SECTION 15510 CHILLED WATER PIPING SYSTEM 00000000PART 1 - GENERAL 1.1 DESCRIPTION: A.

The work under this Section consists of furnishing and installation of chilled water piping system as indicated on the drawings and as specified herein. 1.2 REFERENCES: A. ASME - American Society of Mechanical Engineers: ASME B31.9 ASME B16.9 ASME B16.47 B. Building Services Piping. Factory Made Wrought Butt Welded Fittings Large-Diameter Steel Flanges, NPS 26 through NPS 60.

ASTM - American Society of Testing and Materials: ASTM A 53 ASTM A 183 ASTM A 234 ASTM A 449 ASTM A 536 ASTM A333 ASTM F 1476 Pipe, Steel, Black and Hot-Dipped, Zinc Coated (Galvanized), Welded and Seamless.

Carbon Steel Track Bolts and Nuts

Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures. Quenched and Tempered Steel Bolts and Studs. Ductile Iron Castings. Seamless and Welded Steel Pipe for Low-Temperature Service. Standard Specification for Performance of Gasketed Mechanical Couplings for use in Piping Applications.

C.

ANSI - American National Standard Institute ANSI B1.20.1 ANSI B16.1 ANSI B16.3 ANSI B16.5 ANSI B16.39 Pipe Threads. Cast Iron Flanges and Flanged Fittings, Classes 25, 125, 250 and 800. Malleable-Iron Threaded Fittings, Classes 150 and 300. Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys. Threaded Pipe Unions, Malleable-Iron, Classes 150, 250 and 300.

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ANSI/AWWA C606 D.

Grooved and Shouldered Joints.

BSI - British Standards Institute BS 21 BS 143 BS 1560 BS 4504 BS 5154 Pipe Threads for Tubes and Fittings. Malleable Cast Iron and Cast Copper Alloy threaded Pipe fittings. Steel Pipe Flanges. Flanges and Bolting for Pipes, Valves and Fittings. Copper alloy Globe, Globe Stop, and Check, Check and Gate valves

E.

API American Petroleum Institute: API - 5L API-605 Specification for Line Pipe. Flanges

F.

ISO International Standards 0rganization: ISO 1183 Polyethylene Measurement of Density

G.

HI - Hydraulic Institute: HI E.35.01 Centrifugal Pumps.

1.3

SUBMITTALS: A. Product Data: Submit manufacturer's technical product data and installation instructions for chilled water piping materials and products. B. Shop Drawings: Submit scaled layout drawings of chilled water piping and fittings including, but not necessarily limited to, pipe sizes, location, elevations and slopes of horizontal runs, wall and floor penetrations, and connections. Show interface and spatial relationship between piping and proximate equipment. C. Record Drawings: At project closeout, submit record drawings of installed chilled water piping and piping products. D. Grooved joint couplings and fittings shall be shown on drawings and product submittals, and shall be specifically identified with the applicable style or series designation E. Maintenance Data: Submit maintenance data and parts lists for chilled water piping materials and products. Include this data, product data, shop drawings, and record drawings in maintenance manual. F. Test Results: Submit test results as required.

1.4

WARRANTY:

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A. Submit written guarantee signed by the contractor and manufacturer for the period of 1 year from the date of substantial completion. The guarantee shall cover the repair and replacement of defective materials and workmanship as directed by the Engineer. If manufacturer warranties any equipment for more than one year as a standard practice such warranties shall also be submitted. PART 2 - PRODUCTS 2.1 CHILLED WATER PIPING: A. General: All black steel pipes shall be standard weight, electric-resistancewelded, unless indicated otherwise. Pipes for underground chilled water installation shall be preinsulated pipes suitable for direct burial and shall consist of carrier pipe, insulation and outer casing conforming to following: a. Carrier Pipe: Black steel pipe as indicated below for various size and line pressure, except for providing seamless pipe for all for underground chilled water installation. Fittings for all preinsulated piping shall be by Victaulic or approved equal. Type of fittings shall be as recommended by manufacturer and approved by the Engineer. Insulation: CFC-free rigid polyurethane foam insulation, 48 kg/m3 density (minimum.) to ASTM D 1622, not less than 50 mm thickness. Outer Casing: Extruded high-density polyethylene (HDPE) pipe conforming to ISO or SASO Standards with 950 kg/m3 density (minimum.) to ISO 1183, elongation at break 600% (min) and yield stress 20 MPa (min) to ISO 527-2.

b.

c. d.

