SECTION 15000 PLANT PIPING - GENERAL
PART 1 GENERAL
1.1 SECTION INCLUDES
A. Building piping.
B. Yard piping.
C. This Section provides general piping requirements. The Detail Piping Specifications provide additional requirements.
1.2 REFERENCES
A. American National Standards Institute (ANSI):
1. ANSI B1.20.1-83 - Pipe Threads, General Purpose (In.).
2. ANSI B16.1-75 - Cast Iron Pipe Flanges and Flanged Fittings.
3. ANSI B16.3-77 - Malleable Iron Threaded Fittings.
4. ANSI B16.4-77 - Cast Iron Threaded Fittings.
5. ANSI B16.5-81 - Pipe Flanges and Flanged Fittings.
6. ANSI B16.9-78 - Factory-Made Wrought Steel Buttwelding Fittings.
7. ANSI B16.12-83 - Cast Iron Threaded Drainage Fittings.
8. ANSI B16.14-77 - Ferrous Pipe Plugs, Bushings, and Lock Nuts with Pipe Threads.
9. ANSI B16.18-78 - Cast Copper Alloy Solder Joint Pressure Fittings.
10. ANSI B16.21-78 - Non-Metallic Flat Gaskets for Pipe Flanges.
11. ANSI B16.22-80 - Wrought Copper and Copper Alloy Solder Joint Pressure Fittings.
12. ANSI B16.39-77 - Malleable Iron Threaded Pipe Unions.
13. ANSI B31.1-83 - Power Piping.
14. ANSI B31.5-74 - Refrigeration Piping.
B. American Society for Testing and Materials (ASTM):
1. ASTM A47-77 - Specification for Malleable Iron Castings.
2. ASTM A53-82 - Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated and Seamless.
3. ASTM A74-82 - Specification for Cast Iron Soil Pipe and Fittings.
4. ASTM A106-82 - Specifications for Seamless Carbon Steel Pipe for High Temperature Service.
5. ASTM A120-82 - Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated (Galvanized) Welded and Seamless, for Ordinary Uses.
6. ASTM A135-79 - Specifications for Electric Resistance Welded Steel Pipe.
7. ASTM A183-80 - Specifications for Carbon Steel Track Bolts and Nuts.
8. ASTM A234-82A - Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures.
9. ASTM A333-82 - Specification for Seamless and Welded Steel Pipe for Low Temperature Service.
10. ASTM B32-76 - Specification for Solder Metal.
11. ASTM B88-83 - Specification for Seamless Copper Water Tube.
12. ASTM B280-83 - Specification for Seamless Copper Tube for Air Conditioning and Refrigeration Field Service.
13. ASTM D2104-74 - Specification for Polyethylene (PE) Plastic Pipe, Schedule 40.
14. ASTM 2310-80 - Classification for Machine-Made Reinforced Thermosetting Resin Pipe.
15. ASTM D2564-80 - Specification for Solvent Cements for Poly (Vinyl Chloride) (PVC) Plastic Pipe and Fittings.
16. ASTM D2609-74 - Specification for Plastic Inset Fittings for Polyethylene (PE) Plastic Pipe.
17. ASTM D2665-82 - Specification for Poly (Vinyl Chloride) (PVC) Plastic Drain, Waste, and Vent Pipe and Fittings.
18. ASTM D2729-80 - Specification for Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings.
19. ASTM D2737-83 - Specification for Poly (Vinyl Chloride) (PVC) Plastic Tubing.
20. ASTM D2740-80 - Specification for Poly (Vinyl Chloride) (PVC) Plastic Tubing
21. ASTM D3261-82 - Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Pipe and Tubing.
22. ASTM F402-80 - Practice for Safe Handling of Solvent Cements and Primers Used for Joining Thermoplastic Pipe and Fittings.
C. Cast Iron Soil Pipe Institute (CISPI):
1. CISPI 301-82 - Standard Specification for Cast Iron Soil Pipe and Fittings for Hubless Cast Iron Systems for Drain Waste or Vent, Sewer, Rain Water or Storm Drain Systems.
2. CISPI 310-82 - Specification for Cast Iron Soil Pipe Institute's Patented Joint for Use in Connection with Hubless Cast Iron Systems for Drain, Waste or Vent, Sewer, Rain Water or Storm Drain Systems.
