USACE / NAVFAC / AFCESA / NASA UFGS-33 60 01 (April 2008)
--------------------------
Preparing Activity: USACE Superseding
UFGS-33 60 01 (July 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 33 60 01
VALVES, PIPING, AND EQUIPMENT IN VALVE MANHOLES
04/08
NOTE: This guide specification covers the requirements for valves, piping and
equipment in valve manholes that form a part of an underground heat distribution
system.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
PART 1 GENERAL
NOTE: Design manual UFC 3-430-1 HEATING AND COOLING DISTRIBUTION SYSTEMS contains
information that will assist the designer. Do not allow chilled water lines
or other plastic piping to be routed through manholes where high temperature
piping systems (above 110 degrees C (230 degrees F)) are installed.
Provide the following information on the contract drawings: (1) valve manhole
dimensions, (2) location of all valve manholes, (3) sizes of the pipe in the
valve manholes, (4) location of all valves in the valve manholes, (5) thickness
of the insulation on the pipe, (6) valve manhole details, (7) final elevations
of the valve manholes, (8) valve manhole cover details including manway access
details, (9) how valve manholes are drained and vented, (10) sump pump piping
details, (11) valve manhole equipment dimensions and details, (12) sump pump
capacity, (13) electrical wiring details for the equipment (dedicated service
for sump pump), (14) steam drip trap locations with access and capacities, (15)
steam main drip leg sizes.
This guide specification is to be included as a part of a contract which includes
Sections 33 61 00 PREFABRICATED UNDERGROUND HEATING/COOLING DISTRIBUTION SYSTEM
or 33 52 13 EXTERIOR FUEL DISTRIBUTION; 33 61 13 PRE-ENGINEERED UNDERGROUND
HEAT DISTRIBUTION SYSTEM or 33 63 16 EXTERIOR SHALLOW TRENCH STEAM DISTRIBUTION;
33 61 15 HEAT DISTRIBUTION SYSTEMS IN CONCRETE TRENCHES or 33 63 13EXTERIOR
UNDERGROUND STEAM DISTRIBUTION SYSTEM. Include the following Sections as part
of this contract: 31 00 00 EARTHWORK; 33 71 01 OVERHEAD TRANSMISSION AND DISTRIBUTION
or 33 71 01 OVERHEAD TRANSMISSION AND DISTRIBUTION; 33 70 02.00 10 ELECTRICAL
DISTRIBUTION SYSTEM, UNDERGROUND or 33 71 02.00 20 UNDERGROUND TRANSMISSION
AND DISTRIBUTION; 03 15 13.00 10 EXPANSION JOINTS, CONTRACTION JOINTS, AND WATERSTOPS;
Section [03 31 00.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE][03 30 00 CAST-IN-PLACE
CONCRETE]; 05 05 23.00 10 WELDING, STRUCTURAL; 05 50 13 MISCELLANEOUS METAL
FABRICATIONS; 07 13 53 ELASTOMERIC SHEET WATERPROOFING; 09 90 00 PAINTS AND
COATINGS; 43 02 00 or 40 17 26.00 20 WELDING PRESSURE PIPING; 26 20 00 INTERIOR
DISTRIBUTION SYSTEM or 26 51 00 INTERIOR LIGHTING; and others as applicable
to the project.
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[ALUMINUM ASSOCIATION (AA)AA H35.1/35.1M(2007) Alloy and Temper Designation Systems for Aluminum][ASME INTERNATIONAL (ASME)ASME B1.20.1(1983; R 2006) Pipe Threads, General Purpose (Inch)ASME B16.11(2005) Forged Fittings, Socket-Welding and ThreadedASME B16.20(2007) Metallic Gaskets for Pipe Flanges - Ring-Joint, Spiral Wound, and JacketedASME B16.21(2005) Nonmetallic Flat Gaskets for Pipe FlangesASME B16.3(2006) Malleable Iron Threaded Fittings, Classes 150 and 300ASME B16.34(2004) Valves - Flanged, Threaded and Welding EndASME B16.5(2003) Standard for Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24ASME B16.9(2007) Standard for Factory-Made Wrought Steel Buttwelding FittingsASME B31.1(2007; Addenda 2008) Power PipingASME B40.100(2005) Pressure Gauges and Gauge AttachmentsASME BPVC SEC IX(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section IX, Welding and Brazing Qualifications][ASTM INTERNATIONAL (ASTM)ASTM A 106/A 106M(2008) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature ServiceASTM A 123/A 123M(2008) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel ProductsASTM A 193/A 193M(2008b) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature ServiceASTM A 194/A 194M(2008b) Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or BothASTM A 234/A 234M(2007) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature ServiceASTM A 53/A 53M(2007) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and SeamlessASTM A 733(2003) Standard Specification for Welded and Seamless Carbon Steel and Austenitic Stainless Steel Pipe NipplesASTM B 209(2007) Standard Specification for Aluminum and Aluminum-Alloy Sheet and PlateASTM B 209M(2007) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate (Metric)ASTM C 449(2007) Standard Specification for Mineral Fiber Hydraulic-Setting Thermal Insulating and Finishing CementASTM C 533(2007) Standard Specification for Calcium Silicate Block and Pipe Thermal InsulationASTM C 547(2008e1) Standard Specification for Mineral Fiber Pipe InsulationASTM C 552(2007) Standard Specification for Cellular Glass Thermal InsulationASTM C 647(2008) Properties and Tests of Mastics and Coating Finishes for Thermal InsulationASTM D 2822(2005) Asphalt Roof CementASTM D 3278(1996; R 2004e1) Flash Point of Liquids by Small Scale Closed-Cup ApparatusASTM E 84(2008a) Standard Test Method for Surface Burning Characteristics of Building MaterialsASTM E 96/E 96M(2005) Standard Test Methods for Water Vapor Transmission of MaterialsASTM F 1139(1988; R 2004) Steam Traps and Drains][MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)MSS SP-110(1996) Ball Valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared EndsMSS SP-25(2008) Standard Marking System for Valves, Fittings, Flanges and UnionsMSS SP-45(2003) Bypass and Drain ConnectionsMSS SP-58(2002) Standard for Pipe Hangers and Supports - Materials, Design and ManufactureMSS SP-69(2003; R 2004) Standard for Pipe Hangers and Supports - Selection and ApplicationMSS SP-72(1999) Standard for Ball Valves with Flanged or Butt-Welding Ends for General ServiceMSS SP-80(2008) Bronze Gate, Globe, Angle and Check ValvesMSS SP-83(2006) Standard for Class 3000 Steel Pipe Unions Socket Welding and Threaded][NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)NFPA 70(2007; AMD 1 2008) National Electrical Code - 2008 EditionNFPA 90A(2008) Standard for the Installation of Air Conditioning and Ventilating Systems][THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)SSPC Paint 16(2006) Paint Specification No. 16 Coal Tar Epoxy-Polyamide Black (or Dark Red) PaintSSPC SP 10(2007) Near-White Blast Cleaning][UNDERWRITERS LABORATORIES (UL)UL 723(2008) Standard for Test for Surface Burning Characteristics of Building Materials]1.2 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.][information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] Submit the following in
accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings[; G][; G, [_____]]
Detail drawings, as specified, [_____] days after notice to proceed.
SD-03 Product Data
Piping and Fittings
Valves
Insulation
Sump Pumps and Drainers
Expansion Joints
Manufacturer's descriptive data and technical literature, performance charts, catalog cuts
and installation instructions.
