Section 232113 - Hydronic Piping

Shopping Mall at Jumeirah Village Triangle
SECTION 232113 - HYDRONIC PIPING
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including Conditions of

Contract and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes piping, special-duty valves, and hydronic specialties for
chilled-water cooling, and condenser water systems; makeup water for these
systems; and condensate drain piping.
1.3 STANDARDS
A. The following standards are referred to in this section as alternative
1. BS 10 Flanges for bolting pipes, valves and fittings.

2. BS 21 Pipe threads for tubes and fittings where pressure-type joints are
made on threads (metric dimensions).
3. BS EN 10255 Non-alloy steel tubes suitable for welding and threading.
Technical delivery conditions.
4. BS EN 1044 Filler metals for brazing.
5. BS EN 10253-1 Butt-welding pipe fittings. Wrought carbon steel for
general use and without specific inspection requirements.
6. BS EN 10253-2 Butt-welding pipe fittings. Non alloy and ferritic alloy
steels with specific inspection requirements.
7. BS EN 1092-1 Flanges and their joints. Circular flanges for pipes, valves,
fittings and accessories, PN designated. Steel flanges.
8. ASME American Society of Mechanical Engineers.
9. API American Petroleum Institute.
1.4 SUBMITTALS
A. Quality Manual and Quality plan for Contractor and its related Sub Contractors
including:
1. Inspection Test Plan

2. Orga
Organization Chart, CV’s and certificates for each personal including NDT
Co
Company and Third Party Company; Third party Engineers shall have
mini
minimum 10 years’ experience.
3. Prod
Product Data: For each type of special-duty valve indicated. Include flow
and pressure drop curves based on manufacturer's testing for diverting
fitt
fi
fittings, calibrated balancing valves and automatic flow-control valves.
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B. Shop Drawings: Detail fabrication of piping Isometric & spools, pipe anchors,
hangers, special pipe support assemblies, alignment guides, expansion joints and
loops, and their attachment to the building structure. Detail location of anchors,
alignment guides, welding map and expansion joints and loops.
C. Sustainability Submittals:
1. Product Data: For solvent cements and adhesive primers, documentation

including printed statement of VOC content.
D. Proposal Welding Procedure Specification (PWPS).
E. Welding Procedure Specification (WPS) supported by Procedure Qualification

Record (PQR).
F. Welder Qualification Certificates.
G. Original Mill Certificates for piping, fitting, filler metal,…etc.
H. Calibration Certificate for Equipment and Gauges.
I. Insulation and Coating procedures
J. Field Test Reports: Written reports of tests specified in Part 3 of this Section.
Include the following:
1. Test procedures used.( NDT Procedures, Hydrostatic& leak test

procedures,…etc)
2. Test results that comply with requirements.
3. Failed test results and corrective action taken to achieve requirements.
K. Maintenance Data: For hydronic specialties and special-duty valves to include in

maintenance manuals specified in Division 1.
L. Water Analysis: Submit a copy of the water analysis to illustrate water quality
available at Project site.
1.5 QUALITY ASSURANCE
A. Surface preparation for all steel pipes: Shot blasting to SA 2.5 and then immediate
application of 150 um polyamide epoxy paint to be confirmed for proper bonding
with pre-insulated pipes manufacturer.
B. Welding: Qualify processes and operators according to the ASME Boiler and
Pressure Vessel Code: Section IX, "Welding and Brazing Qualifications" and
ASME B31.1
AS B or ASME B31.9 as applicable. Welders shall be certified for the
type
type of pi pipe material specified, welding process and position of welds required
duri
du ring
ri
duringng fab
fabrication of the piping. Welder’s Qualification Test to be performed on
si aand
site nd attended by Contractor Welding Inspectors, Third Party and Engineer
prio
pr iorr to ccommencing piping fabrication.
io
prior
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C. Non destructive examination shall be performed to all pipe welds in accordance to

ASME B31.1 or ASTM B31.9 as applicable. A Non destructive test shall perform
the tests and submit the related reports after getting the approval and stamping of
third party inspection company, prior prequalification approval should be obtained
from Engineer on NDT & Third Party Inspection both companies.
D. All welds shall be identified by the welder’s mark and a sequence number. The
Contractor shall employ a Certified Welding Inspector (CWI) or CSWIP 3.1,
NDT personal certified as Level 2 minimum in the NDE methods utilized
(independent of the contractor fabricating or installing the piping) to visually
examine all welds in accordance with inspection and examination requirements of
ASME B31.1 or ASME B31.9 as applicable. Any welds failing the visual or
NDE inspection shall be ground out or cutout, re-welded and radio graphed at the
expense of the Contractor. The CWI shall submit a written report signed and
stamped from the approved third party for each weld to the Engineer.
E. Additionally, 5% of all fitting, flange and Butt joint welds shop or field or as per
ASME requirements, minimum of 5% of Butt Joints welds, randomly selected by
the Engineer, shall be radio graphed at the expense of the contractor. The certified
welding inspector shall examine the films and provide a written report to the
Engineer. All welds not meeting the requirements of ASME B31.1 or ASME
B31.9 latest edition as applicable will be ground out, re-welded and re-radio
graphed at the expense of the Contractor. If any 10% of the randomly selected
radio graphed welds fail, all welds in the piping will be radio graphed and
repaired at the expense of the contractor.
F. 10 % of Fillet Joints shall be tested by Dye Pentrent Test Or Magnetic Test
G. ASME Compliance: Comply with ASME B31.1 and ASME B31.9 as applicable
for materials, products, and installation. Safety valves and pressure vessels shall
bear the appropriate ASME label. Fabricate and stamp air separators and
expansion tanks to comply with the ASME Boiler and Pressure Vessel Code,
Section VIII, Division 1.
H. All pre-insulated piping systems shall be completely sealed and waterproof, and
they shall be capable of allowing sufficient movement for thermal expansion and
contraction. Each assembly shall be factory-designed for the specific service
medium, temperature, and pressure. Expansion loops, expansion joints, anchors,
and guides shall be furnished and installed to provide a trouble-free system and
avoid stress on any equipment.
I. On Site Supervision of Underground Pre-insulated Chilled Water Piping

Installation:
1. Th
The pre-insulated pipe manufacturer shall have a determined quality
assu
assurance program to ensure compliance with specifications.
2. All inner polyurethane insulation to be visually inspected to ensure absence
of any void prior to the application of jacket.
3. Th
The following tests shall be performed on daily basis to ensure quality of
inst
in
installation:
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a. Density (greater or equal to 60 50Kg/m3)

b. Thermal conductivity (smaller or equal to 0.023 W/m°C)
c. Compressive strength (greater or equal to 300 KPa)
d. Closed cell content (smaller or equal to 88%)
4. Full Time Factory trained field technical assistance & supervision shall be
provided by pre-insulated manufacturer during installation.
5. Representative's daily written reports to the Resident Engineer: Present the
original of each report on the day it is prepared. The report shall be signed
by the manufacturer's representative. The report shall state whether or not
the condition and quality of the materials used and the installation of the
system is in accordance with the plans, specifications, and published
standards of the manufacturer, and is satisfactory in all respects. If anything
connected with the installation is unsatisfactory, the report shall state that
corrective action has been taken or shall contain the manufacturer's
recommendations for corrective action. The report shall cover any condition
that could result in an unsatisfactory installation. The representative shall
take prompt action to return to the factory all damaged and defective
material, and shall order prompt replacement of such material.
6. On completion of the installation, the Contractor shall deliver to the
Resident Engineer a certificate from the manufacturer that the installation is
in compliance with all installation recommendations and warranty
requirements of the manufacturer.
1.6 COORDINATION
A. Coordinate layout and installation of hydronic piping and suspension system

components with other construction, including light fixtures, HVAC equipment,
fire-suppression-system components, and partition assemblies.
B. Coordinate pipe sleeve installations for foundation wall penetrations.
C. Coordinate piping installation with roof curbs, equipment supports, and roof
penetrations.
D. Coordinate pipe fitting pressure classes with products specified in related

Sections.
E. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into
base..
F. Coordinate installation of pipe sleeves for penetrations through exterior walls and
asse
floor assemblies. Coordinate with requirements for firestopping specified in
Se
Section "P
"Penetration Firestopping" for fire and smoke wall and floor assemblies.
1.77 DELI
LIVE
LIVE
DELIVERY, STORAGE and HANDLING
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A. Products shall be delivered in original, unbroken packages, containers, or bundles

bearing the name of the manufacture.
B. Products shall be carefully stored in a manner that will prevent damage and in an
area that is protected from the elements.
C. End caps weather supplied by the piping manufacturer or fabricated by the

contractor are to be placed at the ends of the piping sections to keep debris and
reptiles from entering inside the pipe while it is placed in storage.
D. Prefabricated sections of the pre-insulated pipe are to be handled per the

manufacturer’s recommendations or instructions.
E. All pre-insulated pipes shall be protected from direct sunlight while transported or
stored.
1.8 EXTRA MATERIALS
A. Water Treatment Chemicals: Furnish sufficient chemicals for initial system

startup and for preventive maintenance for one year from date of Substantial
Completion.
1.9 WARRANTY
A. Manufacturer's warranty form in which manufacturer agrees to repair or replace

components that fails in materials or workmanship within specified warranty
period.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Manufacturers: USA, Europe, Japan or their own Factory:
2.2 PIPING MATERIALS
A. General: Refer to Part 3 "Piping Applications" Article for applications of pipe

and fitting materials.
2.3 PIPE AND TUBING
A. Mini
Mi nimum steel pipe size recommended for hydronic piping is NPS 3/4 (DN 20).
ni
Minimum
B. Chille
ledd Water (above ground),, Condenser Water (above ground), and Vent
le
Chilled
Pipi
Piping
pi ng::
ng
Piping:
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1. Steel pipes DN 50 and smaller: ASTM A53/A53M Grade B, seamless,