3. CISPI HSN-78 - Specification for Neoprene Rubber Gaskets for Hub and Spigot Cast Iron Soil Pipe Fittings.
D. American Society of Mechanical Engineers (ASME):
1. ASME Boiler and Pressure Vessel Code, Section II, Part C.
2. ASME Boiler and Pressure Vessel Code, Section IX.
1.3 PIPING SCHEDULE
A. The Piping Schedule in the Drawings lists each service by name and by legend, and tabulates the applicable Detail Piping Specification section numbers for each piping material to be used in a given service and location. In locations where the referenced specification for a service is unacceptable, due to unique or localized physical or chemical limitations, the specifications for an acceptable alternative material shall be submitted to the Engineer for approval.
B. The Detail Piping Specification section numbers are referenced also as to nominal pipe size, exposed or buried, submerged, concrete encased, test pressure, operating pressure, etc.
1.4 SUBMITTALS
A. Submit shop drawings under the provisions of Division 1. Submit pipe material and joint type for each pipeline.
B. Submit shop drawings under the provisions of Division 1 for all couplings, adapters, wall pipes, sleeves, sealants, dielectric fittings, hangers and supports.
C. Submit shop drawings under the provisions of Division 1 showing double-line drawings of each piping system, locating each support and hanger, identifying the type by catalog number or shop drawing detail number, and showing anchor locations and identifying them by shop drawing detail number. Show also all couplings, adapters, etc.
1.5 DELIVERY, STORAGE AND HANDLING
A. Deliver, store, protect and handle products under the provisions of Division 1.
PART 2 PRODUCTS
2.1 GENERAL
A. The materials to be used for the piping systems shown on the Drawings are listed by service in the Piping Schedule.
B. Like items of material shall be the end products of one manufacturer.
C. Paint and color code all exposed metal piping as specified in Section 09900, PAINTING and the Piping Schedule respectively. Label all exposed piping as specified herein.
D. No change in material or joint selection will be permitted after submittal of shop drawings and their final review by the Engineer.
2.2 PIPE JOINTS FOR EXPOSED PIPING
A. Provide flanged pipe joints on exposed piping 3-inches and larger except as shown otherwise. Grooved end pipe joints may be substituted for flange joints for piping 3 inches and larger except as noted otherwise.
B. Provide joints as specified in the Detail Piping Specifications for all pipe smaller than 3 inches.
C. Provide welded pipe joints where shown on the Drawings.
2.3 PIPE JOINTS FOR BURIED PIPING
A. Provide mechanical joint or push-on joint pipe ends on all buried ductile iron pipe.
B. Restrain by thrust blocks or by tie rods all elbows, tees, pipe plugs and valves or as specified in the Detail Piping Specifications.
C. Provide joints for other buried piping as specified in the Detail Piping Specifications.
2.4 BURIED PIPING EXPANSION PROVISION
A. Install buried piping to allow for thermal expansion due to differences between installation and operating temperatures.
2.5 BUILDING PIPING EXPANSION PROVISIONS
A. Provided flanged coupling adapters or bellows type flexible couplings at connections to equipment.
B. For Air Low Pressure (ALP) piping, provide Elastomer Bellows Expansion Joints as specified herein on as shown on the drawings.
C. Installation of additional flexible couplings to facilitate piping installation is acceptable provided that the Contractor submits complete details describing location, pipe supports, and hydraulic thrust protection.
D. Acceptable types of flexible couplings and expansion joints are as follows:
1. Metallic Piping Systems:
a. Flexible Couplings:
1) Steel pipe: Provide Dresser Style 38; Smith-Blair, Inc. Style 411; or equal.
2) Ductile iron pipe: Provide Dresser Style 138; Smith-Blair, Inc. style 441; or equal, with zinc-plated bolts and nuts.
3) Provide thrust ties as required and shown to sustain the force developed by 1-1/2 times the test pressure specified.
b. Transition Couplings: Provide Dresser Style 62; Smith-Blair, Inc. 413; or equal transition couplings to connect pipes with small differences in outside diameter.
c. Flanged Coupling Adapters:
1) Ductile iron pipe: provide Series 912 as manufactured by Smith- Blair, Inc.; or Style 128W as manufactured by Dresser Industries, Inc.; or equal
2) Steel pipe: provide Series 913 as manufactured by Smith-Blair, Inc.; or Style 128W steel piping, as manufactured by Dresser Industries, Inc.; or equal.
3) Provide thrust ties attached to the pipe with welding lugs or cast- in-place lugs where indicated. Anchor studs placed perpendicular to the longitudinal axis of the pipe are unacceptable.
