SECTION 15481

COMPRESSED AIR SYSTEM

PART	GENERAL

SECTION INCLUDES

Pipe and Pipe Fittings.

Reciprocating air compressor.

Air receiver and accessories.

Aftercooler.

Refrigerated air dryer.

Pressure reducing station.

PRODUCTS INSTALLED BUT NOT FURNISHED UNDER THIS SECTION

Section 01010 - Summary of Work: Owner furnished [air compressor] [air outlet fittings] [________].

RELATED SECTIONS

Section 03300 - Cast-in-Place Concrete.

Section 15140 - Supports and Anchors.

Section 15190 - Mechanical Identification: Identification of piping system.

Section 15245 - Vibration Isolation.

Section 16180 - Equipment Wiring Systems: Electrical characteristics and wiring connections.

REFERENCES

ASME - Boiler and Pressure Vessel Code.

ASME B16.3 - Malleable Iron Threaded Fittings.

ASME B16.18 - Cast Bronze Solder-Joint Pressure Fittings.

ASME B16.22 - Wrought Copper and Bronze Solder-Joint Pressure Fittings.

ASME B16.26 - Cast Bronze Fittings for Flared Copper Tubes.

ASME B31.1 - Power Piping.

ASME B31.9 - Building Services Piping.

ASTM A53 - Pipe, Steel, Black and Hot-Dipped Zinc Coated, Welded and Seamless.

ASTM A120 - Pipe, Steel, Black and Hot-Dipped Zinc Coated (Galvanized), Welded and Seamless, for Ordinary Uses.

ASTM A234 - Pipe Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures.

ASTM B32 - Solder Metal.

ASTM B88 - Seamless Copper Water Tube.

ASTM D2513 - Thermoplastic Gas Pressure Pipe, Tubing and Fittings.

ASTM D2683 - Socket-Type Polyethylene Fillings for Outside Diameter-Controlled Polyethylene Pipe.

NFPA 70 - National Electrical Code.

SUBMITTALS

Submit under provisions of Section [01300.] [________.]

Shop Drawings: Indicate piping system schematic with electrical characteristics and connection requirements.

Product Data: Provide manufacturers catalog literature with capacity, weight, and electrical characteristics and connection requirements.

Test Reports: Submit inspector's certificate for air receiver for inclusion in Operating and Maintenance Manuals.

Manufacturer's Installation Instructions: Indicate hoisting and setting requirements, starting procedures.

PROJECT RECORD DOCUMENTS

Submit under provisions of Section [01700]. [________].

Record actual locations of equipment and components. Modify shop drawings to indicate final locations.

OPERATION AND MAINTENANCE DATA

Submit under provisions of Section [01700.] [________.]

Operation Data: Submit for air compressor, air receiver and accessories, after cooler, refrigerated air dryer, and pressure reducing station.

Maintenance Data: Submit for air compressor, air receiver and accessories, after cooler, refrigerated air dryer, and pressure reducing station.

REGULATORY REQUIREMENTS

Conform to [applicable] [ASME] [___________] code for installation of pressure vessels.

Provide certificate of compliance from [authority having jurisdiction] [________________] indicating approval of air receiver.

Products Requiring Electrical Connection: Listed and classified by [Underwriters' Laboratories, Inc.,] [testing firm acceptable to the authority having jurisdiction] as suitable for the purpose specified and indicated.

DELIVERY, STORAGE, AND HANDLING

Deliver, store, protect and handle products to site under provisions of Section [01600]. [________].

Accept air compressors, refrigerated air dryer on site in factory fabricated containers with shipping skids and plastic pipe end protectors in place. Inspect for damage.

Protect piping and equipment from weather and construction traffic.

WARRANTY

Provide [five] [____] year warranty under provisions of Section [01700]. [________].

Warranty: Include coverage for [reciprocating air compressors] [___________].

MAINTENANCE MATERIALS

Provide maintenance materials under provisions of [01700]. [________].

Provide [two] [____] quart (litre) containers of compressor oil.

PART	PRODUCTS

PIPE AND PIPE FITTINGS

Steel Pipe: ASTM A53 or A120, Schedule 40 black.

Fittings: ASME B16.3, malleable iron, or ASTM A234, forged steel welding type.

Joints: Threaded or welded to [ANSI B31.1] [ANSI B31.9] [ASME Sec 1].

Copper Tubing: ASTM B88, Type [M], [L], [K] hard drawn.

Fittings: ASME B16.18, cast bronze, or ASME B16.22, wrought copper and bronze.

Joints: ASTM B32, solder, Grade 95TA.

Copper Tubing: ASTM B88, Type [K], [L] annealed.

Fittings: ASME B16.26, cast bronze.

Joints: Flared.

Polyethylene Pipe: ASTM D2513, SDR 11.5.