Schedule 40 with threaded ends.
2. Steel pipes DN 65 and up to DN 250: ASTM A53/A53M Grade B or ASTM
A106/A106M Grade B, seamless, Schedule 40 with beveled ends for butt
welding or roll Grooved ends for Coupled Joints.
3. Steel pipes DN 300 to DN 600: ASTM A53/A53M Grade B, or ASTM
A106/A106M Grade B, ERW, Schedule STD and beveled ends for butt
welding or roll Grooved ends for Coupled Joints.
4. Pipes above DN 600: API 5L Grade B, SAW at both sides with helical seam
and beveled ends for butt welding or roll Grooved ends for Coupled Joints.
5. Minimum wall thickness shall be in accordance with the calculation based
on ASME B31.1 to verify that wall thickness is adequate enough as per
actual system pressure:
C. Underground Condenser Water Piping: Ductile iron pipe and fittings, with
mechanical lock joints.
D. Extension of Domestic Water Make-up Piping: as specified for Domestic water

piping. Refer to section 221116 “Domestic Water Piping”.
E. Cooling Coil Condensate Drain Piping:

1. From air handling units: Schedule 40, PVC Pipe with solvent-welded joints
or Galvanized steel sch. 40 pipe
2. From fan coil or other terminal units: Schedule 40, PVC Pipe with solvent-
welded joints or Galvanized steel sch. 40 pipe.
F. Chemical Feed Piping for Condenser Water Treatment: Chlorinated polyvinyl

chloride (CPVC), Schedule 80, ASTM F441/F441M.
G. Diesel Engine Cooling Water: For DN 50 (NPS 2) and smaller, use Schedule 40
steel pipe with threaded joints; for DN 65 (NPS 2-1/2) and larger, use Schedule 40
steel pipe with welded joints.
H. Testing and certification:
1. Testing and certification procedures by an independent testing laboratory

shall demonstrate that casings and end seals are capable of resisting
penetration of water into the casing and insulation at 60 kPa of head
pressure, measured above the highest point of the test sample, subjected
over the entire surface of an 2.5 m test sample of prefabricated pipe for not
less than 48 hours. Test shall use 24 degrees C water for chilled water
service, while the sample is either buried or encased in dry bedding sand
with a minimum of 305 mm of sand all around sample. The carrier pipe size
in the test section shall be 75 mm in diameter and shall be restrained during
the test period. The insulation thickness shall not exceed the maximum
thic
thickness provided for the piping in the project.
2.44 FACT
FA CTOR PRE - INSULATED PIPING AND PIPE-FITTINGS
CT
FACTORY
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A. Description: Factory-fabricated piping with carrier pipe, insulation and

Casing.
B. Carrier Pipe below Ground:
1. Pipe Size below 250 mm shall be schedule 40 ERW black steel

conforming to ASTM A53 Grade B.
Pipe sizes above SO mm shall be beveled ends for welded joints. Pipe
sizes 50 mm and below shall be square end for socket weld joints.
2. Pipe size above 250 mm up to and Including 700 mm (28") shalt be

ERW black steel conforming to ASTM A53 Grade B Standard weight
wall thickness (9.5mm). All pipes shall be with beveled ends for welded
joints or cut grooved ends.
3. Pipe sizes 750 mm (30") and above shall be SAW black steel pipe
conforming to API 5L Grd..B, Extra strong weight wall thickness
(12.7mm).All pipes shalt be with beveled ends for welded.
C. Exterior (OD) Pipe Coating
D. Corrosion Protection
1. Prior to application of the insulation, the piping shalt be coated with a

fusion bonded epoxy coating. The fittings shall be coated with liquid
epoxy. The coater shall be licensed by the fusion bonded epoxy material
supplier.
2. The coating process shall consist of abrasive blasting of the external

surface of the pipe to near white in accordance with SSPC-SP10 or
NACE #2. The pipe shall then be preheated to a temperature between
232°C and 246°C. The epoxy powder shall be deposited electro-
statically onto the blasted pipe surface to a nominal thickness of .36 mm
to .41mm.
3. After application the coating shall be electrically inspected for

continuity at 1500 volts to check for Holidays, pinholes and
discontinuities. Repairs shall be made with a hot melt patch stick or
liquid epoxy. Immediately before applying the polyurethane foam the
pre-insulated piping manufacturer shall re-inspect and repair the coating
as above.
E. Ca
Carrier Pipe Insulation:
1. Thermal Insulation by void free, rigid cellular, 100% CFC free

Polyurethane foam, bonded to the service pipe & the outer jacket and
shall be factory applied.
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2. The external surface of the carrier pipe shall be grit blasted to SA 2 ½

near white metal finish.
3. The pre insulated bonded piping shall comply with standard EN 253 or
equivalent minimum.
4. Pipe Ends shall always be covered In order to prevent inside of the pipes
from debris and other foreign objects.
5. Core Thermal Conductivity shall be <0.03 W/mK as per EN253 - ISO

8497 or equivalent.
6. Service Temperature: Minus 20 to plus 150 deg 0C.
7. Moisture Absorption: maximum below 10% by volume.
8. Minimum 88 % percent closed cell.
9. Core Density: 55 Kg/m3 minimum.
10. Thickness minimum 50 mm thick for pipes up to 400 mm and minimum

75 mm for pipes above
400 mm.
F. Casing: HDPE/GRP
1. For pipes directly lay underground. Casing to include wind down end
seals tested and certified in accordance with paragraph 3 below.
2. The outer protective insulation jacket for Pipe size below and including
DN1200 shall be manufactured from Seamless High Density
Polyethylene (HDPE) and above DN1200 shall be manufactured from
HDPE \ GRP.
a) Casing manufactured from HDPE shall be in accordance with EN

253.
b) GRP Seamless material In accordance with ASTM D2310.Where a

combination of both materials predicts, a method statement of
jointing both should be submitted for the Engineer's approval.
G. Pre
Pre-insulated pipe fittings
1. All fittings are to be factory pre-insulated and shall have the same
carrier, insulation and vapor barrier materials as the connecting straight
length pipes. Pre-insulated fittings shall comply with the requirements in
EN448 or equivalent as minimum. All fittings shall be long radius &
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butt-welding type, with wall thicknesses similar to those of the core

steel pipe, conforming to ASTM A234 WPB and dimensions according
to ANS/AI SME 816.9, with 300 mm long Beveled/Grooved end
steel pipe extension factory welded to each end.
2. Directional changes on pipes of size 200mm dia and larger shall to all
extents possible, be affected by using pipes curved in the factory
according to the indicated curving angle.
3. Bends shall be one of the following types:
a) Bend fittings for pipes diameter up to 315 mm in one joint
b) Pre-fabricated bends for pipes above 315 mm diameter
4. The bend fitting and pre-fabricated bends shall be available In

7.5°,15°,45° and 90°.
H. End seals provided shall be one of the following types:
1. Carrying the outer casing over tapered pipe insulation ends and extending
it to the carrier pipe. Sufficient surface bonding area shall be provided
between the casing and the carrier pipe.
2. Using specially designed molded caps made of jacket of standard

manufactured thickness. A minimum 40mm surface bonding area shall
be provided between the cap and both the casing and carrier pipe.
3. High ratio shrinks sleeves.
4. Paint or mastic shall not be used.
5. End Seals: Test the end seal in independent testing laboratory at 7 meters
(20ft.) head water to certify that HDPE casing can withstand the presence
of water around the casing.
I. Casing: Fire retardant thermosetting filament wound fiberglass reinforced

polyester casing over protected with 1.6 mm Aluminum jacket or HDPE as
specified above.
1. For pipes in valve chambers and where exposed to view.
J. Ca
Casing accessories include the following:
1. Joint Kit: Half-self, pourable or split insulation, casing sleeve, and

sh
shrink-wrap sleeve.
2. Expansion Blanket: Elastomeric foam, formed to fit over piping.
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3. End Seals: Shrink wrap the casing material to seal watertight around
casing and carrier pipe.
K. Source Quality Control: Factory test all factory carrier pipe welds to 150
percent of the operating pressure of system. Furnish test certificates.
1. Fittings:
Fittings for black steel pipes over 50 mm diameter to be, steel, seamless,
butt-welding, with 37 degrees beveled ends, of same schedule, thickness
and rating as pipe of corresponding size to ASTM A420/A420M -05.
2. Elbows to be long radius type.
3. Flanges are to be of same pressure rating, facing, drilling and thickness

as mating flanges on valves, accessories and equipment.
4. Flanges on black steel pipes to be black, forged steel, weld neck type.
5. All fittings shall be factory prefabricated and pre-insulated. Straight

tangent lengths of 300mm shall be added to all ends so that all field joints
are straight sections of pipe. Fitting covers shall be HOPE.HOPE covers
shall be mitered and extrusion welded, butt fusion welded, or molded.
2.5 JOINING MATERIALS
A. Pipe Flange Gasket Materials: Suitable for the chemical and thermal conditions
of the piping system contents.
1. ASME 816.21, non-metallic, flat, asbestos-free, (3mm) maximum thickness,

except where thickness or specific material is indicated.
a. Full-Face Type with Punched Holes: For flat-face, Class 125 cast-iron
and cast-bronze flanges.
b. Narrow-Face Type: For raised-face, Class 250 cast-Iron and steel

flanges. Same outside diameter as raised face.
2. AWWA C110, rubber, flat face, (3 mm) thick, except where other thickness
is indicated; and full-face or ring type, except where type is indicated.
B. Flange
Fl Bolts and Nuts: hot dipped galvanized steel, except where other material
is indic
indicated, of length to allow nuts to utilize full length of bolt thread plus 6
mm
mm.
C. Solder
Sollde
So der Filler Metal: ASTM B 32.
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1. Alloy SnSO: Tin (SO percent) and lead (50 percent).