4) Provide adequate thrust protection to sustain the force developed by 1-1/2 times the test pressures specified.
d. Bellows Type Flexible Couplings:
1) Provide Mercer Style 500; Garlock Style 204; or equal, with single Hypalon bellows and filled arch.
2) Provide flanged joints with steel retaining rings, rated for 125 psi maximum operating pressure and 180º F maximum operating temperature.
3) Provide thrust ties as required and shown to sustain the force developed by 1-1/2 times the test pressure specified.
e. Air Low Pressure (ALP) Elastomer Bellows Expansion Joint:
1) Provide Metraflex Style 711, or equal.
2) Type: provide reinforced, molded, non-filled wide arch type with 150-pound flanged ends, and split stainless steel flanged retaining rings.
3) Tube and cover materials: EPDM.
4) Min. rated lateral deflection, inch: 3/4.
5) Min. axial compression, inch: 1-3/4.
6) Min. working pressure, psig: 100.
7) Min. temperature rating, degrees F: 250.
2. Nonmetallic Piping Systems:
a. Flexible Couplings and Expansion Joints:
1) Provide Peabody Dore' Style E-1608-A; Resistoflex No. R6904; or equal.
2) Bellows: Teflon construction having two convolutions unless otherwise shown.
3) Joints: ductile iron flanges, drilled 150 psi ANSI standard, and Monel reinforcing bands suitable for 100 psi working pressure at 100º F and for the traverse shown on the Drawings.
4) Limit Bolts: provide as specified for adjacent piping and to sustain the force developed by 1-1/2 times the test pressures specified.
2.6 PIPING SUPPORT SYSTEMS
A. General:
1. Piping shall be supported, in general, as described here-in-after and as shown by the pipe support details on the Drawings. Manufacturers' catalog figure numbers are typical of the types and quality of standard pipe supports and hangers to be employed. Provide special support and hangers where standard catalog supports are inapplicable.
2. No attempt has been made to show pipe supports in most locations, either on the Drawings or in the details. The absence of pipe supports and details on any drawings shall not relieve the Contractor of the responsibility for providing them throughout the plant. Where pipe supports are specifically called out on the Drawings, the Contractor shall provide this type of support.
3. Where piping connects to equipment it shall be supported by a pipe support and not by the equipment.
4. Pipe support system components shall withstand the dead loads imposed by the weight of the pipes filled with water, plus hydraulic thrust, and plus any insulation. Commercial pipe supports and hangers shall have a minimum safety factor of 5.
5. All buried and submerged piping supports, guides, anchor bolts, and fasteners, and those installed in wet wells, shall be Type 316 stainless steel.
6. Concrete anchors and anchor bolts shall be as specified in Section 05500.
7. All components of the piping support system shall be hot-dipped galvanized steel, except where stainless steel is specified.
B. Building Piping:
1. Horizontal piping shall be supported with adjustable swivel-ring, split-ring, or Clevis type hangers, Anvil International 104 or 260; Fee & Mason Figure 199 or 239; or equal.
2. Stacked horizontal runs of piping along walls shall be supported by a metal framing system attached to concrete insert channels as shown, Unistrut, Kin- Line, or equal. No pipe shall be supported from the pipe above it.
3. Pedestal pipe supports shall be adjustable, with stanchion, saddle, and anchoring flange as shown, Anvil International 264 or 259; Fee & Mason Figure 291 or 259; or equal.
4. Horizontal piping hanger support rods:
a. Attach to steel beams with I-clamps, to concrete with inserts or flanges with flush shells, and to wood not less than 2-1/2-inch thick with lag screws and angle clips.
b. Provide universal concrete inserts with a load rating greater than the hanger rods they support.
5. Vertical piping hangers and supports shall be channel and pipe straps manufactured by Unistrut, Kin-Line, or equal.
6. Piping supports for vertical piping passing through floor sleeves shall be hot- dipped galvanized steel riser clamps, Anvil International 261; Fee & Mason Figure 241 or 238; or equal.
7. All hangers, rods, clamps, protective shields, metal framing supports, and hanger accessories shall be hot-dipped galvanized unless otherwise noted on the Drawings.
2.7 JOINTS FOR DISSIMILAR PIPE
A. Buried pipe: Joints between dissimilar buried pipe shall be made with insulating couplings, Dresser Style 39, Smith-Blair, Inc. Style 416, or equal.