SD-04 Samples
Insulated Sections[; G][; G, [_____]].
Display of insulated sections, as specified, [_____] days after notice to proceed.
SD-10 Operation and Maintenance Data
Valve Manholes and Accessories
Data Package 2
Data Package 2 in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA.
[Six] [_____] copies of operation and [six] [_____] copies of maintenance manuals for the
equipment furnished. Detail in the operation manuals the step-by-step procedures required for
equipment startup, operation, and shutdown. Include in the operation manuals the manufacturer's
name, model number, parts list, and brief description of all equipment and their basic operating
features. List in the maintenance manuals routine maintenance procedures, possible breakdowns
and repairs, and troubleshooting guides. Include in the maintenance manuals piping and equipment
layout and simplified wiring and control diagrams indicating location of electrical components
with terminals designated for wiring, as installed.
1.3 QUALITY ASSURANCE
1.3.1 Detail Drawings
Submit detail drawings for valve manholes and the piping and equipment in the valve manholes, such as steam traps,
valves, sump pumps, pressure gauges, thermometers and insulation, including a complete list of equipment and
materials, manufacturer's descriptive and technical literature, performance charts and curves, catalog cuts,
installation instructions, and complete wiring and schematic diagrams. Show on the drawings pipe anchors and
guides, and layout and anchorage of equipment and appurtenances in valve manholes, and equipment relationship
to other parts of the work including clearances for maintenance and operation.
1.3.2 Insulated Sections
Submit sample sections for insulation of pipe, elbow, tee, valve, support point, and terminating points. After
approval of materials and prior to insulation of piping, a display shall be prepared of insulated sections showing
compliance with specifications and showing fastening, sealing, jacketing, straps, waterproofing, supports, hangers,
anchors, and saddles. Approved display sample sections shall remain on display at the jobsite during the construction
period until no longer needed by Contracting Officer, then removed.
1.4 DELIVERY, STORAGE, AND HANDLING
Protect all materials and equipment delivered and placed in storage from the weather, excessive humidity, and
excessive temperature variation; dirt, dust, or other contaminants.
PART 2 PRODUCTS
2.1 STANDARD PRODUCTS
Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture
of such products and that essentially duplicate items that have been in satisfactory use for at least 2 years
prior to bid opening. Equipment shall be supported by a service organization that is, in the opinion of the
Contracting Officer, reasonably convenient to the site.
2.2 NAMEPLATES
Each major item of equipment such as sump pump, motor, steam trap, and pressure reducing valve shall have the
manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to
the item of equipment.
2.3 ASBESTOS PROHIBITION
Asbestos and asbestos-containing products will not be allowed.
2.4 ELECTRICAL WORK
Motors, manual or automatic motor control equipment, and protective or signal devices required for the operation
specified shall be provided under this section in accordance with NFPA 70 and Section [33 70 02.00 10 ELECTRICAL
DISTRIBUTION SYSTEM, UNDERGROUND] [33 71 02.00 20 UNDERGROUND TRANSMISSION AND DISTRIBUTION].
2.5 PIPING AND FITTINGS
2.5.1 General Requirements
Piping, fittings and piping accessories inside the valve manholes shall conform to the requirements of ASME B31.1
and shall be suitable for the working pressure and temperature requirements of the system. To the greatest
extent possible, the piping and fittings inside the valve manholes shall match the piping and fittings located
on the outside of the valve manhole. All piping in valve manholes shall be steel with joints welded except that
joints 19 mm 3/4 inch and smaller may be threaded. When threaded joints are used on High Temperature Water Systems,
the interface area where the pipe threads meet the threaded fittings shall be seal welded (continuous fillet
weld) to preclude any water leakage. No supports, anchors, or stays shall be attached to any piping system in
places where either the installation of or the movement of the pipe and its contents will cause damage to the
construction.
2.5.2 Steel Pipe
Pipe shall be black steel, seamless or electric-resistance welded, conforming to the requirements of ASTM A 53/A 53M
, Grade B or ASTM A 106/A 106M, Grade B. Pipe up to and including 250 mm 10 inches in diameter shall be schedule
40. Pipe 300 mm 12 inches in diameter and greater shall be 10 mm 0.375 inch nominal wall thickness. Gauge piping
[, condensate piping,] [drip piping,] and piping 19 mm 3/4 inch in diameter and smaller shall be schedule 80.
2.5.2.1 Nipples
Nipples shall conform to ASTM A 733 as required to match adjacent piping.
2.5.2.2 Pipe Threads
Pipe threads shall conform to ASME B1.20.1. Pipe threads may be used only on pipe 19 mm 3/4 inch or smaller.
All pipe which is to be threaded shall be schedule 80.
2.5.3 Fittings
All fittings, valves, flanges and unions shall have the manufacturer's trademark affixed in accordance with MSS SP-25
so as to permanently identify the manufacturer.
2.5.3.1 Welded Fittings
Welded fittings shall conform to ASTM A 234/A 234M, buttwelded or socket welded, as required to match connecting
piping. Buttwelded fittings shall conform to ASME B16.9, and socket welded fittings shall conform to ASME B16.11
.
2.5.3.2 Unions
Unions shall conform to MSS SP-83 as required to match adjacent piping.
2.5.3.3 Ball Valves
Ball valves shall conform to MSS SP-72 for flanged or buttwelded valves or MSS SP-110 for threaded ball valves.
2.5.4 Insulating Flanges and Dielectric Waterways
NOTE: Electrically insulating flanges or dielectric waterways shall be shown
in manholes where piping is connected to a system that is not cathodically protected.
Insulating flanges and dielectric waterways must be in accessible locations,
such as valve manholes or buildings.
2.5.4.1 Insulating Flanges
For systems in which cathodic protection is provided, insulating flanges or flange gasket kits shall be installed
in the valve manhole at the pipe connection to or from the heat distribution system and at dissimilar metals
and when the carrier pipe and appurtenances are supported in such a way as to electrically ground or alter the
cathodic protection system voltages or currents. The kit shall consist of flanges, a flange gasket, nuts and
bolts, bolt sleeves, and one insulating washer and one steel washer for both ends of each bolt. The manufacturer
shall certify that the gasket kits are capable of electrically isolating the pipe at the [_____] kPa psig pressure
and [_____] degrees C F temperature of the heating medium at the point of application. Evidence of satisfactory
installations operating not less than 2 years shall be submitted in accordance with paragraph SUBMITTALS before
materials are delivered. Ensure that these kits are provided and properly installed according to manufacturer's
published instructions. Bolts shall be torqued to the correct tightness and in the correct bolt pattern as recommended
by the manufacturer's published instructions. Steel flanges shall conform to ASME B16.5 Class [150] [and] [or]
[300] and shall match valves or flanged fittings on which used. Steel flanges shall be flat faced. Gaskets
shall be non-asbestos compressed material in accordance with ASME B16.21, 2 mm 1/16 inch thickness, full face
or self centering flat ring type. Bolts shall conform to the requirements of ASTM A 193/A 193M, Grade B7. The
bolt head shall be marked to identify the manufacturer and the standard to which the bolt complies. Lengths
of bolts shall be such that not less than two full threads extend beyond the nut with the bolt tightened to the
required tension and the washer seated. Nuts shall conform to the requirements of ASTM A 194/A 194M, Grade 7.