2. Alloy SbS: Tin (95 percent) and antimony (5 percent), having 0.20 percent
maximum lead content.
D. Brazing Filler Metals: AWS A5.8.
1. BCuP Series:Copper-phosphorus alloys.
2. BAg1: Silver alloy.
E. Welding Filler Metals: Comply with AWS 010.12 for welding materials
appropriate for wall thickness and chemical analysis of steel pipe being welded.
F. Flanged, Ductile-Iron Pipe Gasket: High grade natural rubber to BS 2494 Part
1.
G. Couplings: Iron body sleeve assembly, fabricated to match outside diameters of

plain-end pressure pipes.
1. Sleeve: ASTM A 126, Class B, gray iron.
2. Followers: ASTM A 47 (ASTM A 47M), Grade 32510 or ASTM A 536

ductile iron.
3. Gaskets: Rubber.
4. Bolts and Nuts: AWWA Clll.
5. Finish: Enamel paint.
H. Thread Sealant: Teflon tape or approved special joint compound.
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2.6 LEAK DETECTION SYSTEM:
Leak detection system shall be provided as per local authority or EMPOWER

requirement.
A. TDR leak detection system:
1. The pre-insulated piping system shall include complete cable-type leak

detection and location system consisting of a microprocessor based
monitoring unit, sensing cable, and auxiliary equipment required to provide
continuous monitoring of the sensing cable string(s) for leaks, shorts and
breaks. If any of these conditions should occur at any point along the
sensing cable, an alarm shall sound, type of condition shall be clearly
identified and the location clearly displayed.
2. The Leak Detection and Location System manufacturer shall have at least
ten years’ experience in supplying leak detection systems for pre-insulated
piping systems.
3. The Leak Detection and Location System shall locate the point of origin of
the first liquid leak or fault (break/short/probe) within ± 0.1% of the sensing
cable string length, or ± 2.5 m, whichever is greater. The system shall
identify the type of alarm leak/break/short as well as the location. The
system shall be able to monitor (detect and locate) a first leak with up to 30
m of sensing cable wetted without significant inaccuracy in location.
4. The system shall be capable of monitoring up to 1,500 m of sensing cable
per sensing cable string from a single monitoring unit.
5. The system shall be capable of monitoring (detecting and locating) for
multiple leaks or additional liquid on the sensing cable. The system shall be
able to monitor multiple leaks with up to 30 m of sensing cable wetted with
reduced location accuracy.
6. The system shall be capable of identifying the location of breaks and shorts
on the sensing cable. When either of these faults occurs, an alarm shall
sound and a display visible on the front of the monitoring unit shall clearly
indicate the type of fault, i.e. BREAK or SHORT and display the location of
the fault.
7. The system shall continuously provide positive indication that it is
monitoring the sensing cable string and the status of the sensing cable
string. The system clock shall provide the time and date on the LCD of the
monitoring panel. The system clock shall be programmable by the user. A
time and date indication shall be included for all events recorded in
memory.
8. The sensing cable shall be installed on or near the service pipe in the
polyurethane insulation. The sensing cable shall be a twisted-pair
consisting of 2 insulated 1.5 mm2 insulated copper wires suitable for
expo
exposure to temperatures up to 130°C. The sensing cable shall detect all
wa
water-based liquids. Maximum length of the sensing cable string shall be
1500 m.
9. Th
The system shall be installed in accordance with the manufacturer's written
inst
in
installation instructions and by properly trained personnel.
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10. The monitoring unit shall be installed in an indoor, temperature controlled

environment.
11. A location map shall be provided with the system by the installing
contractor; indicating the "As Installed" system configuration and sensing
cable string layout. Distance along the sensing cable shall be provided as
references to locate leaks. Distance shall be based upon Calibration Points
taken.
12. The installing contractor shall be responsible for taking and recording
calibration points along each sensing cable string in accordance with the
manufacturer's installation instructions. Calibration points shall be used to
prepare the Location Map.
13. The Leak Detection and Location System manufacturer shall provide a
factory trained field service technician to support the proper installation of
the system by the installer. Field technical assistance shall be provided for
critical periods of installation including:
a. Installation training
b. Field joint connections and testing
c. Monitoring unit connections and testing
d. System start-up and calibration
B. NORDIC Leak Detection System:
1. All pre-insulated straight pipes and fittings shall be provided with a

minimum of two embedded sensor wires in the insulation at a fixed distance
from the steel pipe and surveillance.
a. Sensor wires : 1,5mm2 copper wire

b. Wire resistance: 1.2-1.5 Ω/100m wire
c. Distance to steel service pipe: 15mm
d. Position: ±30-200mm from 12 o’clock position
e. The surveillance system shall comply with BS EN 14419.
2. Connections of the surveillance wires of each straight pipe and straight pipe
to fitting shall be carried out in accordance with the manufacturer's
instructions.
3. The function of the surveillance system shall be based on the electronic
properties of the insulation changing with the moisture content.
4. The monitoring system shall be able to survey the entire system including
straight pipes, bends, branches and all other fittings and be capable of
detecting more than one leak after acknowledgement of previous or current
leak.
5. The monitoring system shall comprise a microprocessor unit, which shall
fast and easily detect and locate any fault by using a built-in pulse echo
me
meter (TDR) also called Cable Radar. The unit shall have an integrated
func
function to ensure that the surveillance system is operational at all times.
6. Th
The surveillance system shall work as a fully documented system taking
me
measurements of each increment of the entire length of the sensor wires and
stor
st
storing the received data on a data base memory, with the measurements
afte
af
after one month of system operating a the design flow and return
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temperatures being used as the start-up data. In monitoring mode actual data
shall be compared with start-up data in order to detect deviations.
7. The signal range shall be a minimum of 3000m of pipeline with an accuracy
of less than 1.0m.
8. The unit shall easily be connected to a computer by means of signal cable,
internet or GSM (TCP/IP) protocol.
2.7 FIELD APPLIED INSULATION:
A. Insulation for valves, fittings, field casing closures, as required, and other piping
system accessories shall be cellular glass conforming to ASTM C552, calcium
silicate conforming to ASTM C533 or polyurethane matching the pipe insulation.
Insulation shall be pre-molded, precut or job fabricated to fit and shall be
removable and reusable. Thickness shall match adjacent piping.
B. Metal jackets shall be provided for all pipe insulation in manholes. Insulation
bands shall be 19 mm wide 0.13 mm stainless steel.
C. Buried fittings and accessories shall be factory fabricated and may have field
foamed polyurethane insulation to match adjacent piping and shall be protected
with a covering matching the pipe casing. Shrink sleeves shall be provided over
casing connection joints.
2.8 END SEALS:
A. General: Each pre-insulated section of piping shall have a complete sealing of the
insulation to provide permanent water and vapor seal at each end of the pre-
insulated section of piping. Pre-insulated sections of piping modified in the field
shall be provided with an end seal which is equivalent to the end seals furnished
with the pre-insulated section of piping. Provide complete sealing of the insulation
at each end of each pre-insulated conduit section by one of the following methods:
1. Carrying the outer casing over tapered pipe insulation ends and extending it
to the carrier pipe. Provide sufficient surface bonding area between the
casing and the carrier pipe to ensure a permanent water and vapor resistant
seal.
2. Using specially designed prefabricated caps made of the same material and
not less than the same thickness as the casing. Provide sufficient surface
bonding area between the cap, and both the casing and carrier pipe, to
ensure permanent water and vapor resistant seal.
B. Factory casing and end seal testing and certification:
1. Te
Testing and certification procedures by an independent testing laboratory
shal
shall demonstrate that casings and end seals are capable of resisting
pene
penetration of water into the casing and insulation at 60 kPa of head
pres
pressure, measured above the highest point of the test sample, subjected
over the entire surface of an 2.5 m test sample of prefabricated pipe for not
ov
less than 48 hours. Test shall use 24 degrees C water for chilled water
le
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service, while the sample is either buried or encased in dry bedding sand
with a minimum of 305 mm of sand all around sample. The carrier pipe size
in the test section shall be 75 mm in diameter and shall be restrained during
the test period. The insulation thickness shall not exceed the maximum
thickness provided for the piping in the project.
2.9 JOINTS:
A. Welded joints: Welded joints between sections of pipe and between pipe and
fittings shall be provided where specified or indicated. Branch connections shall
be made with either welding tees or forged branch outlet fittings attached to the
main and reinforced against external strains.
B. Flanged joints: Flanged joints shall be provided with gaskets and made perfectly
square and tight. Full-faced gaskets shall be used with cast-iron flanges and all
gaskets shall be as thin as the finish of the flange face permits. Gaskets shall be 5
mm (3/16-inch) thick for 25 through 300 mm (1 through 12 inch) flanges and 6
mm (1/4-inch) thick for flanges 350 mm (14 inches) and larger.
C. Threaded joints: Joints shall be made tight with polytetrafluoroethylene tape