B. Joints between dissimilar exposed pipe:
1. Make with insulating flanges, couplings and unions of suitable pressure ratings for system working pressures.
2. Construction materials: Galvanically compatible with the piping to which attached.
3. Joints:
a. 2-inch and smaller: Screwed or solder-joint unions.
b. 2-1/2-inch and larger: Flanged, complete with bolt insulators, dielectric gasket, bolts, and nuts as distributed by Epco Sales, Inc. of Cleveland,
OH.; Capitol Insulation Unions; or equal. Insulating couplings shall be Dresser Style 39; Smith-Blair, Inc. Style 416; or equal.
2.8 SERVICE AND OUTLET SADDLES
A. Ferrous Metal Piping:
1. Outlet Size:
a. 4- inch and smaller: Pipe service saddles for all ferrous metal piping except stainless steel shall be Smith-Blair, Inc., Series 313 or 366; Dresser, Style 91; or equal. Service saddles shall be capable of withstanding 150 psi internal pressure without leakage or overstressing. The run diameter shall be compatible with the outside diameter of the pipe on which the saddle is installed. Taps shall have iron pipe threads. Saddles shall have malleable or ductile iron bodies and galvanized steel straps, steel hex nuts and washers, and neoprene seals. Service saddles shall be of double-strap design. Service saddles shall not be used on glass lined ductile iron pipe, factory applied tapping bosses shall be used.
b. 6-inch and larger: Outlet saddles for ductile iron piping shall be from AMERICAN Ductile Iron, or US Pipe. Outlet saddles shall be rated 250 psi operating pressure, with outlet connections as shown on the drawings. Saddles shall have ductile iron bodies and galvanized steel straps, stainlees steel hex nuts and washers, and SBR rubber gaskets.
B. Plastic Pipe: Service saddles for PVC and CPVC pipe shall have solid polypropylene bodies with Buna-N seals and stainless steel worm drive clamps, or polypropylene threaded inserts with vinyl coated steel saddle bodies and Type 316 stainless steel bolts. Saddles shall be Smith-Blair, Inc., Style 315 or 317; Dresser, Style 194; or equal.
2.9 SLAB, FLOOR, WALL AND ROOF PENETRATIONS AND CLOSURES:
A. All piping penetrations of slabs, floors and walls shall be ductile iron wall pipes with integrally cast or fabricated welded seep rings unless shown otherwise on the Drawings. Verify size and location of all penetrations and place wall pipes before pouring concrete.
B. Ductile Iron Wall Pipes:
1. Provide ductile iron wall pipes of the proper diameter and with joints as shown on the Drawings or as required for connection. Wall pipes shall be a thickness equal to or greater than the remainder of the pipe in the line, and shall comply with the requirements for fittings in the applicable Detail Piping Specification. All wall pipes shall be provided with integrally cast or fabricated welded seep rings. Flanges and mechanical joint bells set flush with the face of walls shall be tapped for stud bolts.
2. Rubber-gasketed compression collars are unacceptable. The Contractor shall place early orders for wall pipes so they are available in sufficient time for placement in concrete forms. Coat wall pipes with System No. 2 as specified in Section 09900. Support wall pipes by formwork to prevent contact with reinforcing steel.
C. Pipe Sleeves:
1. All piping passing through concrete or masonry shall be installed through hot- dipped galvanized steel pipe or Century-Line high density polyethylene sleeves as manufactured by PSI/Thunderline Corporation; or equal. For fire rated rooms, provide hot-dipped galvanized wall sleeves only. Fabricate sleeves as shown on the detail drawings.
2. All sleeves in exterior or water-bearing walls shall have a center flange for water stoppage. The annular space between pipes and sleeves in exterior walls shall be watertight.
3. The annular space between pipes and sleeves in exterior walls shall be watertight. The joint shall be sealed by a modular mechanical unit shaped to continuously fill the annular space between the pipe and wall sleeve. The interconnected rubber links shall be assembled with 316 stainless steel bolts, nuts, and washers pressure plates shall be glass reinforced nylon. Tightening of the bolts shall cause the rubber sealing links to expand, resulting in a watertight seal between the pipe and wall sleeve opening. Closures shall be sized according to manufacturer's instructions for the size of pipes shown on the Drawings. Seals shall be Link-Seal as manufactured by PSI/Thunderline Corporation; or equal.
4. Fire rated pipe-through-wall penetrations shall be sealed be modular type interlocking synthetic rubber links shaped to continuously fill the annular space. Fire seals constructed of steel pressure plates and steel bolts, nuts, and washers and specially formulated fire resistant silicone rubber sealing elements (ASTM D2000 M1GE505). For 1 hour fire stop, use one belt of Link-Seal Model T (FM approved). For 3 hour fire stop, use 2 belts of Link-Seal Model FS. Seals shall be Link-Seal by PSI/Thunderline, or approved equal.