Fittings: ASTM D2683 or ASTM D2513 socket type.

Joints: Fusion welded.

VALVES

Gate Valves

Manufacturers:

[_____________________________] Model [________].

[_____________________________] Model [________].

[_____________________________] Model [________].

Bronze body, bronze trim, [non-rising] [rising] stem, handwheel, inside screw, single wedge or disc, [solder] [or] [threaded] ends.

Ball Valves

Manufacturers:

[_____________________________] Model [________].

[_____________________________] Model [________].

[_____________________________] Model [________].

[Bronze] [Stainless steel] [one] [two] piece body, [stainless] [chrome plated] steel ball, teflon seats and stuffing box ring, lever handle [solder] [or] [threaded] ends [with union.]

Swing Check Valves

Manufacturers:

[_____________________________] Model [________].

[_____________________________] Model [________].

[_____________________________] Model [________].

Bronze swing disc, [solder] [or] [screwed] ends.

Air Outlets

Manufacturers:

[_____________________________] Model [________].

[_____________________________] Model [________].

[_____________________________] Model [________].

Quick Connector: [3/8] [1/4] inch ([10] [6] mm) brass, snap on connector with self closing valve.

UNIONS AND COUPLINGS

Unions

Ferrous Pipe: 150 psig (1 034 kPa) malleable iron threaded unions.

Copper Tube and Pipe: 150 psig (1 034 kPa) bronze unions with soldered joints.

Dielectric Connections: Union with galvanized or plated steel threaded end, copper solder end, water impervious isolation barrier.

Flexible Connector: Neoprene with brass threaded connectors.

COMPRESSOR

Manufacturers:

[_________________________________] Model [________].

Other acceptable manufacturers offering equivalent products.

[_____________________________] Model [________].

[_____________________________] Model [________].

[_____________________________] Model [________].

Type: [Simplex] [Duplex] compressor unit consisting of [air cooled] [water cooled] compressor, air receiver, after cooler, [refrigerated air dryer,] [pressure reducing station,] [spring isolators,] and operating controls.

Compressor: Cast iron housing and head, heat treated forged steel or ductile iron shaft, aluminum alloy connecting rods, aluminum pistons with [non-lubricated carbon] rings, high-strength alloy suction and discharge valves. Statically and dynamically balance rotating parts.

Oil Pressure Switch: Equip compressor to automatically shut down compressor in event of oil pressure failure.

Capacity Reduction: Suction valve unloader with lifting mechanism operated by [oil pressure.] [gas discharge pressure.] [solenoid valve.] [centrifugal force.] Provide for unloaded compressor start.

Base: One piece ribbed cast iron or welded steel base for motor and compressor with provision for V-belt adjustment.

Thermostatic Water Valve: To maintain water temperature through compressor at 98 degrees F (37 degrees C) to 109 degrees F (43 degrees C).

Capacity:

Continuous Delivery: [_____] cfm ([_____] L/sec) of free air.

Intake Conditions: [______].

Discharge Conditions: [_______] psi ([______] kPa) at [_____] ft ([_____] m) altitude.

Electrical Characteristics:

[____] hp ([____] kW).

[____] volts, [single] [three] phase, 60 Hz].

[____] amperes maximum [fuse size] [circuit breaker size] [over current protection].

Refer to Section 16180.

Motor: [Refer to Section 15170.] [NEMA MG1, [____].]

Controls:

Pressure Switch: Line voltage contactor to break at 100 psi (690 kPa) with minimum differential of 20 psi (138 kPa).

Compressor Regulation: Lead-lag switch with time delay relay.

Electrical Alternation: Operate each compressor for 12 hours. If one compressor fails, second shall automatically maintain air pressure.

Wiring Terminations: Provide terminal lugs to match branch circuit conductor quantities, sizes, and materials indicated. Enclose terminal lugs in terminal box sized to NFPA 70.

Disconnect Switch: Factory mount disconnect switch [in control panel.] [on equipment under provisions of Section 16180.]

Cord and Plug: Provide unit with [6] [____] foot ([2] [____] m) cord and plug for connection to electric wiring system [including grounding connector].

AFTERCOOLER

Manufacturers:

[_________________________________] Model [________].

Other acceptable manufacturers offering equivalent products.

[_____________________________] Model [________].

[_____________________________] Model [________].

[_____________________________] Model [________].

Construction: Removable tube nests of non-ferrous metal tubes and corrosion resistant tube plates, safety valves, pressure gage, moisture separator, moisture drain valve, water inlet piping with automatic water valve, automatic condensate trap and overflow piping with open funnel.

Working Pressure: 135 psig (931 kPa).

Discharge: Cool air to within 12 degrees F (7 degrees C) of ambient air temperature at specified flow capacity.

Capacity: [_____] cfm ([_____] L/sec) at psi ([_____] kPa).