applied to the male threads only. Not more than three threads shall show after the
joint is made up.
D. Solder Filler Metals: ASTM B 32, lead-free alloys. Include water-flushable flux
according to ASTM B 813.
E. Brazing Filler Metals: AWS A5.8/A5.8M, BCuP Series, copper-phosphorus alloys

for joining copper with copper; or BAg-1, silver alloy for joining copper with
bronze or steel.
F. Mechanical joints: Sleeve and grooved pipe couplings shall be installed and
protected against corrosion as recommended by the coupling manufacturer. Joints
between nonmetallic and metallic carrier pipe shall be designed and furnished by
the piping system manufacturer. The transition pieces shall be factory fabricated
and shall be designed so that no field chemical welding of the carrier pipe will be
required. Transitional joint connections to manhole steel piping shall be made
inside the manhole except for prefabricated, pre-piped manholes where joints
shall be outside the manhole wall.
G. Insulating joints and dielectric fittings: Shall be installed where shown.
H. Nonmetallic pipe joints: Nonmetallic pipe joints shall be installed in accordance

with the written instructions of the manufacturer.
2.10
2.10 FITT
FITTINGS FOR STEEL PIPE
FITTINGS
A. Gene
General
ne
General
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1. The pipes fittings shall be to ASTM A234/A234M WPB, ASTM

A105/A105M or ASTM A53/A53M Grade B, suitable for butt welding,
seamless or ERW and thickness as per matching pipe.
2. All Butt welded fittings shall be in accordance with ASME B16.9, socket
welded fittings shall be to ASME B16.11.
3. Mechanical coupled joints are allowed as alternative in mechanical rooms .
4. Manufacture trade name to be marked on pipes and fitting
B. 50 mm and Smaller: Screwed. Mechanical couplings are optional for water piping
only.
1. Fitting shall have same wall thickness as pipes.

2. Pipes 50 mm and smaller shall have threaded ends.
3. Forged steel, socket welding or threaded: ASME B16.11.
4. Screwed: 150 pound malleable iron, ASME B16.3. 125 pound cast iron,
ASME B16.4, may be used in lieu of malleable iron. Bushing reduction of a
single pipe size, or use of close nipples, is not acceptable.
5. Unions: ASME B16.39.
6. Water hose connection adapter: Brass, pipe thread to 20 mm garden hose
thread, with hose cap nut.
C. 65 mm and Larger: Welded or flanged joints. Mechanical couplings and fittings

are optional for water piping only.
1. Pipe fitting material shall be to ASTM A 234/A 234M WPB, ASTM

A105/A105M or ASTM A53/A53M Grade B ERW.
2. Butt welding fittings: ASME B16.9 with same wall thickness as connecting
piping. Elbows shall be long radius type, unless otherwise noted.
3. Socket welded fittings shall be in accordance with ASME B16.11.
4. Welding flanges and bolting: ASME B16.5:
a. Water service: Weld neck or slip-on, plain face, with 6 mm (1/8 inch)
thick full face neoprene gasket suitable for 104 degrees C (220
degrees F).
1) Contractor's option: Convoluted, cold formed 150 pound steel

flanges, with Teflon gaskets, may be used for water service.
b. Flange bolting: Carbon steel machine bolts or studs and nuts, ASTM
A307, Grade B.
D. Welded Branch and Tap Connections: Forged steel weldolets, or branchlets and
threadolets may be used for branch connections up to one pipe size smaller than
the main. Forged steel half-couplings, ASME B16.11 may be used for drain, vent
and gage connections.
E. Mechanic
Me
Mechanical Pipe Couplings and Fittings: If used and accepted by The Engineer
shal
sh alll be used with roll grooved pipe, in water service up to 110 degrees C (230
al
shall
degr
de gree
gr
degreesees F)
ee F).
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1. Grooved mechanical couplings: Malleable iron, ASTM A47/A47M or

ductile iron, ASTM A536, fabricated in two or more parts, securely held
together by two or more track-head, square, or oval-neck bolts, ASTM
A183.
2. Gaskets: Rubber product recommended by the coupling manufacturer for
the intended service.
3. Grooved end fittings: Malleable iron, ASTM A47/A47M; ductile iron,
ASTM A536; or steel, ASTM A53/A53M or ASTM A106/A106M,
designed to accept grooved mechanical couplings. Tap-in type branch
connections are acceptable.
2.11 FITTINGS FOR PLASTIC PIPING
A. PVC Plastic Pipe fittings socket-type, schedule 40, ASTM D2466.

1. PVC Solvent Cement: ASTM D2564-04el.
B. Chemical feed piping for condenser water treatment: Chlorinated polyvinyl

chloride (CPVC), Schedule 80, ASTM F439.
2.12 DIELECTRIC FITTINGS
A. Provide where copper tubing and ferrous metal pipe are joined.
B. 50 mm and Smaller: Threaded dielectric union, ASME B16.39.
C. 65 mm and Larger: Flange union with dielectric gasket and bolt sleeves, ASME
B16.42.
D. Temperature Rating, 99 degrees C.
2.13 SCREWED JOINTS
A. Pipe Thread: ANSI B1.20.1.
B. Lubricant or Sealant: Oil and graphite or other compound approved for the
intended service.
C. Grooved Mechanical-Joint Fittings: ASTM A 536, Grade 65-45-12 ductile iron;

ASTM A 47/A 47M, Grade 32510 malleable iron; ASTM A 53/A 53M, Type F,
E, or S, Grade B fabricated steel; or ASTM A 106/A 106M, Grade B steel fittings
with grooves or shoulders designed to accept grooved end couplings.
D. Grooved Mechanical-Joint Couplings: Ductile- or malleable-iron housing and

synthetic rubber gasket of central cavity pressure-responsive design; with nuts,
sy
bolt
bo lts, loc
lt
bolts, locking pin, locking toggle, or lugs to secure grooved pipe and fittings.
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E. Welding Materials: Comply with Section II, Part C, of the ASME Boiler and
Pressure Vessel Code for welding materials appropriate for wall thickness and for
chemical analysis of pipe being welded.
F. Gasket Material: Thickness, material, and type suitable for fluid to be handled;
and design temperatures and pressures.
2.14 VALVES
A. Gate, globe, check, ball, butterfly valves and motorized valves are specified in
Section "General-Duty Valves for HVAC Piping."
B. Asbestos packing is not acceptable.
C. All valves of the same type shall be products of a single manufacturer. Provide
gate and globe valves with packing that can be replaced with the valve under full
working pressure.
D. Provide chain operators for valves 100 mm (4 inches) and larger when the
centerline is located 2400 mm (8 feet) or more above the floor or operating
platform.
E. Refer to Part 3 "Valve Applications" Article for applications of each valve.
F. Dynamic Water Flow Balancing Valves, used for balancing, shut off and
measuring of pressure drop. Balancing valves shall be provided with two
measuring nipples to have the possibility to measure the differential pressure
(water flow indirectly) through the balancing valve and a tight shut off function
with a hidden memory of the setting. Each valve shall be provided with a label
including at least the valve reference number, valve’s diameter, design flow,
setting after balancing and pressure drop in setting and design position. All valves
shall be supplied with Prefab insulation material sourced from the valve
manufacturer, made of Polyurethane, volume weight 50-60 Kg/cubic m.
G. Dynamic Water Flow Balancing Valves, DN 50 (NPS 2) and Smaller: bronze

body, fitted with a red nylon hand-wheel and a protection cap, 1035-kPa (150
psig) working pressure, 107 deg C (225 deg F) maximum operating temperature,
and having threaded end connections.
H. Dynamic Water Flow Balancing Valves, DN 65 (NPS 2-1/2) and Larger: Y-

pattern globe valve style, Cast-iron or steel body, fitted with seat seal cone, bonnet
bolts chromed steel and digital hand wheel, 1035-kPa (150 psig) working
pressure, 107 deg C (225 deg F) maximum operating temperature, and having
flanged or grooved connections.
I. Pressure
Pr
Pressure-Reducing Valves: Diaphragm-operated, bronze or brass body with low
inle
inlett pres
le
inlet pressure check valve, inlet strainer removable without system shutdown, and
nonc
no ncor
nc orro
or
noncorrosive valve seat and stem. Select valve size, capacity, and operating
pressu
pr sure
su
pressure re to suit system. Valve shall be factory set at operating pressure and have
capa
ca pabi
pa bili
bi lity for field adjustment.
li
capability
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J. Safety Valves: Diaphragm-operated, bronze or brass body with brass and rubber,
wetted, internal working parts; shall suit system pressure and heat capacity and
shall comply with the ASME Boiler and Pressure Vessel Code, Section IV:
Heating Boilers, Bear ASME stamp
K. Pressure Relief Valve: Bronze or iron body and bronze or stainless steel trim, with
testing lever. Comply with ASME Code for Pressure Vessels, Section 8; bear
ASME stamp.
L. Automatic Dynamic Flow-Control Valves: Gray-iron body, factory set to