5. Coat steel pipe sleeves with System No. 2, as specified in Section 09900. Support sleeves from formwork to prevent contact with reinforcing steel.
D. Floor Pipes:
1. Provide ductile iron floor pipes with diameter as shown on the Drawings, or as required for connection. Floor pipes shall be a thickness equal to or greater than the remainder of the pipe in the line, and shall comply with the requirements for fittings in the applicable Detail Piping Specification. All floor pipes shall be provided with integrally cast or fabricated welded seep rings. Flanges shall be located a minimum of 6 inches above the top of floor.
2. The Contractor shall place early orders for floor pipes so they are available in sufficient time for placement in concrete forms. Coat floor pipes with System No. 2 as specified in Section 09900. Support floor pipes by formwork to prevent contact with reinforcing steel.
E. Floor Sleeves:
1. Provide hot-dipped galvanized steel pipe floor sleeves for all piping passing through concrete floors. Fabricate sleeves as shown on the detail drawings.
2. The annular space between pipes and sleeves in floors shall be watertight. The joint shall be sealed by a modular mechanical unit shaped to continuously fill the annular space between the pipe and floor sleeve. The interconnected rubber links shall be assembled with 316 stainless steel bolts, nuts, and washers pressure plates shall be glass reinforced nylon. Tightening of the bolts shall cause the rubber sealing links to expand, resulting in a watertight seal between the pipe and floor sleeve opening. Closures shall be sized according to manufacturer's
instructions for the size of pipes shown on the Drawings. Seals shall be Link- Seal as manufactured by PSI/Thunderline Corporation; or equal.
3. Fire rated floor penetrations shall be sealed be modular type interlocking synthetic rubber links shaped to continuously fill the annular space. Fire seals constructed of steel pressure plates and steel bolts, nuts, and washers and specially formulated fire resistant silicone rubber sealing elements (ASTM D2000 M1GE505). For 1 hour fire stop, use one belt of Link-Seal Model T (FM approved). For 3 hour fire stop, use 2 belts of Link-Seal Model FS. Seals shall be Link-Seal by PSI/Thunderline, or approved equal.
4. Coat steel floor sleeves with System No. 2, as specified in Section 09900. Support sleeves from formwork to prevent contact with reinforcing steel.
2.10 FIRESTOPPING
A. For all pipes penetrating a fire rated room, provide hot-dipped galvanized wall sleeves and fill the void with Type II fire resistive caulk. Room fire rating is determined by the door type used, which is found in the Architectural Door Schedule.
B. Type II fire resistive caulk shall be 3M brand CP-25; or equal.
2.11 TAPE WRAP
A. Tape wrap shall be 15-mil butyl rubber adhesive, polyethylene-backed tape as manufactured by Polyken Division of the Kendall Company, Boston, MA; Royston Laboratories, Inc., Pittsburgh, PA; or equal.
2.12 HEAT SHRINK WRAP
A. Heat shrink wrap shall be a cross-linked polyolefin wrap or sleeve with a mastic sealant. Wrap or sleeves shall be Raychem WPC, TPS, flange seal, or equal. Wrap type shall be as recommended by the manufacturer for the specific joint.
2.13 METALLIC MARKING TAPE
A. Electrically conductive 2-inch width bright colored marking tape, designed for direct burial. Tape shall be detectable with standard pipeline detectors.
2.14 HEAT TRACING
A. Provide heat tracing as specified in Division 16.
2.15 PIPING SPECIALTIES
A. Stuffing Box Lubrication/Seal Water Piping: Provide the following seal water components for each pump, piped as shown in the Drawings: pressure regulator, Norgren Type 11-009, Casco Type D, or equal, pressure as determined by pump manufacturer; Y strainer, maximum 60 mesh (0.01 inch opening); needle disc type globe valve, V220 or equal; pressure gage with petcock, minimum 4-inch face, calibrated to read approximately mid-range at stuffing box pressure determined by pump manufacturer.
Provide 1-foot lengths of 3/8-inch seal water hose with NPT fittings at each end. Seal water hose shall be Uniroyal clear plastic tubing rated 125 psig; or equal.
B. Simplex Strainer: Strainers, 3 inches and smaller, for water service shall be iron body, Y- pattern, 125-pound rated, with screwed bronze or bolted iron cap. Screen shall be heavy- gauge stainless steel or monel, 30-mesh. Strainers shall be Crane No. 988-1/2; Mueller No. H-9330; or equal.