AIR DRYER

Manufacturers:

[_________________________________] Model [________].

Other acceptable manufacturers offering equivalent products.

[_____________________________] Model [________].

[_____________________________] Model [________].

[_____________________________] Model [________].

Type: Self contained mechanical refrigeration type complete with heat exchanger, refrigeration compressor, automatic controls, moisture removal trap, internal wiring and piping, and full refrigerant charge.

Air Connections: Inlet and outlet connections at same level, factory insulated.

Heat Exchangers: Air to air and refrigerant to air coils. Provide heat exchangers with automatic control system to bypass refrigeration system on low or no load condition.

Moisture Separator: Centrifugal type located at discharge of heat exchanger.

Refrigeration Unit: Hermetically sealed type to operate continuously to maintain specified 21 degrees F (-6 degrees C) dew point. House unit in steel cabinet provided with access door and panel for maintenance and inspection.

Accessories: Air inlet temperature gage, air inlet pressure gage, on/off switch, high temperature light, power on light, refrigerant gage [,air outlet temperature gage, air outlet pressure gage].

Capacity:

Discharge Air: [_____] degrees F ([_____] degrees C) atmospheric dew point.

Rated Air Flow: [_____] cfm ([_____] L/sec).

Inlet Air Pressure: [_____] psig ([_____] kPa).

Pressure Differential from Inlet to Outlet: Maximum [_____] psi ([_____] kPa).

Electrical Characteristics:

[____] hp ([____] kW).]

[____] volts, [single] [three] phase, 60 Hz.]

[____] amperes maximum [fuse size] [circuit breaker size] [over current protection].

Refer to Section 16180.

Motor: [Refer to Section 15170.] [NEMA MG1, [____].]

Controls: [________].

Wiring Terminations: Provide terminal lugs to match branch circuit conductor quantities, sizes, and materials indicated. Enclose terminal lugs in terminal box sized to NFPA 70.

Disconnect Switch: Factory mount disconnect switch [in control panel]. [On equipment under provisions of Section 16180].

Cord and Plug: Provide unit with [6] [____] foot ([2] [____] m) cord and plug for connection to electric wiring system [including grounding connector].

AIR RECEIVER

Manufacturers:

[_________________________________] Model [________].

Other acceptable manufacturers offering equivalent products.

[_____________________________] Model [________].

[_____________________________] Model [________].

[_____________________________] Model [________].

Receiver: [Vertical] [Horizontal], built to ASME regulations for working pressure of 125 psi (862 kPa). Flange or screw inlet and outlet connections.

Fittings: Adjustable pressure regulator, safety valve, pressure gage, drain cock, and automatic float actuated condensate trap.

Tank Finish: [Shop primed] [Hot dipped galvanized] [Shop vinyl.]

Size:

Diameter: [_____] inches ([_____] mm).

Length: [_____] inches ([_____] mm).

Capacity : [_____] gallons ([_____] L).

PRESSURE REDUCING VALVE

Manufacturers:

[_________________________________] Model [________].

Other acceptable manufacturers offering equivalent products.

[_____________________________] Model [________].

[_____________________________] Model [________].

[_____________________________] Model [________].

Pressure Reducing Station: Consisting of automatic reducing valve and bypass, and low pressure side relief valve and gage. [Provide oil separator where indicated].

Valve Capacity: Reduce pressure from 200 psi (1379 kPa) to 30 psi (207 kPa), adjustable upwards from reduced pressure.

PART	EXECUTION

INSTALLATION

Install in accordance with manufacturer's instructions.

Install compressor unit on concrete housekeeping pad. Refer to Section 03300.

Install compressor unit on vibration isolators. Level and bolt in place. Refer to Section 15242.

Make air cock and drain connection on horizontal casing.

Install line size gate valve and check valve on compressor discharge.

Install replaceable cartridge type filter silencer of adequate capacity for each compressor.

Place shut off valve on water inlet to aftercooler. Pipe drain to floor drain.

Connect condensate drains to nearest floor drain.

Install valved bypass around air dryer. Factory insulate inlet and outlet connections.

Install valved drip connections at low points of piping system.

Install take offs to outlets from top of main, with shut off valve after take off. Slope take off piping to outlets.

Install compressed air couplings, female quick connectors, and pressure gages where outlets are indicated.

Install tees instead of elbows at changes in direction of piping. Fit open end of each tee with plug.

Identify piping system and components. Refer to Section 15190.

FIELD QUALITY CONTROL

Field [inspection and] testing will be performed under provisions of Section [01400] [________].

Compressed Air Piping Leak Test: Prior to initial operation, clean and test compressed air piping in accordance with ANSI B31.1.

Repair or replace compressed air piping as required to eliminate leaks, and retest to demonstrate compliance.

Cap (seal) ends of piping when not connected to mechanical equipment.

END OF SECTION