maintain constant flow with plus or minus 5 percent over system pressure
fluctuations, and equipped with a readout kit including flow meter, probes, hoses,
flow charts, and carrying case. Each valve shall have an identification tag
attached by chain, and be factory marked with the zone identification, valve
number, and flow rate. Valve shall be line size and one of the following designs:
1. Gray-iron or brass body, designed for 1206 kPa (175 psig) at 93 deg C (200
deg F) with stainless-steel piston and spring.
2. Brass or ferrous-metal body, designed for 2068 kPa (300 psig) at 121 deg C
(250 deg F) with corrosion-resistant, tamperproof, self-cleaning, piston-
spring assembly easily removable for inspection or replacement.
3. Combination assemblies, including bronze ball valve and brass alloy control
valve, with stainless-steel piston and spring, fitted with pressure and
temperature test valves, and designed for 2067 kPa (300 psig) at 121 deg C
(250 deg F).
M. Triple Duty Valve: Contractors option for use at pump discharge in lieu of check
valve and balancing/shut-off valve. Triple duty valve is a non-slam check valve
with spring-loaded weighted disc and a calibrated adjustment feature permitting
regulation of pump discharge flow and shut-off. Valves shall be designed to
permit repacking under full line pressure. Unit shall be installed on discharge side
of pump in a horizontal or vertical position with the stem up. Unit shall be cast
iron body construction suitable for maximum working pressure of 1205 kPa (175
PSI) and maximum operating temperature of 149 °C (300 °F), bronze disc and
seat, stainless steel stem and spring.
N. Drain Valves: Valves shall be the gate valve types which are in accordance with
MSS SP-80. Valve shall be manually operated, 20 mm pipe size and above with a
threaded end connection. Valve shall be provided with a water hose nipple
adapter.
O. Drain Cocks: MSS SP-110, DN20 (3/4-inch NPS) ball valve, rated for 2760 kPa
(400-psig) minimum CWP. Include 2-piece, bronze body with standard port,
chrome-plated brass ball, replaceable seats and seals, blowout-proof stem, and
vinyl-cove
vinyl-covered steel handle.
1. Inle
Inlet: Threaded or solder joint.
2. Ou
Outlet: Short-threaded nipple with ANSI/ASME B1.20.7 garden-hose
thre
th
thread and cap.
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2.15 HYDRONIC SPECIALTIES
A. Air Vents
1. Manual Air Vent: Bronze body and nonferrous internal parts; 1035-kPa
(150-psig) working pressure; 107 deg C (225 deg F) operating temperature;
manually operated with screwdriver or thumbscrew; with DN 6 (NPS 1/8)
discharge connection and DN 15 (NPS 1/2) inlet connection.
2. Automatic Air Vent: Designed to vent automatically with float principle;
bronze body and nonferrous internal parts; 1035-kPa (150-psig) working
pressure; 116 deg C (240 deg F) operating temperature; with DN 8
(NPS 1/4) discharge connection and DN 15 (NPS 1/2) inlet connection.
3. Air vents on water coils shall have not less than 3 mm threaded end
connections.
4. Air vents on water mains shall have not less than 20 mm threaded end
connections.
5. Air vents on all other applications shall have not less than 15 mm threaded
end connections
B. Closed Expansion Tanks: Welded carbon steel, rated for 1206-kPa (175-psig)
working pressure and 121 deg C (250 deg F) maximum operating temperature.
Separate air charge from system water to maintain design expansion capacity by a
flexible [bladder] securely sealed into tank. Provide sight glass and include
drain fitting and taps for pressure gage and air-charging fitting. Support vertical
tanks with steel legs or base; support horizontal tanks with steel saddles. Factory
fabricate and test tank with taps and supports installed and labeled according to
the ASME Boiler & Pressure Vessel Code - Section VIII - Pressure Vessels,
Division 1.
C. Tangential-Type Air Separators: Welded black steel; ASME constructed and

labeled for 1206-kPa (175-psig) minimum working pressure and 191 deg C (375
deg F) maximum operating temperature; perforated stainless-steel air collector
tube designed to direct released air into expansion tank; tangential inlet and outlet
connections; threaded connections for DN 50 (NPS 2) and smaller; flanged
connections for DN 65 (NPS 2-1/2) and larger; threaded blowdown connection.
Provide units in sizes for full-system flow capacity. Applicable to central plants.
D. In-Line Air Separators: One-piece cast iron with an integral weir designed to
decelerate system flow to maximize air separation at a working pressure up to
1206 kPa (175 psig) and liquid temperature up to 149 deg C (300 deg F).
E. Air Purgers: Cast-iron body with internal baffles that slow the water velocity to
separate the air from solution and divert it to the vent for quick removal.
Maximum working pressure of 1206 kPa (175 psig) and temperature of 121 deg C
(250 deg F).
F. Bypa
By pass C
pa
Bypass Chemical Feeder: Welded steel construction; 860-kPa (125-psig) working
pres
pr essu
essure; 19-L (5-gal.) capacity; with fill funnel and inlet, outlet, and drain valves.
su
pressure;
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1. Chemicals: Specially formulated, based on analysis of makeup water, to

prevent accumulation of scale and corrosion in piping and connected
equipment.
G. Y-Pattern Strainers: 1035-kPa (150-psig) working pressure; cast-iron body

(ASTM A126-04, Class B), flanged ends for DN 65 (NPS 2-1/2) and larger,
threaded connections for DN 50 (NPS 2) and smaller, bolted cover, perforated
stainless-steel basket, and bottom drain connection.
H. Basket Strainers: 1035-kPa (150-psig) working pressure; high-tensile cast-iron

body (ASTM A126-04, Class B), flanged-end connections, bolted cover,
perforated stainless-steel basket, and bottom drain connection.
I. Flexible Connectors: Stainless-steel bellows with woven, flexible, bronze, wire-

reinforcing protective jacket; 1035-kPa (150-psig) minimum working pressure
and 121 deg C (250 deg F) maximum operating temperature. Connectors shall
have flanged- or threaded-end connections to match equipment connected and
shall be capable of 20-mm (3/4-inch) misalignment.
J. Spherical, Rubber, Flexible Connectors: Fiber-reinforced rubber body with steel

flanges drilled to align with Classes 150 and 300 steel flanges; operating
temperatures up to 121 deg C (250 deg F) and pressures up to 1035 kPa (150
psig).
K. Packed, Slip, Expansion Joints: 1035-kPa (150-psig) minimum working pressure,

steel pipe fitting consisting of telescoping body and slip-pipe sections, packing
ring, packing, limit rods, flanged ends, and chrome-plated finish on slip-pipe
telescoping section.
2.16 WATER FLOW MEASURING DEVICES
A. Minimum overall accuracy plus or minus three percent over a range of 70 to 110
percent of design flow. Select devices for not less than 110 percent of design flow
rate.
B. Venturi Type: Bronze, steel, or cast iron with bronze throat, with valved pressure
sensing taps upstream and at the throat.
C. Wafer Type Circuit Sensor: Cast iron wafer-type flow meter equipped with
readout valves to facilitate the connecting of a differential pressure meter. Each
readout valve shall be fitted with an integral check valve designed to minimize
system fluid loss during the monitoring process.
D. Self-Averaging Annular Sensor Type: Brass or stainless steel metering tube,

shutoff va
valves and quick-coupling pressure connections. Metering tube shall be
rota
ro tatable so all sensing ports may be pointed down-stream when unit is not in use.
ta
rotatable
E. Flow Measurement/Balance
Flow Mea Valves: A system comprised of two valves of bronze
and st
stai
ainl
ai
stainless steel metallurgy designed for 1205 kPa pressure at 121 degrees C,
wi tthe
with herm insulation sleeve.
he
thermal
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F. Measurement and shut-off valve: An on/off ball valve with integral high regain
venturi and dual quick connect valves with integral check valves and color coded
safety caps for pressure/temperature readout.
G. A butterfly balancing valve as specified herein, with memory stop and quick
connect valve for pressure/temperature readout.
H. Flow Measuring Device Identification:
1. Metal tag attached by chain to the device.

2. Include meter or equipment number, manufacturer's name, meter model,
flow rate factor and design flow rate in l/m (gpm).
I. Vent and drain hose and two 3000 mm (10 feet) lengths of hose with quick
disconnect connections.
J. Factory fabricated carrying case with hose compartment and a bound set of
capacity curves showing flow rate versus pressure differential.
K. Provide one portable meter for each range of differential pressure required for the
installed flow devices.
L. Permanently Mounted Water Flow Indicating Meters: Minimum 150 mm

diameter, or 450 mm long scale, for 120 percent of design flow rate, direct
reading in lps with three valve manifold and two shut-off valves.
2.17 EXPANSION JOINTS
A. Factory built devices, inserted in the pipe lines, designed to absorb axial cyclical
pipe movement which results from thermal expansion and contraction. This
includes factory-built or field-fabricated guides located along the pipe lines to
restrain lateral pipe motion and direct the axial pipe movement into the expansion
joints.
B. Manufacturing Quality Assurance: Conform to Expansion Joints Manufacturers

Association Standards.
C. Bellows - Internally Pressurized Type:
1. Multiple corrugations of Type 304 or Type A240-321 stainless steel.