B. Carrier Pipe: 50 mm and Smaller:

1.
2.

Pipe: Black Steel Pipe, ASTM A53, Schedule 40, Type E, Grade B or API 5L, Grade B. Fittings: Black Malleable Iron Screw Fittings, 150 lb. ANSI/ASME B16.3. Joints: Pipe Threads, General Purpose (American) ANSI/ASME B1.20.1.

3.

C. Carrier Pipe: 63 mm to 250 mm:

1. 2.

Pipe: Black Steel Pipe, ASTM A53, Schedule 40, Type E, Grade B or API-5L, Grade B, roll or cut grooved-ends as appropriate to pipe material. Fittings: Victaulic Grooved End Fittings or approved equal: Fittings shall be cast of ductile iron conforming to ASTM A-536, Grade 65-45-12. Fittings shall be provided with an alkyd enamel finish. Joints: Victaulic Standard Mechanical Couplings or approved equal. Manufactured in two segments of cast ductile iron, conforming to ASTM A536, Grade 65-45-12. Gaskets shall be pressure-responsive synthetic rubber, grade to suit the intended service, conforming to ASTM D-2000. Mechanical Coupling bolts shall be zinc plated (ASTM B-633) heat treated carbon steel track head conforming to ASTM A-449 and ASTM A-183, minimum tensile

3.

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strength 110,000 psi (758450 kPa). Mechanical Couplings equal to Victaulic couplings Style 07, 107, 75, 77 or 741, or approved equal. D. Carrier Pipe: 300 mm and Larger:

1. 2.

Pipe: Black Steel Pipe, ASTM A53, Standard Weight, Type E Grade B or API5L Grade B, roll or cut grooved-ends as appropriate to pipe material. Fittings: Fittings shall be supplied with factory grooved ends, for use with Victaulic W07 or W77 couplings and W741 flange adapter or approved equal. Fittings shall be manufactured of ductile iron conforming to ASTM A-536, Grade 65-45-12. Fittings shall be manufactured to the dimensional standards ASME B16.9. Fittings shall be provided with an alkyd enamel finish. Joints: Victaulic Mechanical Couplings or approved equal. Couplings shall consist of two ASTM A-536 ductile iron housing segments, a wide elastomer pressure responsive gasket, and zinc electroplated carbon steel track head bolts and nuts conforming to the physical and chemical requirements of ASTM A-449 and the physical requirements of ASTM A-183. Mechanical Couplings equal to Victaulic couplings Style W07, W77 or W741, approved equal. Gaskets: Victaulic FlushSeal design or approved equal , lubricated per manufacturers recommend and suitable for intended service.

3.

4.

E. Special Fittings:

1.

Dielectric Union or Waterway Fitting: Threaded, grooved or soldered end connections for the pipe material in which installed; constructed to isolate dissimilar materials, prevent galvanic action, and prevent corrosion. Flexible Connectors: Stainless steel bellows with woven flexible bronze wire reinforcing protective jacket; minimum 1035 kPa working pressure, maximum 120oC operating temperature. Connectors shall have flanged or threaded end connections to match equipment connected; and shall be capable of 19 mm misalignment. a. Couplings may be used in lieu of a flexible connector for vibration attenuation and stress relief in systems with operating temperatures to 110C. The couplings shall be placed in close proximity to the source of the vibration.

2.

3.

Gasket Material: Thickness, material, and type suitable for fluid to be handled, and design temperatures and pressures. Welding Materials (Where required): Comply with Section II, Part C ASME Boiler and Pressure Vessel Code for welding materials appropriate for wall thickness and chemical analysis of pipe material being used. Grooved Joint Lubricants: Lubricate gaskets in accordance with the manufacturers recommendations with lubricant supplied by the coupling manufacturer that is suitable for the gasket elastomer and system media.