2.5.4.2 Dielectric Waterways
Dielectric waterways shall have temperature and pressure rating equal to or greater than that specified for the
connecting piping and shall be used for joining dissimilar metals on 19 mm 3/4 inch and smaller threaded pipe.
Waterways shall have metal connections on both ends suited to match connecting piping. Dielectric waterways
shall be internally lined with an insulator specifically designed to prevent current flow between dissimilar
metals. Dielectric flanges shall meet the performance requirements described herein for dielectric waterways.
2.5.4.3 Gaskets Non-Insulating
Provide spiral wound, non-asbestos gasket with centering ring in accordance with ASME B16.20.
2.6 VALVES
NOTE: Select the appropriate valves for the operating temperatures and pressures
of all systems in the project. Delete valve types not included in project.
Use not less than Class 150 for up to 862 kPa (125 psig) steam, and not less
than Class 300 for 863 kPa to 1724 kPa (126 to 250 psig) steam and high temperature
water. For isolation and shutoff, use gate valves only. Steam pressure reducing
valves are not normally part of the system. If needed, designer should refer
to Section 23 70 01.00 10 CENTRAL STEAM-GENERATING SYSTEM, COAL-FIRED or Section
23 22 26.00 20 STEAM SYSTEM AND TERMINAL UNITS for Navy jobs.
Unless otherwise specified, valves shall comply with the material, fabrication, and operating requirements of
ASME B31.1. Valves shall be suitable for the temperature and pressure requirements of the system on which used.
Valves for [steam] [hot water] shall conform to ASME B31.1Class [150] [and] [or] [300], as suitable for the application.
[Valves for condensate services shall conform to ASME B31.1 Class 150.] Valves 19 mm 3/4 inch and smaller may
be bronze where seal welding is not required. Valves 150 mm 6 inches and larger shall have a 25 mm 1 inch minimum
gate or globe bypass valve sized in conformance with MSS SP-45.
2.6.1 Steel Valves
Steel globe, gate, angle, and check valves shall conform to the requirements of ASME B16.34 and ASME B31.1 for
the temperature and pressure requirements of the system. Gate valves 65 mm 2-1/2 inches and smaller shall be
rising stem. Gate valves 80 mm 3 inches and larger shall be outside screw and yoke.
2.6.2 Bronze Valves
2.6.2.1 Globe, Gate, and Angle Valves
Bronze globe, gate, and angle valves shall conform to requirements of MSS SP-80, union bonnet type.
2.6.2.2 Check Valves
Bronze check valves shall conform to the requirements of MSS SP-80.
2.6.3 Packing
Packing used with valves shall not contain asbestos. Valve stem packing shall be die-formed, ring type specifically
designated as suitable for the temperature and pressure of the service and compatible with the fluid in the system.
Packing shall be polytetrafluoroethylene with minimum 50 percent graphite filament. Valves 40 mm 1-1/2 inches
and smaller shall have four or five packing rings and valves 50 mm 2 inches and larger shall have at least six
packing rings. Spiral or continuous packing will not be acceptable. A metal insert shall be provided having
proper clearance around the valve stem at the bottom of the stuffing box and acting as a base for the packing
material. Packing glands shall be furnished with a liner of noncorrosive material and shall be of one piece
construction with provisions for not less than two bolts for packing adjustment.
2.7 STEAM TRAPS
NOTE: The following paragraphs are applicable to steam systems only. Only
these two types will be used. Delete these paragraphs when the distribution
system is not a steam system.
A schedule of steam trap selection will be shown on the drawings. Trap capacity
(kg per second (pounds per hour)) during normal operation, pressure drop (kPa
(psi)), and pressure rating (kPa (psi)) of each trap will be included in this
schedule. Also, show on the drawings a vent valve or test valve connection
downstream of traps for test of trap operation, a strainer ahead of traps, a
union, a check valve in the outlet piping, and shut-off valves on both sides
of trap for trap changeout. A means of bypassing the trap shall be provided
for system warm-up.
Class of trap bodies shall be suitable for a working pressure of not less than 1.5 times the steam supply pressure,
but not less than 1379 kPa 200 psi, and traps shall be capable of operation under a steam-supply pressure as
indicated. Traps shall have capacities as shown when operating under the specified working conditions. Traps
shall fail open.
2.7.1 Bucket Traps
Bucket traps shall be inverted-bucket type with automatic air discharge and conform to ASTM F 1139.
2.7.2 Thermostatic Traps
NOTE: Specify thermostatic traps where the trap location is subject to freezing.
Traps shall be thermostatic type; bimetallic element with automatic air discharge and conform to ASTM F 1139.
2.8 STRAINERS
NOTE: Delete this paragraph for high temperature water systems.
Strainers shall be basket or y-type with connections the same size as the pipe lines in which the connections
are installed. The strainer bodies for steam systems shall be heavy and durable, of cast steel, with bottoms
drilled and plugged. The strainers shall be suitable for the temperature and pressure requirements of the system
on which they are installed. The bodies shall have arrows clearly cast on the sides to indicate the direction
of flow. Each strainer shall be equipped with an easily removable cover and sediment basket. The body or bottom
opening shall be equipped with nipple and gate valve for blowdown. The basket for steam systems shall be not
less than 0.6350 mm 0.025 inch thick stainless steel, Monel or sheet brass, with small perforations of sufficient
number to provide a net free area through the basket of at least 2.5 times that of the entering pipe. The flow
shall be into the basket and out through the perforations. For high temperature hot water systems, only cast
steel bodies and stainless or Monel baskets shall be used.
2.9 PRESSURE GAUGES
NOTE: Delete if not required.
Gauges shall conform to ASME B40.100, and shall be provided with throttling type needle valve or a pulsation
dampener and shut-off valve. Minimum dial size shall be 110 mm 4-1/4 inches.
2.10 DIAL THERMOMETERS
NOTE: Delete if not required.
Dial type thermometer shall be 90 mm 3-1/2 inches in diameter with stainless steel case, remote-type bulb or
direct-type bulb as required. The thermometer shall have an accuracy of plus or minus 1 degree C 2 degrees F
. Thermometer wells of the separable socket type shall be provided for each thermometer with direct-type bulb.
The thermometer shall have a white face with black digits graduated in 1 degree C 2 degrees F increments.
2.11 INSULATION AND JACKETING
NOTE: All piping, valves and fittings for steam, hot water and dual temperature
heat distribution systems in valve manholes require insulation for the protection
of operating and maintenance personnel as well as for the conservation of energy;
whether or not to insulate chilled water lines, valves, and fittings in the
manholes can be determined by the necessity to prevent condensation on the piping
and energy conservation.
The energy savings will vary with the ambient temperature but will be a factor
in warm climates. There may be some isolated cases where the chilled water
distribution pipes entering the manhole are not insulated; therefore, the piping
in the manhole would not normally be insulated unless condensation from the
air forming on the chilled water pipes causes a problem.
2.11.1 General Provisions
All piping, fittings, valves, etc., in the valve manholes shall be insulated. Insulation shall be premolded,
precut or job fabricated to fit and shall be removable and reusable. Thickness of insulation shall be in accordance
with Tables 1 and 2. Insulation jackets shall be provided for all pipe and fitting insulation. Insulation shall
conform to EPA requirements in accordance with Section 01 62 35 RECYCLED / RECOVERED MATERIALS.
2.11.2 Insulation
NOTE: The insulations allowed in this paragraph have passed a 96 hour boiling
test which indicates that satisfactory performance is expected.