2. Internal stainless steel sleeve entire length of bellows.
3. External cast iron equalizing rings for services exceeding 340 kPa (50 psig).
4. Welded ends.
5. Design shall conform to standards of EJMA and ASME B31.1.
6. Ex
External tie rods designed to withstand pressure thrust force upon anchor
f
failu
failure if one or both anchors for the joint are at change in direction of
pipe
pipeline.
7. Inte
Integral external cover.
D. Bell
Bellow
ll owss - Externally Pressurized Type:
ow
Bellows
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1. Multiple corrugations of Type 304 stainless steel.

2. Internal and external guide integral with joint.
3. Design for external pressurization of bellows to eliminate squirm.
4. Welded ends.
5. Conform to the standards of EJMA and ASME B31.1.
6. Threaded connection at bottom, 25 mm (one inch) minimum, for drain or
drip point.
7. Integral external cover and internal sleeve.
E. Expansion Compensators:
1. Corrugated bellows, externally pressurized, stainless steel or bronze.

2. Internal guides and anti-torque devices.
3. Threaded ends.
4. External shroud.
5. Conform to standards of EJMA.
F. Expansion Joint Identification: Provide stamped brass or stainless steel nameplate

on each expansion joint listing the manufacturer, the allowable movement, flow
direction, design pressure and temperature, date of manufacture, and identifying
the expansion joint by the identification number on the contract drawings.
G. Guides: Provide factory-built guides along the pipe line to permit axial movement
only and to restrain lateral and angular movement. Guides must be designed to
withstand a minimum of 15 percent of the axial force which will be imposed on
the expansion joints and anchors. Field-built guides may be used if detailed on the
contract drawings.
PART 3 - EXECUTION
3.1 PIPING APPLICATIONS
A. External chilled water water pipes and chilled water water pipes inside utility
culverts: Pre-insulated piping.
B. Chilled water pipes inside building: Black steel pipes.
C. Condensate drain pipes: For concealed piping use uPVC pipes for exposed / inside
mechanical rooms piping use Galvanized steel pipes.
D. Chilled water/ pipes above ground and exposed to outdoors: Black steel pipes
complete with 0.8mm Aluminum jackets and as weather proofing layer.
E. Condense
Condenser water pipes: Black steel pipes.
3.22
3. VALV
VA LVE APPLICATIONS
LV
VALVE
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A. General-Duty Valve Applications: Unless otherwise indicated, use the following

valve types:
1. Shutoff Duty: Gate, ball, and butterfly valves.

2. Throttling Duty: Globe and ball valves.
B. Install shutoff duty valves at each branch connection to supply mains, at supply
connection to each piece of equipment, unless only one piece of equipment is
connected in the branch line. Install throttling duty valves at each branch
connection to return mains, at return connections to each piece of equipment, and
elsewhere as indicated.
C. Install calibrated balancing valves in the return water line of each heating or
cooling element and elsewhere as required to facilitate system balancing.
D. Install silent type check valves at each pump discharge and elsewhere as required
to control flow direction.
E. Install safety valves as required by the ASME Boiler and Pressure Vessel Code.
Install safety-valve discharge piping, without valves, to floor. Comply with the
ASME Boiler & Pressure Vessel Code - Section VIII - Pressure Vessels,
Division 1, for installation requirements.
3.3 PIPING INSTALLATIONS
A. Install groups of pipes parallel to each other, spaced to permit applying insulation
and servicing of valves.
B. Install drains, consisting of a tee fitting, DN 20 (NPS 3/4) ball valve, and short
DN 20 (NPS 3/4) threaded nipple with cap, at low points in piping system mains
and risers, and elsewhere as required for system drainage.
C. Install piping at a uniform grade of 0.2 percent upward in direction of flow.
D. Reduce pipe sizes using eccentric reducer fitting installed with level side up.
E. Unless otherwise indicated, install branch connections to mains using tee fittings
in main pipe, with the takeoff coming out the bottom of the main pipe. For up-
feed risers, install the takeoff coming out the top of the main pipe.
F. Install strainers on supply side of each control valve, pressure-reducing valve,

solenoid valve, in-line pump, and elsewhere as indicated. Install DN 20
(NPS 3/4) nipple and ball valve in blowdown connection of strainers DN 50
(NPS 2) and larger. Match size of strainer blowoff connection for strainers
th DN 50 (NPS 2).
smaller than
G. Anch
An chors shall be provided wherever necessary or indicated to localize expansion
ch
Anchors
to prev
or to prevent undue strain on piping. Anchors shall consist of heavy steel collars
th llug
with ugs and bolts for clamping and attaching anchor braces, unless otherwise
ug
lugs
indi
indica
di cate
ca ted. Anchor braces shall be installed in the most effective manner to secure
te
indicated.
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the desired results using turnbuckles where required. Supports, anchors, or stays
shall not be attached where they will injure the structure or adjacent construction
during installation or by the weight of expansion of the pipeline. Where pipe and
conduit penetrations of vapor barrier sealed surfaces occur, these items shall be
anchored immediately adjacent to each penetrated surface, to provide essentially
zero movement within penetration seal. Detailed drawings of pipe anchors shall
be submitted for approval before installation.
3.4 INSTALLATION OF PREINSULATED CHILLED WATER PIPING
A. Handling and Storage: Handle and store conduits, pipes, and all accessories to
ensure complete installation in a sound undamaged condition. Unloading, tacking,
moving, and storing of materials shall be in strict accordance with the
manufacturer's requirements. Take special care to ensure that materials which
have exceeded their specified shelf life are not used in the installation of the
system. Before installation all materials shall be inspected for defects. Materials
found to be defective before or after installation shall be repaired or replaced with
sound material, with no additional expense to the Government.
B. Pre-insulated pipes shall be only stored under sheds and shall not be subjected to
any direct sunlight.
C. Installation
1. Installation the pre-insulated piping system shall be in accordance with the

manufacturer’s written instructions.
2. The pre-insulated pipe manufacturer shall provide detailed written
instructions for receiving, handling, storage, excavation, assembly,
alterations, repairs, testing, inspection, field joint insulation and jacketing
and backfilling.
3. Expansion cushions shall be supplied by pre-insulated pipe manufacturer
and installed as per the manufacturers written instructions.
D. Quality Assurance
1. The pre-insulated pipe manufacturer shall have a quality assurance program

in place to ensure compliance with this specification. the quality assurance
program shall be in accordance with ISO9001.
2. Non-destructive examination of all service pipe welds shall be performed in
accordance with ASME B31.1.
3. All polyurethane insulation shall be visually inspected for voids prior to
application of the insulation jacket. If visual examination cannot be
accomplished, the pre-insulated pipe manufacturer shall propose an
alte
alternate method to ensure there are no insulation voids.
4. Th
The testing listed below shall be performed on a daily basis to ensure the
qual
quality of the fire rated PIR insulation. Test reports shall be provided
show
showing compliance.
a. Density (>50kg / m3)
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b. Thermal conductivity (< 0.023 W/m OC)

c. Compressive strength (> 300 kpa)
d. Closed cell content (< 88%)
e. Water absorption (< 10%) for polyurethane insulation
5. The testing listed below shall be performed on a daily basis to ensure the
quality of the insulation jacket. Test reports shall be provided showing
compliance.
a. Hardness (> 60 shore D)
6. The testing listed below shall be performed on a daily basis to ensure the
quality of the insulated pipe assemblies. Test reports shall be provided
showing compliance.
a. HDPE Jacket Thickness
b. HDPE Jacket OD
c. Polyurethane insulation thickness
d. Leak detection wire continuity and resistance
7. Each batch of raw material for the polyurethane insulation and insulation
jacket shall be have a certificate of conformance to ensure the quality of the
raw materials used to produce the insulated pipe assemblies.
8. The testing listed below shall be performed on a pre-qualification basis to
ensure the quality of the pre-insulated pipe assemblies. Test reports shall be
provided showing compliance
a. Shear strength (BS En 253)
b. Impact resistance(BS En 253)
c. Elongation @ break for HDPE jacket
d. Stress crack resistance (BS En 253)
e. Carbon black dispersion (BS En 253)
f. Thermal conductivity aged condition (BS En 253 or alternative
method proposed by manufacturer)
E. Field Service:
1. The pre-insulated pipe manufacturer shall provide a factory trained field

service technician to support the proper installation of the pre-insulated
piping system by the installer.
2. Field technical assistance shall be provided for critical periods of
installation including;
a. Installation training
b. Unloading
c. Field joint insulating and jacketing
d. Testing
3. Th field service technician shall provide field reports for each day on the
The
jobs
jo
jobsite
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F. Installation of Piping Systems:
1. Piping system furnished shall be installed in accordance with the piping

system manufacturer's instructions. Piping shall be installed without
springing or forcing other than what has been calculated for thermal
expansion and contraction. Pipe ends shall have burrs removed by reaming
and shall be installed to permit free expansion and contraction without
damage to joints or hangers. Nonmetallic pipe cut in the field shall be
machined to fit couplings or joints and shall be coated or treated to match
standard factory coated ends. Copper tubing shall not be installed in the
same trench with ferrous piping materials. When nonferrous metallic pipe
(e.g., copper tubing) crosses any ferrous piping material, a minimum
vertical separation of 300 mm shall be maintained between pipes.
Connections between different types of pipe and accessories shall be made
with transition fittings approved by the manufacturer of the piping system.
2. Pitching of horizontal piping: Horizontal piping shall be pitched at a grade
not less than 25 mm in 12 m toward the drain points unless otherwise
indicated.
3. Install vacuum and air relief valves, as required, for filling and draining of
the system.
G. Valve Boxes:
1. Set cover flush with finished grade.

