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HYDRONIC PIPING
PART 1 - GENERAL
B. Diffuser Piping
E. Expansion Compensation
F. Condensate Drainage
G. Service Connections
A. Division 31 00 00 Earthwork
C. Division 26 00 00 Electrical
J. Section 23 05 48 Vibration & Seismic Controls for HVAC Piping and Equipment
1.3 REFERENCES
A. ASTM International:
1. ASTM A 53 - Steel Pipe, Black and Hot Dipped Zinc Coated, Welded and
Seamless, for Ordinary uses (BS 1387 / 3601) - Ref.: Steel in schedule
2. ASTM A 234 - Pipe Fittings of Wrot Carbon Steel and Alloy Steel for Moderate
and Elevated Temperatures
2. ANSI B 16.9 - Specification for steel butt-welding fittings for petroleum industry
(BS 1640)
D. ASME Standard:
F. British Standard:
1. Codes, ordinances, rules and regulations of the State of Kuwait and its lawful
agencies like Ministry of Electricity and Water
C. Products used in the works covered by this Section shall be provided from specialized
manufacturer whose products have been in satisfactory use in similar service for
minimum period of five (5) years.
D. Materials
1. Materials incorporated in the work covered by this Section shall be unused, new
products in good condition. Materials spoiled due to improper storage or
mishandling shall be rejected.
6. Valves and appurtenances shall have manufacturer's name, pressure rating and
size cast-on on the body.
7. Pipes and fittings used in the works shall have the standard of manufacturer,
type, class or rating etc. continuously printed or marked otherwise in compliance
with the standard of manufacture. Materials without such identification shall be
rejected.
F. Valves and similar control gear, used in the works, shall have the manufacturer's name
or logo, size, pressure rating and direction of flow cast-on, on the body.
G. Copper alloys used in the construction of valves, pipe fittings, hydronic specialities etc.;
which comes in contact with water; shall be dezincification resistant type.
H. All grooved joint couplings, fittings, valves, and specialties shall be the products of a
single manufacturer. Grooving tools shall be of the same manufacturer as the grooved
components.
I. All castings used for coupling housings, fittings, valve bodies, etc., shall be date stamped
for quality assurance and traceability.
A. The Project has an aspiration to be assessed against the requirements of LEED for New
Construction 2009 edition, and during the design phase is targeting a LEED Gold
Certification. For an explanation of the LEED certification process and description of the
LEED credits targeted refer division-01 documents-Section (01 81 13) for LEED
Requirements and Appendix.
B. Grooved End Products shall contribute to achieving LEED points based on performance
requirement. Integrating Grooved End Products & solutions into a buildings
infrastructure may/shall contribute to obtaining LEED points under the category of
Sustainable Site, Energy & Atmosphere, Indoor Environmental Quality & Innovation &
Design process.
1.6 SUBMITTALS
1. Manufacturers printed brochures and catalogues (one original and three copies)
with relevant information highlighted (or irrelevant information struck out), along
with write up of selection criteria
3. General piping layout drawings to a scale not smaller than 1: 500 along with
profiles to same horizontal scale; indicating supports, thrust block and the like
4. Builders work drawings of valve chambers and the like to a scale of 1:50 / 1: 20
as appropriate along with details of sleeves and penetrations to same scale
B. Project record documents of all works installed under this Section, including:
1. As-Built Drawings
C. Product data including data on pipe materials, pipe fittings, valve and accessories and
recommended coating materials, samples and manufacturer's installation instructions or
recommendations shall be submitted under provisions of the General Conditions of
Contract.
D. Copies of valve ordering schedules shall be submitted for approval prior to placing the
orders.
G. Grooved joint couplings and fittings shall be shown on drawings and product submittals,
and shall be specifically identified with the applicable style or series designation.
C. Operation and Maintenance Data: Submit instructions for installation and changing
components, spare parts lists, exploded assembly views.
A. Perform Work in accordance with ASME B31.1 ASME B31.9 code for installation of
piping systems and ASME Section IX for welding materials and procedures.
B. Perform Work in accordance with applicable authority AWS D1.1 for welding hanger and
support attachments to building structure.
1.9 QUALIFICATIONS
C. Design piping system hangers and supports under direct supervision of Professional
Engineer experienced in design of this Work and licensed at Project location in State of.
B. Piping system shall be warranted for a period of 15 years. Warranty certificate duly
registered with the manufacturer shall be furnished to the Employer as a prerequisite for
issuance of substantial completion certificate.