Insulation for all piping, fittings, and valves shall be molded calcium silicate conforming to ASTM C 533, Type
I, or molded mineral fiber insulation conforming to ASTM C 547, Class 2, or cellular glass insulation conforming
to ASTM C 552. All insulation shall be asbestos free. Laminated construction shall not be used unless the thickness
exceeds 100 mm 4 inches. Insulations and the manufacturers approved for use are:
a. Delta, available from Rockwool in Leeds, Alabama.
b. MPT-PC and MPT-PF, available from Mineral Products of Texas in Houston, TX.
c. Thermo-12, Super Caltemp, available from Johns Manville in Denver, Colorado.
d. Foamglass (cellular glass), available from Pittsburgh Corning Corporation.
2.11.3 Aluminum Jackets
NOTE: Vapor barrier requirements are only to be included for chilled water
systems.
Aluminum jackets shall be smooth sheet, 0.4064 mm 0.016 inch nominal thickness and conform to the requirements
of ASTM B 209M ASTM B 209, Type 3003, 3105, or 5005.[ Aluminum jackets shall be supplied with a factory installed
moisture barrier. This moisture barrier shall consist of at least 18.1 kg 40 pound kraft paper coated on one
side with a 0.025 mm 1 mil thick polyethylene film. The moisture barrier shall be adhered to the aluminum jacket
over the entire area of the aluminum jacket insulation-side surface.]
2.11.4 Bands
Bands for aluminum jacket shall be 10 mm 3/8 inch wide and 32 gauge thickness made of aluminum or annealed stainless
steel. Bands for insulation shall be 13 mm 1/2 inch wide and 32 gauge thickness made of annealed stainless steel.
2.11.5 Insulation for Flanges, Unions, Valves, and Fittings
Flanges, unions, valves, and fittings shall be insulated with premolded prefabricated, or field fabricated segments
of insulation of the same material and thickness as the manhole pipe insulation. Insulation shall be removable
and reusable and shall have essentially the same thermal characteristics and thickness as the adjoining piping.
2.11.6 Vapor Barrier Coating
The vapor barrier coating shall be fire and water resistant and appropriately selected for either outdoor or
indoor service. Color shall be white. The water vapor permeance of the compound shall not exceed 0.05 perm
and shall be determined according to Procedure B of ASTM E 96/E 96M. The coating shall be a nonflammable, fire
resistant type conforming to ASTM E 84, NFPA 90A and UL 723. The flash point of the compound shall not be less
than 26.7 degrees C 80 degrees F and shall be determined in accordance with ASTM D 3278. All other application
and service properties shall be in accordance with ASTM C 647.
2.11.7 Finishing Cement
Mineral fiber hydraulic-setting thermal insulating cement in accordance with ASTM C 449.
2.11.8 Glass Tape
Glass tape shall meet the requirements of UL 723 and ASTM E 84.
2.11.9 Plain Weave, Untreated
The ends shall be properly interlocked with the picks to ensure that there shall be no raveling of the tape edges.
The tape shall have an average weight of 196.7 plus or minus 10 percent grams per square meter 5.8 plus or minus
10 percent ounces per square yard. An average thickness of 0.1778 plus or minus 0.0254 mm 0.007 plus or minus
0.001 inches. Warp ends/wales of 17 plus or minus 1 per centimeter 42 plus or minus 2 per inch or filling picks/courses
of 13 plus or minus 1 per centimeter 32 plus or minus 2 per inch, a minimum breaking strength of 2679 grams per
mm 150 pounds per inch of width, and after heating to 482 degrees C 900 degrees F for 2 hours. A minimum breaking
strength of 714 grams per mm 40 pounds per inch of width.
2.11.10 Knitted, Untreated
The wales shall be properly interlocked with the courses to ensure that there shall be no raveling of the tape
edges. The tape shall have an average weight of 153 plus or minus 10 percent grams per square meter 4.5 plus
or minus 10 percent ounces per square yard. An average thickness of 0.1778 plus or minus 0.0254 mm 0.007 plus
or minus 0.001 inches, warp ends/wales of 6 plus or minus per 1 centimeter 16 plus or minus 2 per inch. A minimum
breaking strength of 714 grams per mm 40 pounds per inch of width and, after heating to 482 degrees C 900 degrees
F for 2 hours. A minimum breaking strength of 375 grams per mm 21 pounds per inch of width.
2.11.11 Distortion Requirements
There shall be no distortion of the tape when a sample 610 mm 24 inches in length is spread across a flat horizontal
surface and observed for evidence of distortion (such as tendency to curl rather than lie flat). The width tolerance
is plus or minus 3.175 mm 1/8 inch.
2.11.12 Open-Weave Tape
Tape shall be open-weave type and shall have an average weight of [_____] kg per square meter ounce per square
yard and shall be used for embedding between coats of adhesive or coating materials.
2.12 SUMP PUMPS AND DRAINERS
NOTE: Delete this paragraph when positive drainage of the valve manhole is
provided and sump pumps are not needed. Use of duplex sump pumps is encouraged.
Delete text in brackets if a single sump pump is specified.
Provide one or two sump pumps in valve manholes. Units should discharge by
buried piping to the nearest storm sewer if possible. Where not economical
to discharge to a storm sewer, pumps are to discharge above grade. Plan discharge
locations carefully so water will not be discharged over valve manhole tops,
sidewalks, etc. Check available NPSH versus required NPSH for pump selected.
Coordinate power requirements with electrical designer and provide tell-tale
light above ground to indicate sump pump failure.
Drawings will show the following: (a) a dedicated circuit; (b) lockable switches
and circuit breakers that can both be locked ON; (c) permanent labels at key
positions indicated on the drawings so that personnel can understand that the
circuit should be left ON. The label shall be on a corrosion resistant metal
plate and shall read as follows: THIS CIRCUIT SUPPLIES POWER TO THE ELECTRIC
SUMP PUMPS IN THE UNDERGROUND HEAT DISTRIBUTION SYSTEM. THIS CIRCUIT MUST BE
ON AT ALL TIMES; OTHERWISE EXTENSIVE DAMAGE WILL OCCUR TO THE UNDERGROUND HEAT
DISTRIBUTION SYSTEM AND PREMATURE FAILURE WILL OCCUR.
2.12.1 Sump Pumps
Sump pumps with the capacities indicated shall be installed in the valve manholes as shown. The sump pumps furnished
shall be a manufacturer's standard commercial product. Sump pumps shall be electrically driven and submersible,
capable of operating while completely submerged. The pumps and motors shall be capable of continuously pumping
liquids at a temperature of 93 degrees C 200 degrees F. The pumps and motors shall be capable of running without
damage when not submerged. Sump pumps shall have permanently lubricated bearings, monel shafts, bronze impellers,
screened inlets and housings of bronze. Each sump pump shall be capable of passing a 10 mm 3/8 inch sphere.
The motors shall have the wattage (horsepower) horsepower indicated and shall have overload protection. The
discharge piping shall be schedule 80 or shall be protected from corrosion. The pumps shall be automatically
controlled by a submersible switch assembly with pump wiring and switch suitable for submersion in 93 degrees
C 200 degrees F liquids. Motors shall be [120] [240] [_____] volts, 60 Hz, single phase. [Two sump pumps in
a duplex arrangement shall be provided as indicated. An automatic alternating lead-lag controller shall be furnished.]