C. Simplex Strainers: Strainers, for chemical service, 1-1/2-inches and smaller, shall be Y- pattern, threaded, with PVC screen, 1/32-inch perforations. Strainer, for chemical service, 2 to 4-inches, shall be basket style, flanged, with PVC screen, 1/8-inch perforations. Strainer construction all polyvinyl chloride (PVC), Type 1, Grade 1, cell classification conforming to ASTM D-1784. Provide O-ring cover seals. Strainers rated 150 psi at 75 degrees F. Hayward Plastic Products, Inc.; or equal.
D. Flashing Sleeves: Flashing sleeves shall be installed wherever piping passes through concrete roof structures. Where piping passes through wood or metal deck roofs, provide a 4-pound lead flashing extending 8 inches from the pipe in all directions, extended up the pipe, and fitted with a double-threaded flashing for pipes 3 inches and smaller. Flashing shall turn down inside the pipe for 4-inch piping. Flashing sleeves shall be J. R. Smith Figure 1720; Josam No. 26400; or equal.
E. Rupture Disks: Rupture disks shall be made of impervious graphite, inverted type, with a 150 psi rupture pressure. Install rupture disks between ANSI 150 lb flanges, as shown on the Contract Drawings. Manufactured by Fike, Zook, or BS&B.
PART 3 EXECUTION
3.1 GENERAL
A. Drawings do not attempt to show exact details of all piping, and no extra payment will be allowed for obstructions by work of other trades or local obstructions to the work under this Contract that require offsets. Where diagrams have been made to show piping connections, the Contractor is cautioned that these diagrams must not be used for obtaining material quantities. Changes in location of equipment or piping, advisable in the opinion of the Contractor, shall be submitted to the Engineer for approval before proceeding with the work. All measurements and dimensions shall be verified at the site. All equipment shall be adjusted and left in a condition satisfactory to the Engineer.
3.2 PIPE PREPARATION AND HANDLING
A. Each pipe and fitting shall be carefully inspected before the exposed pipe or fitting is installed or the buried pipe or fitting is lowered into the trench. The interior and exterior protective coating shall be inspected, and all damaged areas patched in the field with material similar to the original. Clean ends of pipe thoroughly. Remove foreign matter and dirt from inside of pipe and keep clean during and after laying.
B. Use proper implements, tools, and facilities for the safe and proper handling of the pipe. Carefully handle pipe in such a manner as to avoid any damage to the pipe. Do not drop pipe into trenches under any circumstances.
3.3 PREPARATION OF TRENCH
A. Line and Grade:
1. Do not deviate more than 1 inch from line or 1/4 inch from grade. Measure for grade at the pipe invert, not at the top of the pipe, because of permissible variation in pipe wall thickness.
2. Grade shall be established from batter boards set in or over the trench at maximum 25-foot intervals. A minimum of three sets of batter boards with string line shall be maintained ahead of pipe laying at all times. A laser instrument may be used in place of batter boards.
3. Grade the bottom of the trench by hand to the line and grade to which the pipe is to be laid, with proper allowance for pipe thickness and for gravel bedding cushion when specified or indicated. Remove hard spots that would prevent a uniform thickness of bedding. Before laying each section of the pipe, check the grade with a straightedge and correct any irregularities found. The trench bottom shall form a continuous and uniform bearing and support for the pipe at every point between bell holes, except that the grade may be disturbed for the removal of lifting tackle.
B. Bell (Joint) Holes: At the locations of each joint, dig bell (joint) holes of ample dimensions in the bottom of the trench and at the sides where necessary to permit easy visual inspection of the entire joint.
C. Removal of Water: Provide and maintain ample means and devices at all times to remove and dispose of all water entering the trench during the process of pipe laying. The trench shall be kept dry until the pipe laying and jointing are completed. Remove water as specified in Division 1.
D. Prevent Water and Animals From Entering Pipe: When the pipe laying is not in progress, including the noon hours, the open ends of pipe shall be closed, and no water, animals, or foreign material shall be permitted to enter the pipe.