2. Protect boxes located in roadway against movement by a concrete slab at
least 900 mm square by 150 mm deep.
3. Set other valve boxes with a concrete slab 450 mm by 450 mm by 150 mm
deep and set flush with grade.
4. All exposed portions of valve boxes shall be painted "Traffic Yellow."
H. Pipe Sleeves:
1. Pipe shall be continuous through sleeves. Set in place before concrete is

poured.
2. Seal between sleeve and core opening with modular mechanical type link
seal.
3. Provide where water lines pass through retaining walls and foundation
walls.
I. Cutting of Prefabricated Conduit Sections: Prefabricated conduit sections shall be

cut in strict accordance with the manufacturer's recommendations and standards.
The cut section shall be treated as required to result in the cut section being
identical in every respect to a standard conduit section produced at the factory.
J. Field Ca Casing Closures: Field insulation and encasement of joints shall be

accompli
ac
accomplished after the visual and pressure tests specified are completed. Field
insu
insulation and encasement shall be in accordance with the manufacturer's written
su
insulation
inst
instru
st ructio Thickness dimensions of the insulation and casing materials shall not
ru
instructions.
be les
esss th
es
less than those of the adjoining prefabricated section. Insulating material may
be ffoa
oame
oa me in place polyurethane or premolded polyurethane foam sections. Care
foamed
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should be taken to ensure that field closures are made under conditions of
temperature and cleanliness required to produce a sound continuous vapor barrier.
A standard polyethylene heat shrink sleeve shall be installed over the casing and
shall have a 150 mm overlap at each end.
K. Insulation and Encasement of Pipe Accessories: Flanges, couplings, unions,

valves, fittings, and other pipe accessories, unless otherwise shown or approved,
shall be insulated with removable factory premolded, prefabricated or field
fabricated insulation. For accessories buried underground, the casing material and
thickness shall be identical to that of the adjoining casing material and thickness
shall be identical to that of the adjoining casing except that for polyethylene
casing larger than 300 mm size, the casing material over fittings shall be
reinforced thermosetting resin (RTRP). For accessories in manholes, the casing
material shall be steel or aluminum sheet applied over the insulation. Where
accessories are designated not to be insulated, the adjoining insulation and jacket
shall terminate neatly and in a manner to provide a complete vapor seal.
L. Trenching and Backfilling: Trench bottoms for underground prefabricated conduit

systems shall be smooth and free of sharp objects, stones, and debris that could
puncture the casing. Where this is a problem, the trench should be over excavated
and stabilized by using sand, fine dirt, or similar material. Partial backfilling is
required immediately after installation of the pipe. Selected backfill shall be
tamped in not more than 150 mm layers under and around the conduit to a height
of not less than 150 mm above the top of the casing. During this process, joints
shall be left exposed for visual inspection during field tests.
M. Open Ends: Open ends of pipe lines and equipment shall be properly capped or
plugged during installation to keep dirt and other foreign matter out of the system.
N. Vapor Barrier: Install materials to provide and preserve the integrity of the vapor
barrier.
O. Prefabricated Manhole Tests: Each prefabricated manhole shall be air-tested and

steel manholes spark-tested after installation and before backfill to prove water
tightness and corrosion resistance.
1. Air pressure test: Air pressure test procedure shall be at a pressure of 34

kPa. Manhole shall hold pressure for 2 hours. All seams and penetrations
shall be coated with a soap solution to aid in detecting leaks. All leaks shall
be repaired and proved tight. Protective coating shall be touched up at all
repair points.
2. Holiday detector test: After visual examination and before installation, a
holiday detector test shall be performed on the coated portion of steel
manholes. The tests shall be accomplished with a silicone rubber electric
wire brush or a coil probe testing set connected to an operating bell, buzzer
or other audible signal which will sound when a holiday is detected at 5000
cres voltage, plus or minus 5 percent. The tester shall be of a type which
crest
cann be adjusted in the field. Calibration by the manufacturer of the tester
cannot
shal be required at 6-month intervals, or sooner, whenever crest voltage is
sh
shall
ques
qu
questionable. The manufacturer of the tester shall certify in writing the date
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of calibration and crest voltage setting. The battery shall be maintained at a

charge ample to produce the crest voltage during all tests. Voids detected
shall be repaired by using material identical to that of the original coating.
The repaired sections shall be retested to prove that there is no holiday
present.
3.5 HANGERS AND SUPPORTS
A. Hanger, support, and anchor devices are specified in Section "Hangers and
Supports for HVAC Piping and Equipment." Comply with requirements below
for maximum spacing of supports.
B. Install the following pipe attachments:
1. Adjustable steel clevis hangers for individual horizontal piping less than 6
m long.
2. Adjustable roller hangers and spring hangers for individual horizontal
piping 6 m or longer.
3. Pipe Roller: MSS SP-58 for multiple horizontal piping 6 m or longer,
supported on a trapeze.
4. Spring hangers to support vertical runs.
5. On plastic pipe, install rubber pads or cushions on bearing surfaces to
prevent hanger from scratching pipe.
C. Install hangers for steel piping with the following maximum spacing and
minimum rod sizes:
1. DN 20 (NPS 3/4): Maximum span, 2.1 m; minimum rod size, 10 mm.

2. DN 25 (NPS 1): Maximum span, 2.1 m; minimum rod size, 10 mm.
3. DN 40 (NPS 1-1/2): Maximum span, 2.7 m; minimum rod size, 10 mm.
4. DN 50 (NPS 2): Maximum span, 3 m; minimum rod size, 10 mm.
D. Install ha
hangers for drawn-temper copper piping with the following maximum
spacing and
sp an minimum rod sizes:
1. DN 20 (NPS 3/4): Maximum span, 1.5 m; minimum rod size, 10 mm.

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E. PVC Piping Hanger Spacing: Space hangers according to pipe manufacturer's

written instructions for service conditions. Avoid point loading. Space and install
hangers with the fewest practical rigid anchor points.
F. Support vertical runs at roof, at each floor, and at 3-m intervals between floors.
3.6 PIPE JOINT CONSTRUCTION
A. Ream ends of pipes and tubes and remove burrs. Bevel plain ends of steel pipe.
B. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings
before assembly.
C. Soldered Joints: Apply ASTM B 813, water-flushable flux, unless otherwise

indicated, to tube end. Construct joints according to ASTM B 828 or CDA's
"Copper Tube Handbook," using lead-free solder alloy complying with
ASTM B 32.
D. Brazed Joints: Construct joints according to AWS's "Brazing Handbook," "Pipe

and Tube" Chapter, using copper-phosphorus brazing filler metal complying with
AWS A5.8/A5.8M.
E. Threaded Joints: Thread pipe with tapered pipe threads according to

ASME B1.20.1. Cut threads full and clean using sharp dies. Ream threaded pipe
ends to remove burrs and restore full ID. Join pipe fittings and valves as follows:
1. Apply appropriate tape or thread compound to external pipe threads unless

dry seal threading is specified.
2. Damaged Threads: Do not use pipe or pipe fittings with threads that are
corroded or damaged. Do not use pipe sections that have cracked or open
welds.
F. Welded Joints: Construct joints according to AWS D10.12M/D10.12, using

qualified processes and welding operators according to "Quality Assurance"
Article.
G. Flanged Joints: Select appropriate gasket material, size, type, and thickness for
service application. Install gasket concentrically positioned. Use suitable
lubricants on bolt threads.
H. Plastic Pi
Piping Solvent-Cemented Joints: Clean and dry joining surfaces. Join pipe
and fittin
an fittings according to the following:
1. Co
Comply with ASTM F 402 for safe-handling practice of cleaners, primers,
and solvent cements.
an
2. CP
CPVC Piping: Join according to ASTM D 2846/D 2846M Appendix.
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3. PVC Pressure Piping: Join ASTM D 1785 schedule number, PVC pipe and
PVC socket fittings according to ASTM D 2672. Join other-than-schedule
number PVC pipe and socket fittings according to ASTM D 2855.
4. PVC Nonpressure Piping: Join according to ASTM D 2855.
I. Grooved Joints: Assemble joints with coupling and gasket, lubricant, and bolts.
Cut or roll grooves in ends of pipe based on pipe and coupling manufacturer's
written instructions for pipe wall thickness. Use grooved-end fittings and rigid,
grooved-end-pipe couplings.
J. Mechanically Formed, Copper-Tube-Outlet Joints: Use manufacturer-

recommended tool and procedure, and brazed joints.
K. Pressure-Sealed Joints: Use manufacturer-recommended tool and procedure.

