and

arrange to demonstrate that selection of heaters suits actual motor nameplate full-load currents.

G. Load-Current and List of Settings of Adjustable Overload Relays: Compile after motors have

been installed, and arrange to demonstrate that switch settings for motor running overload

protection suit actual motors to be protected.


A. Testing Agency Qualifications: Member company of NETA or an NRTL.

1. Testing Agency's Field Supervisor: Currently certified by NETA to supervise on-site

testing.


by a qualified testing agency, and marked for intended location and application.

C. Comply with NFPA 70.


A. Store enclosed controllers indoors in clean, dry space with uniform temperature to prevent

condensation. Protect enclosed controllers from exposure to dirt, fumes, water, corrosive

substances, and physical damage.





B. If stored in areas subject to weather, cover enclosed controllers to protect them from weather,

dirt, dust, corrosive substances, and physical damage. Remove loose packing and flammable

materials from inside controllers.


A. Environmental Limitations: Rate equipment for continuous operation under the following

conditions unless otherwise indicated:

1. Ambient Temperature: Not less than minus 22 deg F and not exceeding 104 deg F.

2. Altitude: Not exceeding 6600 feet.

1.7 COORDINATION

A. Coordinate layout and installation of enclosed controllers with other construction including

conduit, piping, equipment, and adjacent surfaces. Maintain required workspace clearances and

required clearances for equipment access doors and panels.

B. Coordinate installation of roof curbs, equipment supports, and roof penetrations.

1.8 EXTRA MATERIALS

A. Furnish extra materials that match products installed and that are packaged with protective

covering for storage and identified with labels describing contents.

1. Fuses for Fused Switches: Equal to ten (10) percent of quantity installed for each size

and type, but no fewer than three of each size and type.

2. Control Power Fuses: Equal to ten (10) percent of quantity installed for each size and

type, but no fewer than two (2) of each size and type.

3. Indicating Lights: Two (2) of each type and color installed.

4. Auxiliary Contacts: Furnish one (1) spare for each size and type of magnetic controller

installed.

5. Power Contacts: Furnish three (3) spares for each size and type of magnetic contactor

installed.

PART 2 - PRODUCTS

2.1 FULL-VOLTAGE CONTROLLERS

A. General Requirements for Full-Voltage Controllers: Comply with NEMA ICS 2, general

purpose, Class A.

B. Motor-Starting Switches: "Quick-make, quick-break" toggle or push-button action; marked to

show whether unit is off or on.







a. Basis of Design: Siemens Energy & Automation, Inc.

b. Eaton Electrical Inc.; Cutler-Hammer Business Unit.

c. General Electric Company; GE Consumer & Industrial - Electrical Distribution.

2. Configuration: Non-reversing or two speed, where indicated.

3. Surface mounting.

4. Red and Green pilot lights (Red = “On”, Green = “Off”).

5. Additional Nameplates: HIGH and LOW for two-speed switches.

C. Fractional Horsepower Manual Controllers: "Quick-make, quick-break" toggle or push-button

action; marked to show whether unit is off, on, or tripped.

Acceptable Manufacturers: Subject to compliance with requirements, provide products





d. Square D; a brand of Schneider Electric.

2. Configuration: Non-reversing or Two speed.

3. Overload Relays: Inverse-time-current characteristics; NEMA ICS 2, Class 10 tripping

characteristics; heaters matched to nameplate full-load current of actual protected motor;

external reset push button; bimetallic type.


1. Red and Green pilot light (Red = “On”, Green = “Off”).

2. Additional Nameplates: HIGH and LOW for two-speed controllers.

D. Integral Horsepower Manual Controllers: "Quick-make, quick-break" toggle or push-button

action; marked to show whether unit is off, on, or tripped.







2. Configuration: Non-reversing or two speed, as indicated.

3. Overload Relays: Inverse-time-current characteristics; NEMA ICS 2, Class 10 tripping

characteristics; heaters and sensors in each phase, matched to nameplate full-load current

of actual protected motor and having appropriate adjustment for duty cycle; external reset

push button; bimetallic type.