4.

5.

F. General Duty Valves:

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1.

As specified in Section 15100 - VALVES.

G. Special Duty Valves:

1.

Calibrated Plug Valves: 1200 kPa water working pressure, 40oC maximum operating temperature, bronze body, plug valve with calibrated orifice. Provide with connections for portable differential pressure meter with integral check valves and seals. Valve shall have integral pointer and calibrated scale to register degree of valve opening. Valves 50 mm and smaller shall have threaded connections and the 65 mm valves shall have flanged connections. Self Contained Flow Control Valves: Class 150, cast iron housing, stainless steel operating parts; threaded connections for 50 mm and smaller, flanged connection for 65 mm and larger. Factory set to automatically control flow rates within plus or minus 5 percent design, while compensating for system operating pressure differential. Provide quick disconnect valves for flow measuring equipment. Provide a metal identification tag with chain for each valve, factory marked with the zone identification, valve model number, and rate flow in m3/min.

2.

H. Piping Specialties:

1.

Manual Air Vent: Bronze body and non-ferrous internal parts; 1035 kPa working pressure, 110oC operating temperature; manually operated with screwdriver or thumb-screws; and having 3 mm discharge connection and 13 mm inlet connection. Automatic Air Vent: Designed to vent automatically with float principles; bronze body and non-ferrous internal parts; 1035 kPa working pressure, 120oCoperating temperature; and having 6 mm discharge connection and 13 mm inlet connection. Pressure and Temperature Taps: Install pressure and temperature taps at all coil connections across two port valves, pumps, chiller evaporator, or otherwise as indicated: a. Taps shall be 13 mm solid brass fittings which shall receive either pressure or temperature probe with valve core or Nordel fitted color coded and marked cap and gaskets, and rated at 135oC and 7000 kPa. Furnish No. 500 pressure gauge adapters with 3-8 mm probe and No. 701, 125 mm stem pocket thermometers with - 5o to 50o range for chilled water.

2.

3.

b.

4.

Chemical Feeder: Bypass type chemical feeders of 19 liter capacity, welded steel construction; 850 kPa working pressure; complete with fill funnel and inlet, outlet, and drain valves. Y-Pattern Strainers: Ductile iron body, ASTM A536, Grade 65-45-12, grooved ends or Cast iron body, ASTM A126, Class B, flanged ends for 65 mm and larger, threaded connections for 50 mm and smaller, bolted cover, perforated Type 304 stainless steel basket, bottom drain connection, , 2065 kPa working pressure.

5.

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a. 6.

For sizes 350 mm to 600 mm, T-pattern strainer, with T-bolt hinged closure and Type 304 stainless steel basket.

BTU Meters: a. b. BTU, Water Metering and independent of BMS System Billing System are completely

BTU Meters, Water Meters and Billing System 1.) Where required by the Contract Documents, the Contractor shall be responsible to provide complete Billing System from a reputable Manufacturer. Billing System shall be fully in coordination with the Client / Operator requirements and shall include, but not limited to following: a) b) c) d) e) Ultrasonic flow meters Temperature Sensors for BTU Metering Data Collection / Calculator and Display Units Data Communication Network to Central Billing System PC Based Billing System Hardware and Software Package Installation, Testing and Commissioning and Training of Client staffs as per the Contract.

2.)

f)
3.) 4.)

BTU Meter shall be manufactured by TAC, Barber Colman, Kamstrup, or approved equal. The BTU Meter shall be made to EN 1434:2004 standards all in accordance with the EU Directives: MID (Measuring Instrument Directive); LVD (Low Voltage Directive); and EMC (Electromagnetic Compatibility Directive). The BTU Meter manufacturer shall be able to deliver calibration certificates from independent laboratory for each of the components, flow sensors, calculator and temperature sensors. Flow sensor shall be ultrasonic type using bidirectional ultrasonic temperature based on transmit time method. The BTU Meter shall be powered by a 3.6 V lithium long life (10 years lifetime) battery, by 230 VAC or by 24 VAC. Flow sensor shall be treaded up to 50 mm and flanged from 65 mm and upwards. The manufacturer should be able to deliver a wide range of flow sensor sizes, DN20

5.) 6.)

7.)

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DN250mm. 8.) It shall be possible to mount the calculator on the flowpart or mount them separately. The cable length between the flow sensor and the calculator must be 2.5 meters. It should be possible, by supply of an extension kit, to provide a longer cable distance (up to 10 meters) between the flowpart and the calculator. The temperature sensors must be of Pt 500 type, direct sensors or pocket sensor type, with built in platinum resistor. The sensors must be of matched pair and conform to EN 60751. The length of the temperature sensor pairs should be 1.5 meters, 3 meters or 5 meters. The location of the flow sensor shall be as such that it eliminates air pockets and keep the instrument piping free of dirt, rust and corrosion which may block the transmitter sensing part. The Calculator must have provision for 2 independent communication modules. Communication shall be M-Bus in accordance with international standard (EN 1434), LonWorks, 0/4 20mA, pulse output or wireless On M-Bus and wireless communication modules it shall be possible to take pulse input as standard. months, 15 years with optional storage of hourly values for 58 days,

9.)

10.)

11.)

12.)

13.) Data must be stored in the calculator for 460 days, 36

14.) The calculator shall have optional RTC (real Time Clock)
15.) c. The calculator shall have 2 pulse input, 1 for electricity meter and 1 for water meter.

Billing System Hardware and Software shall be completely independent of BMS System 1.) Windows based, Windows 2000 or Windows XP It shall be capable of preparing billing invoices for individual tenants based on their consumption The system must be able to handle customer information, like name, address, etc. It shall be possible to export data in standard CSV format to an accounting system and it must be possible to customize the data to be exported. It must have a standard database like MS Access Reading interval must be selectable and it shall be possible

2.)
3.) 4.)

5.)
6.)
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to read the meters in groups or select a single meter. 7.) It shall be possible to connect to the system for display of data from other work stations via a LAN.

2.2 DIAPHRAGM-TYPE COMPRESSION TANKS: A. Size and number as indicated; construct of welded carbon steel for 850 kPa working pressure, 1900C maximum operating temperature. Separate air charge from system water to maintain design expansion capacity, by means of a flexible diaphragm securely sealed into tank. Provide taps for pressure gauge and air charging fitting, and drain fitting. Support vertical tanks with legs or base; support horizontal tanks with steel saddles. Tank, with taps and supports, shall be constructed, tested, and labeled in accordance with ASME Pressure Vessel Code, Section VIII, Division 1.

2.3 MAKE-UP WATER CONNECTION: A. Provide pressure relief valve and automatic cold sweet water fill assembly complete with pressure reducing valve, after meter arrester, sight glass, backflow preventer with test cocks, water filter, vacuum breaker and valved by-pass. 2.4 AIR SEPARATOR: A. Type: The air release tank shall be of the in-the-pipe-line type with tangential openings for water in and out. The inside shall be specifically designed to create a low velocity vortex for the separation of free air from the water stream. B. Size: The size of the air release tank shall be based on the line size of the pipe shown on the drawings. C. Shell: The shell shall be constructed of welded carbon steel; ASME constructed and labeled for 8.78 kg/cm2 (850 kPa) water working pressure and 1900C operating temperature.

D. Strainer: The tank shall be equipped with an internal steel strainer with perforations sized for water flow. The strainer shall be installed in a location of assist in the separation of air. The strainer shall be removable from the bottom by unbolting the steel bolt heads. E. Drain: The tank shall be equipped with a bottom drain and this drain shall be piped to the nearest open site drain. The drain line shall be equipped with a gate valve and a union to facilitate the removal of the strainer. 2.5 CHILLED WATER PUMPS: A. General: 1. Centrifugal pump fabrication, installation and testing shall be in conformance with Hydraulic Institute Standards. 2. The selection of pump type and pump drive shall be based on each specific application requirements. Pump drivers shall be selected to be non-

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overloading over the whole range of the Q-TDH curves, consideration temperature variations of the fluid being pumped. 3. Pump Q-TDH curve shall be such that it provides stable operation for the pump when operating at any point on the curve. Shut-off head shall be approximately 25 to 35 percent above the rated head. 4. Provide vertical in-line pumps, single stage singe or double suction type as shown on drawings, with pump characteristics which provide rising heads to shut off. Refer to pump schedule for pump flows, heads, motor speed, enclosure, efficiency and power requirements. 5. Pumps shall be of variable or constant speed drive as required and capable of parallel operation. For pumps with variable speed drive, the control system shall include as a minimum, the programmable logic pump controller, adjustable frequency drive(s) and remote sensor/transmitter as required. All additional items required to properly execute the sequence of operation shall be provided. B. Pumps shall be split couple type, with rigid spacer type coupling; capacity and type as shown on the drawings. C. Pump Casing: Cast Iron for working pressure below 12.05 bar at 65 C (PN16 flange rating) and Ductile Iron for working pressures to 25 bar at C (PN25 flange rating).Suction discharge connection shall be flange and the same time size and shall be drilled and tapped for seal flush and gauge connections. D. Impeller: Bronze, fully enclosed type. Dynamically balance. E. Shaft: Provide Stainless Steel pump Shaft with stainless steel sleeves. F. Coupling: Rigid spacer type of high tensile aluminum alloy. Couplings shall be split to allow removal from pump and motor shaft, leaving space between the shaft sufficient to replace all mechanical seal components without disturbing the pump or motor. G. Pump Motor shall be TEFC Class F. H. Mechanical Seal: Shall be Stainless Steel outside multi spring balanced type with secondary seal. Provide bronze gland plate with Stainless Steel trim. Provide factory installed flush line with manual vent. I. All Split coupled pumps shall be provided with a lower seal chamber throttle bushing. Seal flush line fittings, if required: 1. 2. Supply in the flush line to the mechanical seal a 50 micron cartridge filter and sight flow indicator, to suit the working pressure encountered. Filters shall be changed, by the installing contractor, after system is flushed and on a regular basis until over to the owner.

J. Pump performance tests shall be conducted in accordance with the Hydraulic Institute test codes as described in HI E.35.01, E.37.01 and E.39.01. In addition, each pump shall be tested at five points of operation from shut-off head to runout condition, including the guaranteed pump's performance point.

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K. The manufacturer shall submit certificate, including test data to show that pump meets performance specifications. 2.6 CHEMICAL TREATMENT FOR CHILLED WATER SYSTEM: A. The analysis and treatment recommendation shall be made by a specialist with a minimum of 5 years experience in this field. B. The Contractor shall supply and/or install the water treatment facilities and chemicals as listed below. Chemicals shall be specially formulated to prevent accumulation of scale and corrosion in piping system and connected equipment, developed based on a water analysis of make-up water. 1. 2. 3. 4. Chemical pot feeder complete with sampling point and valving as indicated. Corrosion scale and electrolytic action inhibiter dosing in the chilled water system. Test Kit. Carry out tests on local water necessary to finalize details of the water treatment.

C. Treatment: 1. 2. 3. Thoroughly clean and system of oil grease and swarf deposits using an approved soluble solvent in accordance with the manufacturer's instructions. Circulate the solution for at least one hour, drain and then flush system thorough with fresh water. Does system with corrosion and electrolytic action and scale inhibitor.

D. Handover: 1. 2. 3. 4. 2.7 INSULATION: A. Refer to Section 15250 - MECHANICAL INSULATION. 00PART 3 - EXECUTION 3.1 INSTALLATION: A. Refer to Section 15050 - BASIC PIPING MATERIALS AND METHODS for The Contractor shall supply a test kit and instruct the user in its use. Full instructions shall be given to the user on the dosing methodology. Prior to handover, the Contractor shall carry out his own tests and ensure the system is correctly dosed. Provide the user with 6 months supply of chemicals.

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basic piping installation instructions. Refer to the drawings for further details. The entire chilled water system installation shall conform to the requirements of ASME B 31.9 Building Services Piping, IAPMO Uniform Mechanical Code, ARI Standard 260, and ANSI B 9.1, or equivalent. B. Install above ground black steel pipes with threaded joints and fittings for 50 mm and smaller, and with Victaulic fittings for 65 mm or larger. For underground pre-insulated pipe use Victaulic fittings. Provide concrete support at the interval of maximum 4000 mm, at both sides of coupling and at change of direction. Provide concrete thrust blocks at each change of direction. Details of concrete support and thrust block shall be as approved by the Engineer. C. Grooved joints shall be installed in accordance with the manufacturers latest published installation instructions. Grooved ends shall be clean and free from indentations, projections, and roll marks in the area from pipe end to groove. Gaskets shall be of an elastomer grade suitable for the intended service, and shall be molded and produced by the coupling manufacturer. The grooved coupling manufacturers factory trained representative shall provide on-site training for contractors field personnel in the use of grooving tools and installation of grooved joint products. The representative shall periodically visit the jobsite and review contractor is following best recommended practices in grooved product installation. (A distributors representative is not considered qualified to conduct the training or jobsite visit(s).) D. Proper foundations for mounting of piping system shall be provided, including supports, vibration isolators, guides, anchors, clamps and brackets. E. Pumps shall be installed in strict conformance with manufacturer's written instructions. F. If oil grease lubricated bearings are supplied with the pumps, the oiler shall be filled with the specified lubricating oil, or bearings shall be pre-lubricated with specified grease prior to start-up. G. Field testing of the pumps shall be performed at the time of overall system start-up and testing. Installed pumps shall meet the performance specifications. H. Pipe Workmanship: Install completed system, size as shown on the drawings. Install piping parallel or perpendicular to the building construction. Allow for expansion. I. Air Vents: Provide at all changes in elevation downward in direction of flow. Except where shown, provide automatic air vents. Also provide air vents at system high points. J.The air separator shall be installed dead level in both directions and shall be supported from the structure so that all pipes can be removed without moving the air separator. The separator shall be installed so that the strainer can be removed without moving the tank. K. The chilled water piping, valves, fittings, separator and expansion tank shall be insulated as per Section 15250 - MECHANICAL INSULATION. L.Chilled Water Treatment:

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1.

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

2.

3.2

FIELD QUALITY CONTROL A. The grooved coupling manufacturers factory trained representative shall provide onsite training for contractors field personnel in the use of grooving tools and installation of grooved joint products. The representative shall periodically visit the jobsite and review contractor is following best recommended practices in grooved product installation. (A distributors representative is not considered qualified to conduct the training or jobsite visit(s).) Preparation for testing: Prepare chilled water piping in accordance with ASME B 31.9 and as follows: 1. Leave joints uninsulated and exposed for examination during the test.

B.

2. Provide temporary restraints for expansion joints which cannot sustain the reactions due to test pressure. 3. Flush system with clean water. Clean strainers.

4. Isolate equipment that is not to be subjected to the test pressure from the piping. 5. Install relief valve set at a pressure no more than 1/3 higher than the test pressure, to protect against damage by expansion of liquid or other source of over pressure during the test. C. Testing: Test chilled water piping as follows: 1. 2. Use ambient temperature water as the testing medium. Use vents installed at high points in the system to release trapped air while filling the system. Use drains installed at low points for complete removal of the that liquid. Subject piping system to a hydrostatic test pressure which at every point in the system in not less than 1.5 times the design working pressure. The test pressure shall not exceed the maximum pressure for any vessel, pump, valve, or other component in the system under test. Make a check to verify that the stress due to pressure at the bottom of vertical runs does not exceed either 90 percent of specified minimum yield strength, or 1.7 times the "SE" value in Appendix A of ASME B 31.9, Code for pressure piping, building services piping. After the hydrostatic 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 as appropriate, and repeat

3.

4.

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hydrostatic test until there are no leaks. 5. 3.3 For further requirements refer to Section 15990 - TESTING, ADJUSTING AND BALANCING.

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

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