E. Pipe Cover: Minimum pipe cover shall be 6 feet unless otherwise indicated by Drawings or Detail Pipe Specifications.
F. Metallic Marking Tape: Provide over all buried non-metallic piping, minimum 6-inches below finished grade.
3.4 LAYING BURIED PIPE
A. All buried pipe shall be laid on the prepared granular base and bedded to ensure uniform bearing. No pipe shall be laid in water or when, in the opinion of the Engineer, trench conditions are unsuitable. Joints shall be made as specified for the respective types. Take all precautions necessary to prevent uplift and floating of the pipe before backfilling. Pipe bedding, pipe zone, and trench backfill materials and workmanship shall be as specified in Division 2.
B. Provide all special tools, appliances and lubricants for jointing pipe. Joints shall be made in accordance with manufacturer's recommendations. Backfill adequately to assure that joints, once home, are held in place.
C. Provide concrete thrust blocks or galvanized steel thrust ties at all changes of direction, tees, pipe plugs and valves for buried piping with mechanical joints or push-on joints.
D. Where the pipe is connected to concrete structures, the connection shall be made as shown. If the connection is not shown, make connection such that a standard pipe joint or flexible coupling is located no more than 2 feet from the structure.
E. Connect dissimilar pipe materials by means of a flexible coupling specified under JOINTS FOR DISSIMILAR PIPE. Install couplings in strict accordance with the manufacturer's recommendations.
F. Use concrete closure collars only when approved by the Engineer, and only when standard rubber gasketed joints or flexible couplings are impractical. Before the closure collars are poured, wash the pipe to remove all loose material and soil from the surface on which the concrete will be placed. Wet concrete pipe thoroughly prior to pouring the collars. Wrap and securely fasten a light gauge of sheet metal or building felt around the pipe to insure that no concrete will enter the line. Place reinforcement as shown on the Drawings. Make entire collar in one pour using 3,000 psi concrete and extend a minimum of 12 inches on each side of the joint. The minimum thickness around the outside diameter of the pipe shall be 6 inches. No collar shall be poured in water. After the collars are poured and have taken their initial set, cure by covering with well- moistened earth.
3.5 INSTALLATION OF EXPOSED PIPING
A. Unless shown otherwise, piping shall be parallel to building lines. Hangers on adjacent piping shall be aligned where possible.
B. Unless noted otherwise on the Drawings, horizontal pipe support or hanger spacing and hanger rod sizing for steel and ductile iron pipe shall be as follows:
Pipe Size
Maximum Support Hanger Span
Minimum Rod Size Single Rod Hangers
1-inch and Smaller 6 feet 3/8-inch
1-1/4-inch thru 2-1/2-inch 8 feet 3/8-inch
3-inch and 4-inch 10 feet 1/2-inch
6-inch 12 feet 5/8-inch
8-inch 12 feet 3/4-inch
10-inch and 12-inch 14 feet 7/8-inch
14-inch and 16-inch 16 feet 1-inch
Pipe Size Maximum Support Hanger Span
Minimum Rod Size Single Rod Hangers
18-inch
16 feet
1-1/8
20-inch thru 24-inch
18-feet
1-1/4
30-inch and larger
As Shown on Drawings
1. When supporting ductile iron pipe, locate hanger rods at all non-rigid joints and at each change of direction.
2. Hanger minimum rod size for copper pipe shall be the same as for steel pipe. Hanger span shall be 2 feet less per size than for steel pipe, with 1-inch and smaller supported every 5 feet or less.
3. Hanger rod sizing for plastic pipe shall be same as for steel pipe. Spacing of hangers shall be as recommended by the manufacturer for the flow temperature in the pipe.
4. Hanger rod sizing and support spacing for stainless steel pipe shall be as shown in the Detail Piping Specification.
5. Vertical sway bracing shall be provided where shown, or on 10-foot maximum centers.
6. All piping shall be supported in a manner that will prevent undue strain on any valve, fitting, or piece of equipment. In addition, pipe supports shall be provided at changes in direction or elevation, adjacent to flexible couplings, and where otherwise shown. Pipe supports and hangers shall not be installed in equipment access areas or bridge crane runs.
C. All pipe flanges shall be set level, plumb, and aligned. All flanged fittings shall be true and perpendicular to the axis of the pipe. All bolt holes in flanges shall straddle the vertical centerline of pipes.
D. Unions shall be installed where required for piping or equipment installation, even though they are not shown on the Drawings.
E. Plastic flanges shall be bolted using a filler gasket at any joint with a raised face. The filler gasket shall bear the bolt load uniformly and remove the flange moment from that part of the flange protruding beyond the outer edge of the raised face.
F. Piping shall be installed without springing or forcing the pipe in a manner that would set up stresses in the pipe, valves, or connected equipment.