5. Red and Green pilot light (Red = “On”, Green = “Off”).

6. Additional Nameplates: HIGH and LOW for two-speed controllers.





7. N.O. auxiliary contact.

E. Magnetic Controllers: Full voltage, across the line, electrically held.


by one of the following




2. Configuration: Non-reversing.

3. Contactor Coils: Pressure-encapsulated type with coil transient suppressors.

a. Operating Voltage: Depending on contactor NEMA size and line-voltage rating,

manufacturer's standard matching control power or line voltage.

4. Power Contacts: Totally enclosed, double-break, silver-cadmium oxide; assembled to

allow inspection and replacement without disturbing line or load wiring.

5. Control Circuits: 24 or 120-V ac; obtained from integral CPT, with primary and

secondary fuses of sufficient capacity to operate integral devices and remotely located

pilot, indicating, and control devices.

a. CPT Spare Capacity: Calculated by Div. 26 Contractor to power all control loads.

6. Bimetallic Overload Relays:

a. Inverse-time-current characteristic.

b. Class 10 tripping characteristic.

c. Heaters in each phase matched to nameplate full-load current of actual protected

motor and with appropriate adjustment for duty cycle.

d. Ambient compensated.

e. Automatic resetting.

7. N.C. or N.O., isolated overload alarm contact.

8. External overload reset push button.

F. Combination Magnetic Controller: Factory-assembled combination of magnetic controller,

OCPD, and disconnecting means.







2. Fusible Disconnecting Means:





a. NEMA KS 1, heavy-duty, horsepower-rated, fusible switch with clips or bolt pads

to accommodate Class J or Class R fuses.

b. Lockable Handle: Accepts three padlocks and interlocks with cover in closed

position.

c. Auxiliary Contacts: N.O./N.C., arranged to activate before switch blades open.

3. Nonfusible Disconnecting Means:

a. NEMA KS 1, heavy-duty, horsepower-rated, non-fusible switch.


position.


2.2 REDUCED-VOLTAGE MAGNETIC CONTROLLERS

A. General Requirements for Reduced-Voltage Magnetic Controllers: Comply with NEMA ICS 2,

general purpose, Class A; closed-transition; adjustable time delay on transition.

B. Reduced-Voltage Magnetic Controllers: Reduced voltage, electrically held.






2. Configuration:

a. Wye-Delta Controller: Four contactors, with a three-phase starting resistor/reactor

bank.

b. Part-Winding Controller: Separate START and RUN contactors, field-selectable

for 1/2- or 2/3-winding start mode, with either six- or nine-lead motors; with

separate overload relays for starting and running sequences.

c. Autotransformer Reduced-Voltage Controller: Medium-duty service, with integral

overtemperature protection; taps for starting at 50, 65, and 80 percent of line

voltage; two START and one RUN contactors.




4. Power Contacts: Totally enclosed, double-break, silver-cadmium oxide; assembled to



















C. Combination Reduced-Voltage Magnetic Controller: Factory-assembled combination of

reduced-voltage magnetic controller, OCPD, and disconnecting means.










position.


3. Non-fusible Disconnecting Means:

a. NEMA KS 1, heavy-duty, horsepower-rated, non-fusible switch.


position.


2.3 MULTISPEED MAGNETIC CONTROLLERS

A. General Requirements for Multispeed Magnetic Controllers: Comply with NEMA ICS 2,

general purpose, Class A.

B. Multispeed Magnetic Controllers: Two speed, full voltage, across the line, electrically held.










2. Configuration: Non-reversing, two winding.




4. Power Contacts: Totally enclosed, double break, silver-cadmium oxide; assembled to






6. Compelling relays shall ensure that motor will start only at low speed.

7. Accelerating timer relays shall ensure properly timed acceleration through speeds lower

than that selected.

8. Decelerating timer relays shall ensure automatically timed deceleration through each

speed.

9. Antiplugging timer relays shall ensure a time delay when transferring from FORWARD

to REVERSE and back.










C. Combination Multispeed Magnetic Controller: Factory-assembled combination of reduced-

voltage magnetic controller, OCPD, and disconnecting means.















position.


3. Nonfusible Disconnecting Means:

a. NEMA KS 1, heavy-duty, horsepower-rated, nonfusible switch.


position.


2.4 ENCLOSURES

A. Enclosed Controllers: NEMA ICS 6, to comply with environmental conditions at installed

location.

1. Dry and Clean Indoor Locations: Type 1.

2. Outdoor Locations: Type 3R; Cooling Tower Enclosure: Type 4X.

3. Kitchen and Wash-Down Areas: Type 4X stainless steel.

4. Other Wet or Damp Indoor Locations: Type 4.

2.5 ACCESSORIES

A. General Requirements for Control Circuit and Pilot Devices: NEMA ICS 5; factory installed in

controller enclosure cover unless otherwise indicated.

1. Push Buttons, Pilot Lights, and Selector Switches: Heavy-duty type.

a. Push Buttons: Recessed or Shrouded types; maintained or momentary, as

indicated.

b. Pilot Lights: Incandescent types; colors as indicated; push to test.

c. Selector Switches: Rotary type.

2. Elapsed Time Meters: Heavy duty with digital readout in hours; nonresettable.

3. Meters: Panel type, 2-1/2-inch minimum size with 90- or 120-degree scale and plus or

minus two percent accuracy. Where indicated, provide selector switches with an off

position.

B. N.C. or N.O. auxiliary contact(s).

C. Control Relays: Auxiliary and adjustable solid-state time-delay relays.

D. Phase-Failure, Phase-Reversal, and Undervoltage and Overvoltage Relays: Solid-state sensing

circuit with isolated output contacts for hard-wired connections. Provide adjustable

undervoltage, overvoltage, and time-delay settings.

E. Breather and drain assemblies, to maintain interior pressure and release condensation in Type 4,

Type 4X, Type 7 or Type 9 enclosures installed outdoors or in unconditioned interior spaces

subject to humidity and temperature swings.





F. Sun shields installed on fronts, sides, and tops of enclosures installed outdoors and subject to

direct and extended sun exposure.

G. Cover gaskets for Type 1 enclosures.

H. Terminals for connecting power factor correction capacitors to the line and load side of

overload relays.

I. Spare control wiring terminal blocks, quantity as indicated; unwired.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine areas and surfaces to receive enclosed controllers, with Installer present, for

compliance with requirements and other conditions affecting performance of the Work.

B. Examine enclosed controllers before installation. Reject enclosed controllers that are wet,

moisture damaged, or mold damaged.


3.2 INSTALLATION

A. Wall-Mounted Controllers: Install enclosed controllers on walls with tops at uniform height

unless otherwise indicated, and by bolting units to wall or mounting on lightweight structural-

steel channels bolted to wall. For controllers not at walls, provide freestanding racks complying

with Division 26 Section "Hangers and Supports for Electrical Systems."

B. Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and

temporary blocking of moving parts from enclosures and components.

C. Install fuses in each fusible-switch enclosed controller.

D. Install fuses in control circuits if not factory installed. Comply with requirements in

Division 26 Section "Fuses."

E. Install heaters in thermal overload relays. Select heaters based on actual nameplate full-load

amperes after motors have been installed.

F. Install, connect, and fuse thermal-protector monitoring relays furnished with motor-driven

equipment.

G. Install power factor correction capacitors. Connect to the line and load side of overload relays.

If connected to the load side of overload relays, adjust overload heater sizes to accommodate the

reduced motor full-load currents.

H. Comply with NECA 1.





3.3 IDENTIFICATION

A. Identify enclosed controllers, components, and control wiring. Comply with requirements for

identification specified in Division 26 Section "Identification for Electrical Systems."

1. Identify field-installed conductors, interconnecting wiring, and components; provide

warning signs.

2. Label each enclosure with engraved nameplate.

3. Label each enclosure-mounted control and pilot device.

3.4 CONTROL WIRING INSTALLATION

A. Install wiring between enclosed controllers and remote devices. Comply with requirements in

Division 26 Section "Control-Voltage Electrical Power Cables."

B. Bundle, train, and support wiring in enclosures.

C. Connect selector switches and other automatic-control selection devices where applicable.

1. Connect selector switches to bypass only those manual- and automatic-control devices

that have no safety functions when switch is in manual-control position.

2. Connect selector switches with enclosed-controller circuit in both manual and automatic

positions for safety-type control devices such as low- and high-pressure cutouts, high-

temperature cutouts, and motor overload protectors.


A. Testing Agency: Engage a qualified testing agency to perform tests and inspections.

B. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect,

test, and adjust components, assemblies, and equipment installations, including connections.

C. Perform tests and inspections.

1. Manufacturer's Field Service: Engage a factory-authorized service representative to

inspect components, assemblies, and equipment installations, including connections, and

to assist in testing.

D. Acceptance Testing Preparation:

1. Test insulation resistance for each enclosed controller, component, connecting supply,

feeder, and control circuit.

2. Test continuity of each circuit.

E. Tests and Inspections:

1. Inspect controllers, wiring, components, connections, and equipment installation. Test

and adjust controllers, components, and equipment.





2. Test insulation resistance for each enclosed-controller element, component, connecting

motor supply, feeder, and control circuits.

3. Test continuity of each circuit.

4. Verify that voltages at controller locations are within plus or minus 10 percent of motor

nameplate rated voltages. If outside this range for any motor, notify Engineer and Owner

before starting the motor(s).

5. Test each motor for proper phase rotation.

6. Perform each electrical test and visual and mechanical inspection stated in

NETA Acceptance Testing Specification. Certify compliance with test parameters.

7. Correct malfunctioning units on-site, where possible, and retest to demonstrate

compliance; otherwise, replace with new units and retest.

8. Perform the following infrared (thermographic) scan tests and inspections and prepare

reports:

a. Initial Infrared Scanning: After Substantial Completion, but not more than 60 days

after Final Acceptance, perform an infrared scan of each multi-pole enclosed

controller. Remove front panels so joints and connections are accessible to

portable scanner.

b. Follow-up Infrared Scanning: Perform an additional follow-up infrared scan of

each multi-pole enclosed controller 11 months after date of Substantial

Completion.

c. Instruments and Equipment: Use an infrared scanning device designed to measure

temperature or to detect significant deviations from normal values. Provide

calibration record for device.

9. Test and adjust controls, remote monitoring, and safeties. Replace damaged and

malfunctioning controls and equipment.

F. Enclosed controllers will be considered defective if they do not pass tests and inspections.

G. Prepare test and inspection reports including a certified report that identifies enclosed

controllers and that describes scanning results. Include notation of deficiencies detected,

remedial action taken, and observations after remedial action.

3.6 ADJUSTING

A. Set field-adjustable switches, auxiliary relays, time-delay relays, timers, and overload-relay

pickup and trip ranges.

B. Adjust overload-relay heaters or settings if power factor correction capacitors are connected to

the load side of the overload relays.

C. Set field-adjustable circuit-breaker trip ranges as specified in Division 26 Section "Overcurrent

Protective Device Coordination Study."





3.7 PROTECTION

A. Replace controllers whose interiors have been exposed to water or other liquids prior to

Substantial Completion.

3.8 DEMONSTRATION


adjust, operate, and maintain enclosed controllers.

END OF SECTION




WIRING DEVICES 262726-1

SECTION 262726

WIRING DEVICES

PART 1 - GENERAL

1.1 SUMMARY


1. Single and duplex receptacles, ground-fault circuit interrupters, integral surge

suppression units, and isolated-ground receptacles.

2. Single- and double-pole snap switches and dimmer switches.

3. Device wall plates.

4. Pin and sleeve connectors and receptacles.

5. Floor service outlets, poke-through assemblies, service poles, and multi-outlet

assemblies.

1.2 DEFINITIONS

A. EMI: Electromagnetic interference.

B. GFCI: Ground-fault circuit interrupter.

C. PVC: Polyvinyl chloride.

D. RFI: Radio-frequency interference.

E. TVSS: Transient voltage surge suppressor.

1.3 SUBMITTALS


B. Shop Drawings: List of legends and description of materials and process used for premarking

wall plates.

C. Samples: One for each type of device and wall plate specified, in each color specified.

D. Field quality-control test reports.


A. Source Limitations: Obtain each type of wiring device through one source from a single

manufacturer.







intended use.

C. Comply with NFPA 70.

1.5 COORDINATION

A. Receptacles for Owner-Furnished Equipment: Match plug configurations.

1. Cord and Plug Sets: Match equipment requirements.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

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

following:

1. Wiring Devices:

a. Bryant Electric, Inc./Hubbell Subsidiary.

b. Eagle Electric Manufacturing Co., Inc.

c. Hubbell Incorporated; Wiring Device-Kellems.

d. Leviton Mfg. Company Inc.

e. Pass & Seymour/Legrand; Wiring Devices Div.

2. Wiring Devices for Hazardous (Classified) Locations:

a. Crouse-Hinds/Cooper Industries, Inc.; Arrow Hart Wiring Devices.

b. EGS/Appleton Electric Company.

c. Killark Electric Manufacturing Co./Hubbell Incorporated.

2.2 RECEPTACLES

A. Straight-Blade-Type Receptacles: Comply with NEMA WD 1, NEMA WD 6, DSCC W-C-

596G, and UL 498.

B. Straight-Blade and Locking Receptacles: Heavy-Duty grade.

C. Straight-Blade Receptacles: Heavy-Duty grade.

D. GFCI Receptacles: Straight blade, through type, Heavy-Duty grade, with integral

NEMA WD 6, Configuration 5-20R duplex receptacle; complying with UL 498 and current

UL 943. Design units for installation in a 2-3/4-inch-deep outlet box without an adapter.

E. Industrial Heavy-Duty Pin and Sleeve Devices: Comply with IEC 309-1.





2.3 CORD AND PLUG SETS

A. Description: Match voltage and current ratings and number of conductors to requirements of

equipment being connected.

1. Cord: Rubber-insulated, stranded-copper conductors, with Type SOW-A jacket; with

green-insulated grounding conductor and equipment-rating ampacity plus a minimum of

30 percent.

2. Plug: Nylon body and integral cable-clamping jaws. Match cord and receptacle type for

connection.

2.4 WALL PLATES

A. Single and combination types to match corresponding wiring devices.

1. Plate-Securing Screws: Metal with head color to match plate finish.

2. Material for Finished Spaces: 0.04-inch-thick #4 brushed satin-finished stainless steel.

3. Material for Unfinished Spaces: Steel.

4. Material for Wet Locations: Cast aluminum with spring-loaded lift cover, and listed and

labeled for use in "wet locations."

2.5 FINISHES

A. Color:

1. Wiring Devices Connected to Normal Power System: White, unless otherwise indicated

or required by NFPA 70.

2. Wiring Devices Connected to Emergency Power System: Red.

3. GFCI Duplex Outlets: Grey.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install devices and assemblies level, plumb, and square with building lines.

B. Remove wall plates and protect devices and assemblies during painting.

C. Wrap 277v. toggle switch terminals with (HM) two (2) layers of U.L. Listed electrical tape.

Wrap after making connections and before securing device into metal wall or surface box.

D. Where circuit supplies power to GFCI and non-GFCI receptacles, do not loop GFCI outlet

devices fully in line with other circuit devices. “Pig-Tail” connect outlet in box such that

operation of ground fault opens the circuit at the device for user protection but other circuit

devices remain on-line.





3.2 IDENTIFICATION

A. Comply with Division 26 Section "Electrical Identification".

3.3 CONNECTIONS

A. Ground equipment according to Division 26 Section "Grounding and Bonding."

B. Connect wiring according to Division 26 Section "Conductors and Cables."

C. Tighten electrical connectors and terminals according to manufacturer's published torque-


UL 486A and UL 486B.


A. Perform the following field tests and inspections and prepare test reports:

1. After installing wiring devices and after electrical circuitry has been energized, test for

proper polarity, ground continuity, and compliance with requirements.

2. Test GFCI operation with both local and remote fault simulations according to

manufacturer's written instructions.

B. Remove malfunctioning units, replace with new units, and retest as specified above.

END OF SECTION




ENCLOSED SWITCHES AND CIRCUIT BREAKERS 262816 - 1

SECTION 262816

ENCLOSED SWITCHES AND CIRCUIT BREAKERS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes individually mounted switches and circuit breakers used for the

following:

1. Feeder and equipment disconnect switches.

2. Feeder branch-circuit protection.

3. Motor disconnect switches.

1.2 SUBMITTALS

A. Product Data for disconnect switches, circuit breakers, and accessories specified in this Section.

B. Product Data for switches, circuit breakers, and accessories specified in this Section. Include

the following:

1. Descriptive data and time-current curves.

2. Let-through current curves for circuit breakers with current-limiting characteristics.

3. Coordination charts and tables and related data.

C. Wiring diagrams detailing wiring for power and control systems and differentiating between

manufacturer-installed and field-installed wiring.

D. Qualification data for firms and persons specified in the "Quality Assurance" Article to

demonstrate their capabilities and experience. Include lists of completed projects with project

names and addresses, names and addresses of Engineers and owners, and other information

specified.

E. Field test reports indicating and interpreting test results.

F. Maintenance data for tripping devices to include in the operation and maintenance manual as

specified.


A. Testing Agency Qualifications: In addition to the requirements specified in Division 1 Section

"Quality Control," an independent testing agency shall meet OSHA criteria for accreditation of

testing laboratories, Title 29, Part 1907, or shall be a full member company of the InterNational

Electrical Testing Association (NETA).





1. Testing Agency's Field Supervisor: Person currently certified by NETA or the National

Institute for Certification in Engineering Technologies, to supervise on-site testing

specified in Part 3.

B. Source Limitations: Obtain disconnect switches and circuit breakers from one source and by a

single manufacturer.

C. Comply with NFPA 70 for components and installation.

D. Listing and Labeling: Provide disconnect switches and circuit breakers specified in this Section

that are listed and labeled.

1. The Terms "Listed" and "Labeled": As defined in the National Electrical Code,

Article 100.

2. Listing and Labeling Agency Qualifications: A "Nationally Recognized Testing

Laboratory" (NRTL) as defined in OSHA Regulation 1910.7.

E. Provide all enclosed breakers, disconnects, switches, with copper lugs. Use of aluminum is not

allowed.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, provide disconnect switches and

circuit breakers by one of the following:

1. Fusible Switches:

a. Eaton Corp.; Cutler-Hammer Products.

b. Square D Electric.

c. Siemens.

2. Molded-Case Circuit Breakers:

a. Eaton Corp.; Cutler-Hammer Products.

b. Square D Electric.

c. Siemens.

3. Combination Circuit Breaker and Ground Fault Trip:

a. Eaton Corp; Cutler Hammer Products.

b. Square D.

c. Siemens.

4. Molded-Case, Current-Limiting Circuit Breakers:

a. Eaton Corp; Cutler Hammer Products.

b. Square.





c. Siemens.

2.2 DISCONNECT SWITCHES

A. Enclosed, Nonfusible Switch: NEMA KS 1, Type HD, with lockable handle in open position.

Heavy duty rated.

B. Enclosed, Fusible Switch, 800 A and Smaller: NEMA KS 1, Type HD, clips to accommodate

specified fuses, enclosure consistent with environment where located, handle lockable with 2

padlocks, and interlocked with cover in CLOSED position. Heavy duty rated.

C. Enclosure: NEMA KS 1, Type 1, unless otherwise specified or required to meet environmental

conditions of installed location.

1. Outdoor Locations: Type 3R or Type 4.

2. Other Wet or Damp Indoor Locations: Type 4. Type 3R.

D. Lugs shall be copper, CU, and sized to accept wire size indicated on plan.

2.3 ENCLOSED CIRCUIT BREAKERS

A. Enclosed, Molded-Case Circuit Breaker: NEMA AB 1, with lockable handle.

B. 1. Where used in circuits for HVAC equipment, HVAC combination equipment, motor circuits,

provide U.L. Listed, HACR circuit breakers.

C. Characteristics: Frame size, trip rating, number of poles, and auxiliary devices as indicated and

interrupting rating to meet available fault current.

D. Application Listing: Appropriate for application, including switching fluorescent lighting loads

or heating, air-conditioning, and refrigerating equipment.

E. Circuit Breakers, 200 A and Larger: Trip units interchangeable within frame size.

F. Circuit Breakers, 400 A and Larger: Field-adjustable, short-time and continuous-current

settings.

G. Current-Limiting Trips: Where indicated, let-through ratings less than NEMA FU 1, Class RK-

5.

H. Current Limiters: Where indicated, integral fuse listed for circuit breaker.

I. Molded-Case Switch: Where indicated, molded-case circuit breaker without trip units.

J. Lugs: Mechanical lugs and power-distribution connectors for number, size, and material of

conductors indicated.

K. Shunt Trip: Where indicated.

L. Accessories: As indicated.





M. Enclosure: NEMA AB 1, Type 1, unless otherwise specified or required to meet environmental

conditions of installed location.

1. Outdoor Locations: Type 3R or Type 4.

2. Other Wet or Damp Indoor Locations: Type 4.

N. Lugs shall be copper, CU, and sized to accept wire size indicated on plan.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install disconnect switches and circuit breakers in locations as indicated, according to

manufacturer's written instructions.

B. Install disconnect switches and circuit breakers level and plumb.

C. Install wiring between disconnect switches, circuit breakers, control, and indication devices.

D. Connect disconnect switches and circuit breakers and components to wiring system and to

ground as indicated and instructed by manufacturer.


tightening values. Where manufacturer's torque values are not indicated, use those

specified in UL 486A and UL 486B.

E. Identify each disconnect switch and circuit breaker according to requirements specified in other

sections.


A. Testing: After installing disconnect switches and circuit breakers and after electrical circuitry

has been energized, demonstrate product capability and compliance with requirements.

1. Procedures: Perform each visual and mechanical inspection and electrical test stated in

NETA ATS, Section 7.5 for disconnect switches and Section 7.6 for molded-case circuit

breakers. Certify compliance with test parameters.

B. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance;

otherwise, remove and replace with new units and retest.

3.3 ADJUSTING

A. Set field-adjustable disconnect switches and circuit-breaker trip ranges as indicated.

3.4 CLEANING





A. After completing system installation, including outlet fittings and devices, inspect exposed

finish. Remove burrs, dirt, and construction debris and repair damaged finish including chips,

scratches, and abrasions.

PART 4 - FUSES

4.1 SUBMITTALS

A. Product Data for each fuse type specified.

B. Product Data for each fuse type specified. Include the following:

1. Descriptive data and time-current curves.

2. Let-through current curves for fuses with current-limiting characteristics.

3. Coordination charts and tables and related data.

C. Field test reports indicating and interpreting test results.

D. Maintenance data for tripping devices to include in the operation and maintenance manual as

specified.


A. Source Limitations: Obtain fuses from one source and by a single manufacturer.

B. Comply with NFPA 70 for components and installation.

C. Listing and Labeling: Provide fuses specified in this Section that are listed and labeled.

1. The Terms "Listed" and "Labeled": As defined in the National Electrical Code,

Article 100.

2. Listing and Labeling Agency Qualifications: A "Nationally Recognized Testing

Laboratory" (NRTL) as defined in OSHA Regulation 1910.7.

4.3 EXTRA MATERIALS

A. Furnish extra materials described below that match products installed, are packaged with

protective covering for storage, and are identified with labels describing contents.

1. Spare Fuses: Furnish quantity equal to 20 percent of each fuse type and size installed,

but not less than 1 set of 3 of each type and size.

4.4 MANUFACTURERS

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

following:





1. Cooper Industries, Inc.; Bussmann Div.

2. Eagle Electric Mfg. Co., Inc.

3. Gould Shawmut.

4. Tracor, Inc.; Littelfuse, Inc. Subsidiary.

4.5 EXAMINATION

A. Examine utilization equipment nameplates and installation instructions to verify proper fuse

locations, sizes, and characteristics.

B. Do not proceed with installation until unsatisfactory conditions have been corrected.

4.6 FUSE APPLICATIONS

A. Main Feeders: Class J, time delay.

B. Motor Branch Circuits: Class RK1, time delay.

C. Other Branch Circuits: Class RK5, non-time delay.

4.7 INSTALLATION

A. Install fuses in fusible devices as indicated. Arrange fuses so fuse ratings are readable without

removing fuse.

B. Provide and install steel spare fuse cabinet mount in main electric room unless otherwise

directed by the owner. Install spare fuse cabinet with hinged doors.

4.8 IDENTIFICATION

A. Install typewritten labels on inside door of each fused switch to indicate fuse replacement

information.

END OF SECTION