All controllers, water level switches, and electrical connections shall be suitable for service at 100 percent
humidity, at 93 degrees C 200 degrees F temperature, and occasional water submersion. The sump pumps automatic
control switches shall have demonstrated 200,000 cycles at 93 degrees C 200 degrees F and 100 percent relative
humidity and shall withstand total submersion in water at 93 degrees C 200 degrees F. Another switch shall be
provided to indicate high water level, and shall be connected to an emergency warning light mounted on or adjacent
to the valve manhole as indicated. This high water level alarm shall be set at a level which is below the bottom
of any pipe in the valve manhole. Auxiliary contacts in a separate junction box shall be provided to permit
connection to a [future] Energy Monitoring and Control System (EMCS) for monitoring the operation of each pump
motor and the high water level alarm system.
2.12.2 Drainers
Provide automatic type drainers to operate on 862 kPa (gage) 125 psig steam supply. The drainer shall operate
when the water level rises sufficiently in the sump, the float shall rise and open the steam control valve to
admit steam to the drainer, which in turn shall pump the water from the sump. When the water level is lowered
by the pumping action, the float shall lower and close the steam valve to stop the pumping action until water
again gathers in the sump. Provide each drainer with controls to accomplish the above sequence of operation.
The automatic float-operated steam valve shall be designed to prevent dead centering under field conditions and
to lengthen the life of the valve seat. The valve shall have a high grade, renewable composition disc and a
stainless steel or hard, noncorrosive bronze renewable seat inserted in the valve body. The drainer shall be
constructed of corrosion-resistant copper and bronze. Piping from manhole drainers shall be ASTM A 53/A 53M,
Weight Class XS (Extra Strong), hot-dip galvanized steel pipe with ASME B16.11 or ASME B16.3, Class 300, hot-dip
galvanized threaded fittings. Provide a steam pressure regulating vaalve assembly for manhole drainers for operation
on steam system above 862 kPa (gage) 125 psig.
2.13 CONCRETE VALVE MANHOLES AND ACCESSORIES
NOTE: If the referenced sections are not to be included in the project specifications,
applicable paragraphs from the referenced sections must be incorporated into
this specification. The designer is also advised that, for Army projects, Section
31 00 00 EARTHWORK, and if electrically operated sump pumps are installed, either
Section 33 71 01 OVERHEAD TRANSMISSION AND DISTRIBUTION or Section
33 70 02.00 10 ELECTRICAL DISTRIBUTION SYSTEM, UNDERGROUND, or applicable portions
of the above specifications, must be included as part of the project specifications.
For Navy jobs, Section 31 23 00.00 20 EXCAVATION AND FILL, and if electrically
operated sump pumps are installed, either Section 33 71 01 OVERHEAD TRANSMISSION
AND DISTRIBUTION or Section 33 71 02.00 20 UNDERGROUND TRANSMISSION AND DISTRIBUTION,
or applicable portions of the above specifications must be included as part
of the project specifications.
The design of manholes including size, reinforcing, arrangement, penetrations,
equipment and piping within the valve manholes is the responsibility of the
designer. Valve manholes shall be designed to provide proper venting and drainage
and adequate room for maintenance without stepping on or over any equipment.
When electric sump pumps are used, the electrical distribution and tie in points
must be designed and shown on the drawings.
In most cases, valve manhole covers will consist of open grates. If manhole
top is to be used as part of a sidewalk and valve manhole is not deep, a solid
plate cover may be used without special provisions for manhole ventilation.
These tops must be designed to be removed or opened completely during maintenance
operations. For larger and deeper valve manholes, raised frame solid plate
cover shall be required.
2.13.1 Valve Manhole Construction
Valve manhole dimensions shall be as indicated. [The valve manholes shall be constructed of reinforced concrete
as indicated and in accordance with Section 03 40 00.00 10 PLANT-PRECAST CONCRETE PRODUCTS FOR BELOW GRADE CONSTRUCTION.
][Valve manholes shall be provided with a 762 mm 30 inch standard cast iron frame and removable cover as a minimum,
or a 900 by 900 mm 36 by 36 inch watertight, hinged steel cover not less than 13 mm 1/2 inch thick.] Valve manholes
shall be drained as shown. Concrete sections shall not be less than 150 mm 6 inches thick. [The top shall be
a cast concrete slab of the same strength and thickness as the valve manhole or fabricated from stainless steel,
hot dipped galvanized steel or aluminum.] [The top shall be [open grate cover] [or] [raised frame] [solid plate
cover (8 mm 5/16 inch thick checker pattern) conforming to AA H35.1/35.1M].] [When open grate covers are used
for direct buried conduit systems, the top of the grate will be at least 150 mm 6 inches above the surrounding
grade. When used for concrete shallow trenches, the top of the grate will be flush with the concrete trench
top. Open grates will be constructed of galvanized steel. A checkered plate cover (also referred to as diamond
plate or embossed plate), shall be installed over the grating in colder climates and where accumulation of trash
is a problem. This checkered plate shall be attached to the grating and shall be removable.] [Solid plate covers
shall be used for HTHW and steam/condensate direct buried conduit systems only. Solid plate covers shall not
be used for shallow trench systems which are often used as sidewalks, or when substantial loadings are expected.
Ventilation openings shall be provided around the entire perimeter below the raised top. The solid plate cover
assembly shall be removable. The cover, constructed of aluminum, shall also provide sectionalized access for
inspection and maintenance.] [When concrete covers are used for direct buried conduit systems, the top of the
concrete cover shall be designed to be a minimum of 150 mm 6 inches above the surrounding grade. When used for
concrete shallow trenches, the cover shall be designed to be flush with the trench top. Concrete requirements
for this cover shall be similar to those required for valve manhole construction. Concrete cover shall be designed
to support anticipated loadings. A 1220 by 1220 mm 4 by 4 foot aluminum access door (Bilco model JD-2AL or equal
with slip resistant finish) shall be provided in the concrete top. For concrete shallow trench systems, a single
150 mm 6 inch gooseneck pipe shall be used to allow steam to exit the valve manhole if a leak or excessive heat
loss is present; the gooseneck shall be installed off to one side of the valve manhole concrete top to minimize
pedestrian traffic interference. For direct buried systems, two 150 mm 6 inch goosenecks shall be used. One
shall extend below the top; the other shall be similar but shall extend to within 600 mm 2 feet of the manhole
floor to provide natural air movement.] Valve manhole sides shall be constructed by one monolithic pour and
shall extend not less than 150 mm 6 inches above grade unless otherwise stated. Valve manholes shall be waterproofed
in accordance with Section 07 13 53 ELASTOMERIC SHEET WATERPROOFING. All steel components shall be protected
from corrosion.
2.13.2 Ladders
Valve manhole ladders shall be steel, shall have nonslip surfaces, and shall consist of uprights with steps or
rungs. Ladders shall not be less than 406.4 mm 16 inches in width, with 19.1 mm 3/4 inch diameter rungs, spaced
304.8 mm 12 inches apart. The two stringers shall be a minimum 9.5 mm 3/8 inch thick and 63.5 mm 2-1/2 inches
wide. Ladders shall be adequately anchored to the wall by means of steel inserts spaced not more than 2 m 6
feet apart vertically, and installed to provide at least 150 mm 6 inches of space between the wall and rungs.
Ladders and inserts shall be galvanized after fabrication in conformance with ASTM A 123/A 123M.
2.13.3 Pipe Sleeves
Pipe sleeves of sufficient length to pass through valve manhole or building walls shall be provided. Pipe sleeves
shall be zinc-coated steel pipe, conforming to the requirement of ASTM A 53/A 53M, Schedule 40 or standard weight.
The pipe sleeves shall be secured in the proper position and location during construction of the valve manhole
or building wall. For manhole top penetrations, the diameter of the pipe sleeve will be large enough to allow
at least 6 mm 1/4 inch of clearance between the pipe insulation and the sleeve, and, the sleeve will be sized
to accommodate the specific mechanical seal size used for the [conduit] [or] [uninsulated chilled water pipe]
penetration. The space between the sleeve and the pipe casing, and the caulking and sealing materials shall
be selected so there shall be NO electrical continuity between the pipe sleeve and the pipe casing when finished.
2.13.3.1 Pipe Sleeves Through Valve Manhole Cover
Insulation shall be continuous through sleeves as shown on the drawings. Aluminum jacket shall be provided over
the insulation. Aluminum jacket shall be smooth sheet 0.4064 mm 0.016 inch nominal thickness, ASTM B 209M ASTM B 209
. Where penetrating valve manhole top, pipe shall be insulated as required for valve manhole service up to a
point flush with the top of the flashing and the end of the insulation shall be sealed with waterproof coating.
Insulation exposed to the weather shall butt tightly against the flashing and valve manhole insulation, and the
aluminum jacket required for piping exposed to the weather shall extend 50 mm 2 inches beyond the insulation
to form a counterflashing. The entire valve manhole top penetration shall be flashed and counterflashed as shown
on the drawings. Waterproof coating shall conform to ASTM D 2822, Type I.
2.13.3.2 Pipe Sleeves for Conduit Penetrations
A modular mechanical type sealing assembly will be used between the valve manhole pipe sleeve and the [conduit
casing] [or] [uninsulated chilled water pipe]. The mechanical seal shall consist of interlocking elastomeric
links shaped to continuously fill the annular space between the [casing] [or] [uninsulated chilled water pipe]
and sleeve. The link material shall be a synthetic elastomeric capable of withstanding long term exposure at
205 degrees C 400 degrees F without deterioration. The links shall be attached to each other with corrosion
resistant steel bolts, nuts and pressure plates. The link, bolts, nuts and pressure plates shall be the product
of single manufacturer and shall be furnished as the product of single manufacturer and shall be furnished as
a package or kit. The links shall be loosely assembled with bolts to form a continuous rubber belt around the
[casing] [or] [uninsulated chilled water pipe] with a pressure plate under each bolt head and each nut. After
the seal assembly is properly positioned in the sleeve, tightening of the bolt shall cause the rubber sealing
elements to expand and provide a watertight seal between the [casing] [or] [the uninsulated chilled water pipe]
and the sleeve. The pipe sleeve diameter shall be sized so that no more than one half of the seal assembly's
expansion capability is used to achieve a water seal.
2.13.4 Pipe Supports
Pipe Supports shall be in accordance with MSS SP-58 and MSS SP-69, type as shown. All pipe supports, including
structural cross support members, shall be galvanized in accordance with Section 05 50 13 MISCELLANEOUS METAL
FABRICATIONS. Chains, straps, or single point supports shall not be used.
2.14 EXPANSION JOINTS
NOTE: Expansion joints generally will not be used in the design of the piping
layout. If no other method is available to handle the expansion problem in
a specific location, the design layout using an expansion joint at a specific
location must be justified by a design analysis and approved in the planning
phase of the piping layout, prior to including expansion joints in the specifications.
Cold spring (pipe expansion) will be shown on the drawings. Sizing of expansion
loops and bends will not be based on cold spring.
If expansion joints or ball joints are required, the locations will be indicated
on the drawings. Since expansion joints are high maintenance items, they must
be located in a readily accessible location. Type I and III slip joint, packed
expansion joints are adjustable gland type and require continuing maintenance
to contain leakage and are now manufactured by only one company making them
proprietary. For these reasons, these types are not specified.
Coordinate this paragraph with paragraph PIPING in PART 3; remove this whole
paragraph or subparagraphs not required in the project.
[2.14.1 Guided Slip Tube
NOTE: Expansion joints shall provide for either single or double slip of the
connected pipes, as required or indicated, and for not less than the traverse
indicated. The joints shall be designed for hot water working pressure in accordance
with applicable requirements of EJMA-01 and ASME B31.1. This joint is designed
for packing injection under full line pressure.
Internally-externally guided type, injected semiplastic type packing, with service outlets. Joints shall be
for minimum working pressure of ASME Class 150. Provide single or double slip tube type as indicated. Provide
flanged or buttwelding end connections as indicated.
][2.14.2 Flexible Ball
NOTE: The ball joint will be designed for packing injection under full line
pressure to contain leakage. Balls and sockets will be of equivalent material
as the adjoining pipeline. The exterior spherical surface of carbon steel balls
will be plated with 0.051 mm (2 mils) of hard chrome in accordance with ASTM
B 650. The ball type joints will be designed and constructed in accordance
with ASME B31.1 and Section VIII, Boiler and Pressure Vessel Code, where applicable.
Flanges where required will conform to ASME B16.5. Gaskets and compression
seals will be compatible with the service intended.
Provide chromium plated steel balls capable of 360-degree rotation plus 15-degree angular flex movement. Provide
pressure molded composition gaskets designed for continuous operation temperature of 274 degrees C 525 degrees
F. Joints shall be for minimum working pressure of ASME Class 150. Provide flanged or buttwelding end connections
as indicated.
][2.14.3 Bellows-Type
NOTE: Bellows type joints must be flexible, guided expansion joints. The expansion
element will be stabilized corrosion resistant steel. Bellows type expansion
joints will conform to the applicable requirements of EJMA-01 and ASME B31.1
with internal liners. The joints will be designed for the working temperature
and pressure suitable for the application but will not be less than 1034 kPa
(150 psig).
Type 304 staniless steel corrugated bellows, reinforced with rings, internal sleeves, and external protective
covers. Provide limit stops to limit total movement in both directions. Cold set the joints to compensate for
temperature at time of installation. Joints shall withstand 10,000 cycles over a 20 year period. Joints shall
be for minimum working pressure of ASME Class 150. Provide single or double bellows expansion joint as indicated.
Provide first pipe alignment guide no more than four pipe diameters from the expansion joint; provide second
pipe alignment guide no more than 14 pipe diameters from the first guide. Provide flanged or buttwelding end
connections as indicated.
]2.15 MISCELLANEOUS METAL
NOTE: Include miscellaneous metals located in trenches or valve manholes in
Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.
Miscellaneous metal not otherwise specified, shall conform to Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.
Miscellaneous metal bolted together, shop welded, or assembled in the field, and pipe supports, including structural
cross support members and anchors, shall be hot-dip galvanized in accordance with Section 05 50 13 MISCELLANEOUS
METAL FABRICATIONS.
PART 3 EXECUTION
3.1 EXAMINATION
After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Contracting
Officer of any discrepancy before performing the work.
3.2 SITE WORK
3.2.1 Excavation, Trenching, and Backfilling
Excavation, trenching, and backfilling of the valve manholes shall be as shown and in accordance with Section
31 00 00 EARTHWORK.
3.2.2 Electric Work
Any wiring required for the operation of the equipment specified, but not shown on the electrical drawings, shall
be provided under this section in accordance with Sections [33 71 01 OVERHEAD TRANSMISSION AND DISTRIBUTION,
and Section 33 70 02.00 10 ELECTRICAL DISTRIBUTION SYSTEM, UNDERGROUND] [33 71 01 OVERHEAD TRANSMISSION AND DISTRIBUTION
and Section 33 71 02.00 20 UNDERGROUND TRANSMISSION AND DISTRIBUTION].
3.2.3 Painting
The heat affected zone of field welded galvanized surfaces and other galvanized surfaces damaged during installation
shall be cleaned in compliance with SSPC SP 10, and painted in accordance with Section 09 90 00 PAINTS AND COATINGS.
Steel and iron appurtenances, piping, and supports shall be cleaned in compliance with SSPC SP 10, and painted
in accordance with SSPC Paint 16, coal-tar epoxy-polyamide.
3.3 PIPING
3.3.1 General
NOTE: Delete provisions in brackets and all other references to threaded connections
for high temperature water systems.
If expansion joints are required, coordinate this paragraph with paragraph EXPANSION
JOINTS in PART 2.
For Guided Slip Tube expansion joints the end connections will be flanged or
beveled for welding as indicated. Joint shall be provided with an anchor base
where required or indicated. Where adjoining pipe is carbon steel, the sliding
slip shall be seamless steel plated with a minimum of 0.051 mm (2 mils) of hard
chrome in accordance with ASTM B 650. All joint components shall be fabricated
from material equal to that of the pipeline. Initial setting shall be made
in accordance with the manufacturer's recommendations to compensate for ambient
temperature at time of installation. Pipe alignment guides shall be installed
as recommended by the joint manufacturer, but in any case shall not be more
than 1.5 m (5 feet) from expansion joint except that in lines 100 mm (4 inches)
or smaller, guides will be installed not more than 600 mm (2 feet) from the
joint. Service outlets will be provided where indicated.
Flexible ball joints will be constructed of alloys as appropriate for the service
intended. Joint ends will be threaded (to 50.8 mm (2 inches) only), grooved,
flanged or beveled for welding as indicated or required, and must be capable
of absorbing a minimum of 15-degree angular flex and 360-degree rotation.
For Bellows-Type joints, guiding of piping on both sides of expansion joint
will be in accordance with the published recommendations of the manufacturer
of the expansion joint. When a joint is installed within four pipe diameters
of an anchor, only one side needs guiding.
All piping in valve manholes shall be steel and insulated. Insulation shall be protected with [an aluminum]
[galvanized steel] jacket [, except for chilled water lines where indicated not to be insulated.] Pipe shall
be accurately cut to measurements established at the site and shall be worked into place without springing or
forcing. Pipe and insulation shall clear all openings and equipment. Excessive cutting or other weakening of
structural members to facilitate piping installation will not be permitted. Burrs shall be removed from ends
of pipe by reaming. Installation shall permit free expansion and contraction without damage to joints or hangers.
Piping shall be installed in accordance with ASME B31.1. Joints for piping in valve manholes shall be welded
[, except joints at traps, strainers, and at valves and piping 19 mm 3/4 inch and smaller which may be threaded].
[Flanged joints will be permitted for dielectric isolation only.] Supports, anchors, or stays shall not be attached
where either expansion or the weight of the pipe will cause damage to permanent construction. The method of
attaching supports shall not interfere with the operation of the cathodic protection system.
3.3.2 Welded Joints
Joints between sections of pipe, between sections of pipe and valves, and between sections of pipe and fittings
shall be welded [except where joints are allowed to be screwed for pipe sizes 19 mm 3/4 inch and smaller].
The welding shall conform to the requirements specified in paragraph WELDING.
3.3.3 Flanged and Threaded Joints
3.3.3.1 Flanged Joints
Flanged joints shall be faced true, provided with gaskets, and made perfectly square and tight. Flanged joints
shall be used only for electrical isolation and in other special cases where connected equipment is available
with only flanged joints, or when specifically shown on the drawings. Electrically isolated flange joints shall
be provided at all connections to or from the heat distribution system and between dissimilar metals.
3.3.3.2 Threaded Joints
Threaded joints shall have graphite or inert filler and oil, graphite compound, or polytetrafluoroethylene tape
applied to the male threads only. Unions shall be provided at all screwed valves, strainers and connections
to equipment 19 mm 3/4 inch and smaller. Dielectric unions shall be used at connections of dissimilar metals
in 19 mm 3/4 inch and smaller piping. When used on High Temperature Water Systems, threaded joints shall be
seal welded.
3.3.4 Reducing Fittings
Eccentric reducers in horizontal runs shall be installed with the straight side down. Changes in horizontal
piping sizes shall be made through eccentric reducing fittings.
3.3.5 Branch Connections
Branches from mains shall branch off top of mains as indicated or as approved. Connections shall ensure unrestricted
circulation, elimination of air pockets, and shall permit the complete drainage of the system. Branch connections
may be made with either welding tees or forged branch outlet fittings. Branch outlet fittings where used shall
be forged and shall be no larger than two nominal pipe sizes smaller than the main run. Branch outlet fittings
shall be reinforced to withstand external strains and designed to withstand full pipe bursting strength.
3.3.6 Pipe Supports in Valve Manholes
Horizontal and vertical runs of pipe in valve manholes shall be securely supported.
3.4 WELDING
NOTE: If the need exists for more stringent pipe welding requirements, delete
the sentences in the first set of brackets.
[Piping shall be welded in accordance with qualified procedures, using performance qualified welders and welding
operators. Procedures and welders shall be qualified in accordance with ASME BPVC SEC IX. Welding procedures
qualified by others, and welders and welding operators qualified by another employer may be accepted as permitted
by ASME B31.1. The Contracting Officer shall be notified 24 hours in advance of tests and the tests shall be
performed at the work site. The welder or welding operator shall apply his assigned symbol near each weld he
makes as a permanent record.] [Welding and nondestructive testing procedures for piping shall be as specified
in Section [43 02 00] [40 17 26.00 20] WELDING PRESSURE PIPING.] Structural members shall be welded in accordance
with Section 05 05 23 WELDING, STRUCTURAL.
3.5 INSULATION
The insulation shall be installed so that it will not be damaged by pipe expansion or contraction. Insulation
shall not become wet before, during, or after installation. Insulation installed over welds shall be grooved
to assure a snug fit. Insulation shall be held in place with stainless steel straps. A minimum of 2 bands shall
be installed on each individual length of insulation and maximum spacing shall not exceed 450 mm 18 inch centers.
3.5.1 Installation
Material shall be installed in accordance with published installation instructions of the manufacturer. Insulation
materials shall not be applied until piping tests are completed. Prior to application, surfaces shall be thoroughly
cleaned of moisture, grease, dirt, rust, and scale, and painted where required.
3.5.2 Insulation on Pipes Passing Through Sleeves
Insulation shall be continuous, as required by paragraph Pipe Sleeves Through Valve Manhole Cover. Aluminum
jackets shall be provided over the insulation. When penetrating valve manhole walls, aluminum jacket shall extend
not less than 50 mm 2 inches beyond the sleeve on each side of the wall and shall be secured with an aluminum
band on each side of the wall. Where flashing is provided, the jacket shall be secured with not less than one
band located not more than 25 mm 1 inch from the end of the jacket. When penetrating valve manhole tops, pipe
shall be insulated as required for valve manhole service as indicated.
3.5.3 Covering of Insulation in Valve Manholes
The insulation for pipe, flanges, valves, and fittings shall be covered with [aluminum] [galvanized steel] jackets.
3.5.4 Insulation of Piping Accessories in Valve Manholes
Flanges, couplings, unions, valves, fittings, and other pipe accessories, unless otherwise shown or approved,
shall be insulated with removable and reusable factory premolded, prefabricated, or field fabricated insulation.
For accessories in valve manholes, [aluminum] [galvanized steel] sheet shall be applied over the insulation.
Where accessories are designated not to be insulated, the adjoining insulation and jacket shall terminate neatly.
The terminations for the chilled water systems shall provide a complete vapor seal.
3.5.5 Insulation Sealing for Chilled Water Systems
The ends of insulation shall be sealed with vapor barrier. Penetrations shall be caulked. Caulking shall be
applied to parting line between equipment and removable section insulation. Upon completion of installation
of the insulation, including removable sections, two coats of vapor barrier coating shall be applied with a layer
of glass cloth embedded between the coats. The total dry thickness of the finish shall be 1.6 mm 1/16 inch.
The coating shall be applied so that the removable sections are coated separate from the body of the equipment
so these sections remain removable. Coating shall be applied to flanges, unions, valves, anchors, fittings and
accessories, all terminations, and all insulation not protected by factory vapor barrier jackets or PVC fitting
covers. Tape seams shall overlap 25 mm 1 inch. The coating shall extend out onto the adjoining pipe insulation
50 mm 2 inches. Insulation terminations shall be tapered to unions at a 45-degree angle.
3.5.6 Insulation Thickness
NOTE: Delete inapplicable columns in Tables 1 and 2.
The minimum thickness of insulation for [the heat distribution system] [and] [condensate return system] [each
section of pipe] shall be in accordance with Tables 1 and 2.
TABLE 1
Minimum Pipe Insulation Thickness (In millimeters)
For steam (110 to 2,800 kPa (gage)) and High Temperature
Hot Water Supply and Return (120 to 230 degrees C)
Nominal MPT-PC Delta Thermo-12 Foamglass
Pipe MPT-PF Super
Diameter Caltemp
(mm)
25 50 63 100 115
40 50 63 100 115
50 65 85 110 125
65 65 85 110 125
80 75 100 125 150
100 75 100 125 150
125 75 100 125 150
150 85 110 135 150
200 85 110 135 150
250 100 125 150 165
300 100 125 150 165
350 100 125 150 165
400 100 125 150 165
450 100 125 150 165
TABLE 1
Minimum Pipe Insulation Thickness (In inches)
For steam (16 to 408 psig) and High Temperature
Hot Water Supply and Return (250 to 450 degrees F)
Nominal MPT-PC Delta Thermo-12 Foamglass
Pipe MPT-PF Super
Diameter Caltemp
(inches)
1.0 2.0 2.5 4.0 4.5
1.5 2.0 2.5 4.0 4.5
2.0 2.5 3.5 4.5 5.0
2.5 2.5 3.5 4.5 5.0
3.0 3.0 4.0 5.0 6.0
4.0 3.0 4.0 5.0 6.0
5.0 3.0 4.0 5.0 6.0
6.0 3.5 4.5 5.5 6.0
8.0 3.5 4.5 5.5 6.0
10.0 4.0 5.0 6.0 6.5
12.0 4.0 5.0 6.0 6.5
14.0 4.0 5.0 6.0 6.5
16.0 4.0 5.0 6.0 6.5
18.0 4.0 5.0 6.0 6.5
TABLE 2
Minimum Pipe Insulation Thickness (In millimeters)
For Low Pressure Steam (less than 110 kPa (gage)), Condensate Return
and Low Temperature Hot Water (less than 120 degrees C)
Supply and Return
Nominal MPT-PC Delta Thermo-12 Foamglass
Pipe MPT-PF Super
Diameter Caltemp
(mm)
25 40 50 80 80
40 40 50 80 80
50 40 50 80 80
65 40 50 80 80
80 50 65 85 85
100 50 65 85 85
125 50 65 85 85
150 65 80 110 110
200 65 80 110 110
250 80 100 125 125
300 80 100 125 125
350 80 100 125 125
400 80 100 125 125
450 80 100 125 125
TABLE 2
Minimum Pipe Insulation Thickness (In inches)
For Low Pressure Steam (less than 16 psig), Condensate Return
and Low Temperature Hot Water (less than 250 degrees F)
Supply and Return
Nominal MPT-PC Delta Thermo-12 Foamglass
Pipe MPT-PF Super
Diameter Caltemp
(inches)
1.0 1.5 2.0 3.0 3.0
1.5 1.5 2.0 3.0 3.0
2.0 1.5 2.0 3.0 3.0
2.5 1.5 2.0 3.0 3.0
3.0 2.0 2.5 3.5 3.5
4.0 2.0 2.5 3.5 3.5
5.0 2.0 2.5 3.5 3.5
6.0 2.5 3.0 4.5 4.5
8.0 2.5 3.0 4.5 4.5
10.0 3.0 4.0 5.0 5.0
12.0 3.0 4.0 5.0 5.0
14.0 3.0 4.0 5.0 5.0
16.0 3.0 4.0 5.0 5.0
18.0 3.0 4.0 5.0 5.0
3.6 VALVE MANHOLES AND ACCESSORIES
NOTE: Provide design details on drawings of concrete reinforcing, size, dimensions
of valve manhole, piping arrangements, type of removable cover, valve manhole
penetrations, pipe and equipment supports, etc.
3.6.1 Piping and Equipment in Valve Manholes
Piping and equipment in valve manholes shall be installed to provide easy access without stepping on piping or
equipment, and to provide sufficient working room. Piping and equipment in valve manholes shall be installed
and supported as shown on the drawings. All globe, angle and gate valves shall be installed with the stems horizontal
or above. Submit Data Package 2 as related to all equipment provided for the project.
3.6.2 Sump Pumps Installation
NOTE: Coordinate this paragraph with the specified requirements in paragraph
SUMP PUMPS.
Sump pumps shall be installed as indicated. All electrical connections shall be hard wired.[ Monitoring of
each pump motor and the high water alarm shall be connected to the Energy Monitoring and Control System (EMCS).
Coordinate electrical requirements of EMCS with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM]. Electrical circuits
to the sump pumps shall be dedicated circuits. All circuit breakers and switches in the electrical power distribution
to the sump pumps shall be capable of being locked in the "ON" position and will be signed as follows:
a. THIS CIRCUIT SUPPLIES POWER TO THE ELECTRIC SUMP PUMPS IN THE UNDERGROUND DISTRIBUTION SYSTEM. THIS
CIRCUIT MUST BE "ON" AT ALL TIMES; OTHERWISE EXTENSIVE DAMAGE WILL OCCUR TO THE UNDERGROUND HEAT DISTRIBUTION
SYSTEM AND PREMATURE FAILURE WILL OCCUR.
b. The words on the sign shall be stamped on a corrosion resistant metal plate with letters 10 mm 3/8
inch high, and the plate shall be affixed permanently near the switch or circuit breaker.
3.7 TESTS
Tests of piping in the valve manholes will be performed as part of the testing of the direct buried conduit system.
These tests shall include the piping in the valve manhole and performed in accordance with the system supplier's
Approved Brochure or the contract specifications.