A. Products shall be delivered to site, stored and protected under provisions of the General
Conditions of Contract.
B. Two (2) coats of approved primer shall be applied to all untreated ferrous pipes prior to
storage.
C. Pipes shall not be allowed to come in contact with any sharp objects during
transportation, loading, unloading and stacking. Suitable type of web slings shall be used
for handling of pipes. Metallic cables, chains or hooks shall not be used on the pipes
under any circumstance
D. Pipes shall be stored in a flat, level ground; raised on timber bearers such that the lowest
part of the pipe is not less than 150 mm above the ground
E. Pipes shall be stored on elevated racks and the ends kept closed with factory-
manufactured plugs to prevent the entry of foreign matter.
F. Rubber and plastic products shall be stored out of direct sunlight and protected in an
appropriate manner to prevent deterioration.
G. Valves shall be delivered and stored in shipping containers with labelling in place.
Further:
1. Plug and ball valves shall be kept in open position and gate / globe valves in
closed position to prevent damage to valve seats
H. Pipes supplied in pallets or crates shall be kept as such until time of installation. Piping
supplied loose shall be stored in layers, not exceeding four high. Socket ended pipes
shall be stored with the socket at either end in alternate layers. Pipes of different sizes
and / or thickness shall be stacked separately.
I. Valves shall be supplied with plastic caps to prevent damage to the ends.
B. Test certificates from agencies (approved for the purpose by the Employer) and / or
approved, independent laboratories or testing agencies shall be furnished in respect of
the following:
A. HVAC chilled water supply and return system pipe work starting from the outlet of header
connection(s) within the HVAC plant room to flanged outlets of service connections
within building served shall be included in the scope of this Section.
PART 2 - PRODUCTS
1. Sumitomo, Japan
3. Mannesman, Germany
2. Grinnell, USA
3. Shurjoint, USA
2.2 PIPES
2.3 FITTINGS
A. Pipe fittings shall be of Ductile Iron with Grooved End or Same Material of Construction,
Strength & Method of jointing as pipes.
C. Prefabricated fittings supplied by the piping system manufacturers may be used, where
appropriate, subject to the approval of the Engineer.
2.4 JOINTS
D. Pressure ratings of Pipe / Fitting / joints (Figures stated are working water pressures at
ambient temperature):
1. Malleable iron Fitting (items A,B,C & D) : 2,065 kPa (300 psig)
1. Black Steel Fittings: Malleable Iron unions with brass seat, threaded ends
1. Black steel piping: Cast / forged steel threaded / welding neck / slip-on flanges
2. Compressed fibre gaskets shall be used at all flanges (use of rubber gaskets is
prohibited)
C. Dielectric connections:
1. Up to DN 50 (2 inch): Unions with one end malleable iron threaded and the other
end copper solder
3. Both unions and flanges shall have water impervious isolation barrier certified to
withstand a minimum 600 volts on a dry line with no flashover
D. Pressure ratings of Flanges, unions and couplings shall be rated for 1,724 kPa (250
psig) working water pressure at ambient temperature.
Joints using grooved pipe ends and rigid / flexible grooved couplings with EPDM gaskets.
A. Pipe end preparation: Rolled or cut as appropriate to pipe material, wall thickness,
pressures, size and method of joining. Pipe ends to be grooved in accordance with
manufacturers current listed standards.
B. Fittings: Full flow ductile iron fittings with grooves or shoulders designed to accept
grooved end couplings; all as listed in manufacturers current catalogue.
C. Valves: Ductile Iron Grooved End / Flanged valves designed to accept grooved
end/Flange couplings as listed in manufacturers current catalogue
D. Housing: Cast malleable / ductile iron, forged / fabricated steel housing clamps Rigid or
Flexible type designed to engage and lock; permitting limited angular deflection,
contraction and expansion. Galvanized housing shall be used for galvanized pipes.
E. Gasket: "C" shaped EDPM rated to 110O C sealing gasket. Alternative gasket materials
shall be used where appropriate to match with the coupling.
F. Fasteners: High tensile steel bolts with track head; nuts and washers.
G. Pressure Rating: Fittings and valves with grooved ends and joints shall be rated for
2,065 kPa (300psig) working water pressure at ambient temperature as appropriate.