Leave insertion marks on pipe after assembly.
L. Mechanical and Heat Fusion Joints: Assemble joints according to fitting

manufacturer’s written instructions.
3.7 HYDRONIC SPECIALTIES INSTALLATION
A. Install manual air vents at top of risers and high points in piping, at heat-transfer
coils, and elsewhere as required for system air venting.
B. Install automatic air vents in mechanical equipment rooms only at high points of
system piping, at heat-transfer coils, and elsewhere as required for system air
venting.
C. Install in-line air separators in pump suction lines. Install piping to

compression/expansion tank with a 2 percent upward slope toward tank. Install
drain valve on units DN 50 (NPS 2) and larger.
D. Install combination air separator and strainer in pump suction lines. Install piping
to compression/expansion tank with a 2 percent upward slope toward tank. Install
blowdown piping with gate valve; extend to nearest drain.
E. Install bypass chemical feeders in each hydronic system where indicated, in

upright position with top of funnel not more than 1200 mm above floor. Install
feeder in bypass line, off main, using globe valves on each side of feeder and in
the main between bypass connections. Pipe drain, with ball valve, to nearest
equipment drain.
F. Install expansion tanks on floor. Vent and purge air from hydronic system, and
ensure tank is properly charged with air to suit system design requirements.
G. Install ex
In expansion tanks above air separator. Install gage glass and cocks on end of
tank
tank. Ins
nk
tank. Install tank fitting in tank bottom and charge tank. Use manual vent for
init
in itia
itial fill to establish proper water level in tank.
ia
initial
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1. Support tank from floor or structure above with sufficient strength to carry
weight of tank, piping connections, and fittings, plus weight of a full tank of
water. Do not overload building components and structural members.
Install expansion tanks on floor. Vent and purge air from hydronic system, and
ensure tank is properly charged with air to suit system design requirements.
3.8 TERMINAL EQUIPMENT CONNECTIONS
A. Size for supply and return piping connections shall be same as for equipment
connections.
B. Install control valves in accessible locations close to connected equipment.
C. Install bypass piping with globe valve around control valve. If multiple, parallel
control valves are installed, only one bypass is required.
D. Install ports for pressure and temperature gages at coil inlet connections.
3.9 CHEMICAL TREATMENT
A. Perform an analysis of supply water to determine the type and quantities of

chemical treatment needed to keep system free of scale, corrosion, and fouling,
and to sustain the water characteristics appropriate to use.
B. Fill system and perform initial chemical treatment.
C. Comply with requirements of Section "HVAC Water Treatment."
3.10 FIELD QUALITY CONTROL
A. Prepare hydronic piping according to ANSI/ASME B31.9 and as follows:
1. Leave joints, including welds, uninsulated and exposed for examination

during test.
2. Provide temporary restraints for expansion joints that cannot sustain
reactions due to test pressure. If temporary restraints are impractical, isolate
expansion joints from testing.
3. Flush system with clean water. Clean strainers.
4. Isolate equipment from piping. If a valve is used to isolate equipment, its
closure shall be capable of sealing against test pressure without damage to
valve. Install blinds in flanged joints to isolate equipment.
5. Inst
Install safety valve, set at a pressure no more than one-third higher than test
pres
pressure, to protect against damage by expanding liquid or other source of
over
overpressure during test.
B. Perf
Perfor
rform the following tests on hydronic piping:
or
Perform
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1. Use ambient temperature water as a testing medium unless there is risk of

damage due to freezing. Another liquid that is safe for workers and
compatible with piping may be used.
2. While filling system, use vents installed at high points of system to release
trapped air. Use drains installed at low points for complete draining of
liquid.
3. Check expansion tanks to determine that they are not air bound and that
system is full of water.
4. Subject piping system to hydrostatic test pressure that is not less than 1.5
times the design pressure. Test pressure shall not exceed maximum
pressure for any vessel, pump, valve, or other component in system under
test. Verify that stress due to pressure at bottom of vertical runs does not
exceed either 90 percent of specified minimum yield strength or 1.7 times
"SE" value in Appendix A of ANSI/ASME B31.9, "Building Services
Piping."
5. After hydrostatic test pressure has been applied for at least 10 minutes,
examine piping, joints, and connections for leakage. Eliminate leaks by
tightening, repairing, or replacing components, and repeat hydrostatic test
until there are no leaks.
6. Prepare written report of testing.
C. In addition to mentioned code requirements, ensure the following further specific

requirements for welding joints in hydronic piping:
a. Primary welding procedure specification to be submitted for review

and approval by welding engineer.
b. Procedure qualification to be done prior to any welding activity on

site.
c. Welder qualification test to be done prior to any welding activity on

site.
d. Mill certificate for consumable material “Electrode, flux,..etc” to be

submitted for review and approval and the mechanical test for
electrode material may be required.
e. Heat input during welding is important value so the visual inspection

for welding activity “before, during and after” welding is required.
3.11 ADJUSTING
A. Mark calibrated nameplates of pump discharge valves after hydronic system

balancing has been completed, to permanently indicate final balanced position.
B. Perf
Perform these adjustments before operating the system:
rf
Perform
1. Op valves to fully open position. Close coil bypass valves.

Open
2. Ch
Check pump for proper direction of rotation.
3. Se automatic fill valves for required system pressure.
Set
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4. Check air vents at high points of system and determine if all are installed
and operating freely (automatic type), or bleed air completely (manual
type).
5. Set temperature controls so all coils are calling for full flow.
6. Check operation of automatic bypass valves.
7. Check and set operating temperatures of boilers, chillers, and cooling
towers to design requirements.
8. Lubricate motors and bearings.
3.12 PAINTING
A. All exposed surfaces of ferrous and non-ferrous piping outdoors or indoors in

equipment rooms and exposed to view in occupied spaces shall be cleaned,
primed and painted.
B. Refer to Sections "Interior Painting" and "Exterior Painting" for painting

requirement.
3.13 CLEANING
A. Flush hydronic piping systems with clean water. Remove and clean or replace
strainer screens. After cleaning and flushing hydronic piping systems, but before
balancing, remove disposable fine-mesh strainers in pump suction diffusers.
END OF SECTION 232113
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Section 232113 - Hydronic Piping

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Shopping Mall at Jumeirah Village Triangle

SECTION 232113 - HYDRONIC PIPING

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including Conditions of

A. The following standards are referred to in this section as alternative

1. BS 10 Flanges for bolting pipes, valves and fittings.

1. Inspection Test Plan

1. Product Data: For solvent cements and adhesive primers, documentation

D. Proposal Welding Procedure Specification (PWPS).

E. Welding Procedure Specification (WPS) supported by Procedure Qualification

F. Welder Qualification Certificates.

G. Original Mill Certificates for piping, fitting, filler metal,…etc.

H. Calibration Certificate for Equipment and Gauges.

I. Insulation and Coating procedures

1. Test procedures used.( NDT Procedures, Hydrostatic& leak test

K. Maintenance Data: For hydronic specialties and special-duty valves to include in

1.5 QUALITY ASSURANCE

C. Non destructive examination shall be performed to all pipe welds in accordance to

F. 10 % of Fillet Joints shall be tested by Dye Pentrent Test Or Magnetic Test

I. On Site Supervision of Underground Pre-insulated Chilled Water Piping

a. Density (greater or equal to 60 50Kg/m3)

A. Coordinate layout and installation of hydronic piping and suspension system

B. Coordinate pipe sleeve installations for foundation wall penetrations.

D. Coordinate pipe fitting pressure classes with products specified in related

A. Products shall be delivered in original, unbroken packages, containers, or bundles

C. End caps weather supplied by the piping manufacturer or fabricated by the

D. Prefabricated sections of the pre-insulated pipe are to be handled per the

1.8 EXTRA MATERIALS

A. Water Treatment Chemicals: Furnish sufficient chemicals for initial system

A. Manufacturer's warranty form in which manufacturer agrees to repair or replace

A. Manufacturers: USA, Europe, Japan or their own Factory:

2.2 PIPING MATERIALS

A. General: Refer to Part 3 "Piping Applications" Article for applications of pipe

2.3 PIPE AND TUBING

1. Steel pipes DN 50 and smaller: ASTM A53/A53M Grade B, seamless,

D. Extension of Domestic Water Make-up Piping: as specified for Domestic water

E. Cooling Coil Condensate Drain Piping:

F. Chemical Feed Piping for Condenser Water Treatment: Chlorinated polyvinyl

H. Testing and certification:

1. Testing and certification procedures by an independent testing laboratory

A. Description: Factory-fabricated piping with carrier pipe, insulation and

B. Carrier Pipe below Ground:

1. Pipe Size below 250 mm shall be schedule 40 ERW black steel

2. Pipe size above 250 mm up to and Including 700 mm (28") shalt be

C. Exterior (OD) Pipe Coating

1. Prior to application of the insulation, the piping shalt be coated with a

2. The coating process shall consist of abrasive blasting of the external

3. After application the coating shall be electrically inspected for

1. Thermal Insulation by void free, rigid cellular, 100% CFC free

2. The external surface of the carrier pipe shall be grit blasted to SA 2 ½

5. Core Thermal Conductivity shall be <0.03 W/mK as per EN253 - ISO

6. Service Temperature: Minus 20 to plus 150 deg 0C.

7. Moisture Absorption: maximum below 10% by volume.

8. Minimum 88 % percent closed cell.

9. Core Density: 55 Kg/m3 minimum.

10. Thickness minimum 50 mm thick for pipes up to 400 mm and minimum

a) Casing manufactured from HDPE shall be in accordance with EN

b) GRP Seamless material In accordance with ASTM D2310.Where a

butt-welding type, with wall thicknesses similar to those of the core

3. Bends shall be one of the following types:

a) Bend fittings for pipes diameter up to 315 mm in one joint

b) Pre-fabricated bends for pipes above 315 mm diameter

4. The bend fitting and pre-fabricated bends shall be available In

H. End seals provided shall be one of the following types: