SECTION 15/1/6

CHILLED WATER PIPING SYSTEM

PART 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 Building Services Piping.

B. ASTM - American Society of Testing and Materials:

ASTM A 53 Pipe, Steel, Black and Hot-Dipped, Zinc Coated

(Galvanized), Welded and Seamless.

ASTM A 234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for
Moderate and Elevated Temperatures.

C. ANSI - American National Standard Institute

ANSI B1.20.1 Pipe Threads.

ANSI B16.1 Cast Iron Flanges and Flanged Fittings, Classes 25, 125,
250 and 800.

ANSI B16.3 Malleable-Iron Threaded Fittings, Classes 150 and 300.

ANSI B16.5 Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and
Other Special Alloys.

ANSI B16.22 Wrought Copper and Copper Alloy Solder-Joint Pressure

Fittings.

ANSI B16.39 Threaded Pipe Unions, Malleable-Iron, Classes 150, 250

and 300.

D. BSI - British Standards Institute

BS 21 Pipe Threads for Tubes and Fittings.

BS 143 Malleable Cast Iron and Cast Copper Alloy threaded Pipe
Fittings.

BS 1560 Steel Pipe Flanges.

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 BS 4504 Flanges and Bolting for Pipes, Valves and Fittings.

BS 5154 Copper alloy Globe, Globe Stop, and Check, Check and
Gate valves

E. ISO – International Standards 0rganization:

ISO 1183 Polyethylene – Measurement of Density

F. 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. 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.

E. Test Results: Submit test results as required.

1.4 WARRANTY:

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.

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PART 2 - PRODUCTS

2.1 CHILLED WATER PIPING:

A. Pipes

1. Pipes for above ground installation shall be seamless Black steel, Schedule
40, conforming to ASTM A 53, with beveled ends.

2. Pipes for underground chilled water installation shall be pre-insulated pipes

suitable for direct burial and shall consist of carrier pipe, insulation and outer
casing conforming to the following:

a. Carrier Pipe: Fiberglass pre-insulated pipes, 16 bar in key-lock (direct

burial.); sizes as shown on drawings and approved by the Engineer.

b. Insulation: CFC-free rigid polyurethane foam insulation, 48 kg/m3 density

(minimum.) to ASTM D 1622, not less than 50 mm thickness.

c. 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. Fittings:

1. Install above ground black steel pipes with threaded joints and fittings for 50
mm and smaller, and with VICTAULIC or approved equal fittings for 65 mm or
larger pipes. Fittings for all preinsulated piping shall be by Victaulic. Type of
Victaulic fittings shall be as recommended by Victaulic manufacturer and
approved by the Engineer.

a. Malleable-Iron Threaded Fittings: ANSI B16.3, Class 150, standard

pattern, for threaded joints. Treads shall confirm to ANSI B1.20.1.

2. Dielectric Union: Threaded or soldered end connections for the pipe material
in which installed; constructed to isolate dissimilar materials, prevent galvanic
action, and prevent corrosion.

3. 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.

4. Gasket Material: Thickness, material, and type suitable for fluid to be

handled, and design temperatures and pressures.

5. Welding Materials (Where required): Comply with Section II, Part C ASME
Boiler and Pressure Vessel Code for welding materials appropriate for wall
thickness and chemical analysis of pipe material being used.

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 C. General Duty Valves:

1. As specified in Section VALVES.

D. Special Duty Valves:

1. Calibrated Plug Valves: 1200 kPa water working pressure, 40 oC 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.

2. Circuit Setters: A calibrated balance valve equipped with readout valves and
provided with differential pressure meter.

3. 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.

E. Piping Specialties:

1. Manual Air Vent: Bronze body and non-ferrous internal parts; 1035 kPa
working pressure, 110 oC operating temperature; manually operated with
screw-driver or thumb-screws; and having 3 mm discharge connection and 13
mm inlet connection.

2. 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.

3. Pressure and Temperature Taps: Install pressure and temperature taps at all
coil connections across two port valves, pumps, chiller evaporator, or
otherwise as indicated:

a. Taps shall be 13 mm solid brass fittings which shall receive either

pressure or temperature probe with valve core or Nordel fitted color
coded and marked cap and gaskets, and rated at 135 oC and 7000 kPa.

b. Furnish No. 500 pressure gauge adapters with 3-8 mm probe and No.
701, 125 mm stem pocket thermometers with - 5 o to 50o range for chilled
water.

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.

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 5. Y-Pattern Strainers: 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, 850 kPa
working pressure.

2.2 DIAPHRAGM-TYPE COMPRESSION TANKS:

A. Size and number as indicated; construct of welded carbon steel for 850 kPa
working pressure, 190 0C 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/cm 2 (850 kPa) water working pressure and 190 0C 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

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 application requirements. Pump drivers shall be selected to be non-
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. Pumps shall be of variable or constant speed drive as required and capable

of parallel operation.

5. 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 of the capacities and types as shown on the drawings.

C. Chilled water pump being the integrated component of pipe work shall be split
couple vertical inline or horizontal split-case type as shown on drawings and
equipped with mechanical seals. Specific pump ratings and types shall be as
indicated on plans. Pump shall be split coupled type with rigid spacer type coupling.

D. Pump and motor shall be mounted on a high grade, heat-treated cast-iron common
baseplate and shall be installed with suction guides. Pump motor shall be TEFC
Class ‘F’.

E. Casing: Cast iron, split volume, double suction, rated for greater than 10.54 kg/cm o
(150 psi) actual working discharge pressure, with renewable bronze wearing rings,
flanged suction and discharge connections and shall be drilled and tapped for seal
flange and gauge connections..

F. Impeller: Bronze enclosed double suction type, keyed to shaft with a slightly press
and suitable lock-nut arrangement.

G. Shaft: Stainless steel shaft with stainless steel sleeves.

H. Drive: Split coupling with space between the shafts sufficient to replace mechanical
seal without disturbing pump or motor coupling guard.

I. Commercial pre-lubricated grease, or oil-lubricated bearings shall be used.

J. Mechanical seal shall be stainless steel multi-spring balance type with secondary
seal suitable for specific application and shall be accessible and easily replaceable
type.

K. 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.

L. The manufacturer shall submit certificate, including test data to show that pump
meets performance specifications.

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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. Chemical pot feeder complete with sampling point and valving as indicated.

2. Corrosion scale and electrolytic action inhibiter dosing in the chilled water
system.

3. Test Kit.

4. Carry out tests on local water necessary to finalize details of the water
treatment.

C. Treatment:

1. Thoroughly clean and system of oil grease and swarf deposits using an
approved soluble solvent in accordance with the manufacturer's instructions.

2. Circulate the solution for at least one hour, drain and then flush system
thorough with fresh water.

3. Does system with corrosion and electrolytic action and scale inhibitor.

D. Handover:

1. The Contractor shall supply a test kit and instruct the user in its use.

2. Full instructions shall be given to the user on the dosing methodology.

3. Prior to handover, the Contractor shall carry out his own tests and ensure the
system is correctly dosed.

4. Provide the user with 6 months supply of chemicals.

2.7 INSULATION:

A. Refer to Section MECHANICAL INSULATION.

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PART 3 - EXECUTION

3.1 INSTALLATION:

A. Refer to Section BASIC PIPING MATERIALS AND METHODS for basic piping
installation instructions. Refer to the drawings for further details. The entire chilled
water system installation shall conform to the 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. Proper foundations for mounting of piping system shall be provided, including
supports, vibration isolators, guides, anchors, clamps and brackets.

D. Pumps shall be installed in strict conformance with manufacturer's written

instructions.

E. 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.

F. 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.

G. Pipe Workmanship: Install completed system, size as shown on the drawings.

Install piping parallel or perpendicular to the building construction. Allow for
expansion.

H. 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.

I. 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.

J. The chilled water piping, valves, fittings, separator and expansion tank shall be
insulated as per Section MECHANICAL INSULATION.

K. Chilled Water Treatment:

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.

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 2. Results of the chemical analysis and the proposed treatment method are to
be submitted to the Engineer for review and approval prior to the Contractor's
filling the system.

3.2 FIELD QUALITY CONTROL

A. 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.

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.

B. Testing: Test chilled water piping as follows:

1. Use ambient temperature water as the testing medium.

2. 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.

3. 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.

4. 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
hydrostatic test until there are no leaks.

5. For further requirements refer to Section TESTING, ADJUSTING AND

BALANCING.

3.3 ADJUSTING AND CLEANING

A. Clean and flush chilled water piping system. Remove, clean, and replace strainer

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 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.

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