H. Grooved End Products shall confirm to LEED requirements under applicable categories.
I. COUPLINGS:
a. Rigid Type: Housings shall be cast with offsetting angle-pattern bolt pads
to provide rigidity and system support and hanging in accordance with
ANSI B31.1 and B31.9.
2. Sizes DN 350 (14 inch) through DN 600 (24 inch): Advanced Grooved Series
(AGS) with lead-in chamfer on housing key and wide width gasket.
a. Rigid Type: Housing key shall fill the wedge shaped AGS groove and
provide rigidity and system support and hanging in accordance with
ANSI B31.1 and B31.9.
b. Flexible Type: Housing key shall fit into the wedge shaped AGS groove
and allow for linear and angular pipe movement.
A. Entire piping network shall be monitored by an alarm system using a documented and
proven technique measuring the resistance between the copper wires and between
copper wires and the pipe for detecting leaks. The system will comprise:
4. Means and methods for break in alarm wire and locating faults
5. Operation manual
B. Controller, complete with power supply, interface with Building Management System,
wiring / cabling to power source as well as BMS shall be provided by this Section.
A. Contractor shall calculate expansion / contraction and provide for all required
appurtenances, in his tender.
B. Where, expansion compensation is not required, in the opinion of the Grooved piping
system manufacturer; this shall be clearly stated in the tender and correlated with
warranty requirements.
1. Directional changes: Bends and U-loops shall be provided along each sector.
Pipe work shall be anchored at midpoints of long straight runs to direct
expansion / contraction towards bends and / or U-loops
E. Piping shall be covered with foam pads made from granulated, compressed, soft
polyurethane foam with a density of approx. 100 kg/M3, in expansion zones; to
accommodate movements due to expansion / contraction. This shall generally be used
at bends, service connections and similar areas.
PART 3 - EXECUTION
3.1 COORDINATION
B. Contractor shall ensure that the work under this section shall not interfere with those of
other trades and are compatible with the architectural finishes prior to placing orders,
fabrication and installation.
C. Electrical power supply requirements and location and type of the interface shall be co-
ordinated with the Electrical Works of the project. Information as required by MEW, for
obtaining approvals, shall be furnished.
D. Contractor shall furnish templates, patterns, setting out plans and other items for
incorporation in works of other trades and ensure the placement of sleeves, inserts etc.
in their work; on time.
E. Where work is installed in close proximity to or will interfere with work of other trades, the
Contractor shall assist in working out satisfactory space arrangements. Composite shop
drawings shall be prepared, to a suitable scale, showing how the work is installed in
relation to the work of other trades.
F. Sufficiency of dimensions of plant areas, doorways etc. and suitability of slabs and other
structural members for placement, operation and maintenance of equipment shall be
verified and shortcomings brought to the attention of the Engineer.
G. Contractor shall resolve conflicts in requirements with other trades. Only those, which
cannot be solved without changes to structure or those, which involves major changes to
system design, shall be referred to the Engineer.
C. A list of such trained personnel shall be furnished to the Engineer prior to starting of
works at site.
D. Personnel, not included in the said list, and not carrying such identification of training
shall not be allowed to partake in activities related to the execution of the works.
3.3 SUPERVISION
A. Services of a competent representative of the piping contractor shall be provided for all
hydronic piping other than pre-insulated piping, to inspect and to certify works executed
at site in the following three stages:
B. Manufacturers representative for Pre-insulated piping shall, during each such visit,
prepare reports and furnish copies directly to the Employer.
A. Materials shall be carefully inspected visually for damages and other defects; while
suspended above the trench immediately before installation in final position.
C. If more than 10 % of materials from a batch are rejected, the Engineer will have the right
to reject the whole consignment.
A. Existing ground along the line of the pipe work shall be cleared, particularly at all
manholes, building connections and other appurtenances.
B. Sight rails shall be set in position, using a surveyor's level and properly established
temporary benchmarks alongside the work. Transferring levels by means of a straight
edge and spirit level will not be allowed.
C. Where long lengths of slightly sloping pipe work are to be laid in trenches, sight rails
shall be fixed across the trench at intervals not exceeding 20 M, at a height equal to the
length of the boning rod, at the point where the sight rail is fixed. There shall, at all times,
no less than three sight rails in position on each length of pipe work under construction,
at any one gradient.
D. Deviations from given levels may not be greater than 20 mm and in gradients not
greater than 1/20 of the given gradient.
A. Pipes shall be cut perpendicular to the axis, with approved cutting tools. Spigot ends
shall be tapered by a grinder and a fast drying coal tar applied at the bared areas.
B. Scale and dirt, on inside and outside and weld splatter shall be removed before
assembly.
C. Piping connections to valves and equipment shall be made with Flanges or Grooved End
wherever possible.
D. Coating on galvanized iron pipes and fittings shall be repaired with approved paint
(recommended by the manufacturer) where factory coating has been damaged.
E. Sleeves shall be provided for pipe passing through partitions, walls and floors.
A. Grooved joints shall be installed in accordance with the manufacturers latest published
installation instructions.
B. Grooved ends shall be clean and free from indentations, projections, and roll marks in
the area from pipe end to groove.
C. Gaskets shall be of an elastomer grade suitable for the intended service, and shall be
molded and produced by the coupling manufacturer.
D. The grooved coupling manufacturers factory trained representative shall provide on-site
training for contractors field personnel in the use of grooving tools and installation of
grooved joint products.
E. The representative shall periodically visit the jobsite and review contractor is following
best recommended practices in grooved product installation.
B. Exposed piping shall be installed parallel or at right angles to the building walls, except
where otherwise shown on the Contract drawings.
C. Minimum clearances shall be provided between piping covered by this Section and those
of other trades.
D. Adequate clearance shall be provided around the piping for the installation of insulation
and access to valves and fittings.
F. Piping shall be installed in such a way that allows for expansion and contraction without
stressing pipe joints or connected equipment. Requirements of Section 23 05 16 shall be
referred to and complied with in all respects.
G. Access doors shall be provided where valves and fittings are not exposed. Size and
location of access doors shall be co-ordinated with relevant trades.
A. Tapered reducer fittings shall be installed where changes occur in pipe sizes (use of site
fabricated fittings or bushings will not be permitted).
B. Tapered, factory manufactured reducer fittings (eccentric type at suction and concentric
type at discharge) shall be installed at pump connections. Eccentric reducer fittings shall
be installed with level crown.
C. Factory manufactured Grooved End fittings shall be installed where changes occur in
pipe direction. Bending or forming of piping shall not be permitted without the written
permission of the Engineer.
D. Use of main sized saddle branch connections or directly connecting profiled branches
(weldolets) to mains in steel piping is allowed if main is two pipe sizes larger than the
branch (branches shall not project inside the main pipe).
A. Piping shall be installed in such a way that conserves space and does not interfere with
the use of space.
B. Minimum clearances shall be provided between piping covered by this Section and those
of other trades.
C. Pipes shall be handled with utmost care so as not to subject the pipes to shocks, which
may crack or break the sheath.
D. Piping shall be protected against the ingress of foreign material before the pipe is placed
in new line.
E. If pipe or appurtenance cannot be placed into the trench and in place, without getting
earth into it, each end shall be covered with a heavy, tightly woven canvas bag of
suitable size before lowering them into the trench. The bag shall be left there until the
connection is to be made to the adjacent pipe.
F. Pipes shall be laid and connected at the required depth in straight line and true to the
gradient on an even foundation as shown on the drawings, for the full length of the
barrel.
G. Piping shall be kept free of earth, dirt, and extraneous matter and clean every pipe after
installation by special cleaning tools approved by the Engineer. Mirrors, lamps and
H. Pipe shall not be laid when, in the opinion of the Engineer, conditions are unsuitable.
I. Grooved joints shall be installed in accordance with the manufacturers latest published
installation instructions (I-100).
A. Piping shall be sloped and arranged to drain at the system low points. Additional drain
valves / automatic ball drips shall be provided at pipe segments that cannot be drained
otherwise their discharge piped to a convenient location.
B. All drains connected to Terminal Building sanitary sewer system, to include siphon
A. Full depth threads shall be cut on prepared pipe ends, preferably using power driven
machines using cutting fluids. Threads shall be cleaned thoroughly before applying
thread sealant.
B. Teflon thread sealing tapes or hard setting, non-toxic sealing compounds shall be used
on the male thread (only) before making joints. Joints opened for repairs shall be
brushed clean and given fresh sealing tape or compound.
3.16 VALVES
A. Valves shall be installed with stem upright or horizontal, not inverted; except with the
written permission of the Engineer, for each location.
B. Valves shall be same size as pipeline, except where shown otherwise on the Contract
Drawings.
C. Gate, ball or butterfly valves shall be used for shutoff and to isolate equipment, risers or
branches serving two or more cooling terminals.
D. Globe / plug valves shall be used for throttling service. Non-lubricated plug valves shall
be used only when shut-off or isolating valves are also provided.
E. Drain valves shall be installed at system low points and at the foot of risers.
F. In-line spring loaded check valves shall be installed at the discharge of pumps.
G. Valves shall be pad-locked in open or closed position with leather straps, as required.
H. Appropriate valve gland packing, sealing and gasket materials shall be selected for the
temperature and pressure encountered.
D. Dielectric unions or flanged fittings shall be used wherever joining dissimilar metals.
A. Ends of piping shall be kept closed with factory manufactured plugs or blind flanges with
integral indicating flags, to prevent the entry of foreign matter, during the progress of the
work. Such plugs or flanges shall be removed on completion of the works.
B. Piping surface shall be protected from splashes of cement, plaster, paint and similar
construction materials.
C. Piping shall be blown out using dry compressed air, prior to testing.
A. Pipes shall be jointed, plugged and shall have been in position for at least 24 hours,
before the tests are carried out.
B. Piping shall be tested for line, gradient and water tightness. Labour and necessary
testing instruments such as gauges, pumps etc. shall be provided by the Contractor as
directed by the Engineer. A minimum of two (2) # identical pressure gauges shall be
installed at extremities of the piping circuit to be tested.
C. Piping shall be filled with clean fresh water, leaving all high points open to allow for
purging of air.
D. System shall be pressure tested using manual pumps in increments of 25 % of the test
pressure. A standing period of 10 minutes shall be allowed after each pressure
increment. Pressure testing using motor driven pump shall not be permitted.
E. System shall not be over-pressurised under any circumstance. Calibrated pressure relief
valves shall be installed in the tested circuit, if the test pressure is close to the maximum
permissible working pressure of any of the system components.
F. Valves and control devices shall be kept in the open position, during. After completion of
pressure test, valves shall be closed, one at a time, starting from the pressure release
end, so as to ensure tightness of the valve.
G. Piping shall be tested with water at a pressure of 689 kPa (100 psig) or 1.5 times the
system working pressure, whichever is greater, but limited to 1,379 kPa (200 psig).
Pressure shall be maintained for at least 4 hours. Temperature of the circuit shall be
recorded along with the pressure readings and pressure fluctuations due to ambient
temperature variations shall be allowed for.
H. Joints shall be checked for leaks by swabbing with a dry tissue. Drop in pressure to the
order of 10 kPa (1.5 psig) per hour, but without any visible leaks, shall be considered as
acceptable.
I. Chilled / hot water coils and control valves shall not be subjected to the test pressure.
J. Piping shall be tested in segments during the progress of the work. An official log book
shall be maintained for recording the tests carried out on sections of piping, including test
pressure, date of test and approval signature of Engineer's representative witnessing the
test.
K. Provision shall be made for emptying of pipes without letting water out and flooding the
trench (Contractor shall provide temporary basins, pumps etc. as appropriate).
Following protective coatings / wrappings shall be given to the piping, on completion of the
works. Piping above louvered ceilings shall be painted black as further described in architectural
finish schedule.
2. One (1) layer of asphalt impregnated felt wrap with 25 mm (1 inch) overlaps
2. One (1) layer of asphalt impregnated felt wrap with 25 mm (1 inch) overlaps
2. Two (2) coats of enamel paint (or colour matching with the surrounding
architectural finish, in areas exposed to view)
2. One (1) layer of asphalt impregnated felt wrap with 25 mm (1 inch) overlaps
A. Piping shall be flushed with fresh water, intended for HVAC services, after completion of
tests.
B. No segment of ferrous / copper piping shall be left partially filled with water at any time,
to prevent the occurrence of internal corrosion.
C. Suitable proprietary and / or conventional cleaning chemical(s) shall be used for a period
of 2 to 4 days for this purpose.
B. System demonstrations shall be conducted only after the substantial completion of the
project. A minimum of one week's written notice shall be given and the Employer's
written consent obtained, prior to such demonstrations.
C. After completion of works, the piping system shall be filled completely (gravity head
only) with clean fresh water of less than 20 microns filtration fineness (as supplied by
plumbing services).
D. Valves at inlets and outlets kept closed and sealed by chains and padlocks, until system
start-up, and keys handed over to the Employer.
END OF SECTION