3.6 VENTS AND DRAINS
A. Vent the high point and drain the low point of all exposed pipelines, whether shown on the Drawings or not, with 3/4-inch valves on those pipelines 2-1/2-inch and larger and 1/2-inch valves on those pipelines 2-inch and smaller. Valve types shall be as shown on the Drawings. Where valves do not appear in the Schedule for a service listed, Type V300 valves shall be used.
3.7 WALL PIPES AND PIPE SLEEVES
A. Verify the size and location of all building and structure penetrations before concrete is poured. Wall pipes and pipe sleeves embedded in concrete walls, floors, and slabs shall be embedded as specified in Division 3 and as shown. Support all pipes embedded in concrete walls, floors, and slabs with formwork to prevent contact with the reinforcing steel.
3.8 INSTALLATION OF FLEXIBLE COUPLINGS AND FLANGED COUPLING ADAPTERS, GROOVED JOINT COUPLINGS, AND SERVICE SADDLES
A. Before installation, thoroughly clean oil, scale, rust, and dirt from the pipe to provide a clean seat for the gasket. Care shall be taken that the gaskets are wiped clean before they are installed. If necessary, flexible couplings and flanged coupling adapter gaskets may be lubricated with soapy water or manufacturer's standard lubricant before installation on the pipe ends. Install in accordance with the manufacturer's recommendations. Bolts shall be tightened progressively, drawing up bolts on opposite sides a little at a time until all bolts have a uniform tightness. Workmen tightening bolts shall use torque-limiting wrenches.
3.9 INSTALLATION OF INSULATING FLANGES, COUPLINGS AND UNIONS
A. Install insulating flanges, couplings, or unions wherever copper and ferrous metal piping are connected, wherever dissimilar ferrous metal are connected, wherever submerged metallic piping is connected to unsubmerged piping, and where shown on the Drawings. Insulated joints connecting submerged piping to exposed piping shall be installed above maximum water surface elevation and before the first pipe support not having coated anchor bolts or adhesive-bonded concrete anchors. All submerged metallic piping shall be isolated from the concrete reinforcement.
3.10 TESTING
A. General: Conduct pressure and leakage tests on all newly installed pipelines. Furnish all necessary equipment and material and make all taps in the pipe, as required. The Engineer will monitor the tests. Test pressures and fluid medium shall be as specified in the Piping Schedule on the drawings.
B. Testing New Pipe That Connects To Existing Pipe: New pipelines that are to be connected to existing pipelines shall be tested by isolating the new pipe.
C. Buried Piping:
1. Conduct final acceptance tests on buried piping that is to be hydrostatically tested after the trench has been completely backfilled. The Contractor may, if field conditions permit, as determined by the Engineer, partially backfill the trench and leave the joints open for inspection and conduct an initial service leak test. The acceptance test shall not, however, be conducted until all backfilling has been completed.
2. Buried piping that is to be pneumatically tested or subjected only to an initial service leak test shall have all joints exposed for the acceptance test.
D. Exposed Piping:
1. Conduct the tests on exposed piping after the piping has been completely installed, including all supports, hangers, and anchors.
E. Hydrostatic Leak Tests:
1. Equipment - Furnish the following equipment for the hydrostatic tests:
ers
able hose quired
2. Exposed Piping - Water shall be used as the hydrostatic test fluid unless otherwise specified. Test water shall be clean and shall be of such quality as to minimize corrosion of the materials in the piping system. Vents at all high points of the piping system shall be opened to purge air pockets while the piping system is filling. Venting during the filling of the system also may be provided by the loosening of flanges having a minimum of four bolts or by the use of equipment vents. All parts of the piping system shall be subjected to the test pressure specified in the Piping Schedule. The hydrostatic test pressure shall be continuously maintained for a minimum time of 30 minutes and for such additional time as may be necessary to conduct examinations for leakage. Examination for leakage shall be made at all joints and connections. The piping system, exclusive of possible localized instances at pump or valve packing, shall show no visual evidence of weeping or leaking. Correct any visible leakage.
3. Buried Piping:
a. Some leakage is permissible from buried water and wastewater pressure lines. Consequently, the hydrostatic testing of these pipelines must be conducted in a different manner, as follows:
b. Where any section of pipe is provided with concrete thrust blocking, do not make the pressure test until at least 5 days have elapsed after the thrust blocking is installed. If high-early cement is used for thrust blocking, the time may be reduced to 2 days. When testing cement- mortar lined piping, slowly fill the section of pipe to be tested with water and allow to stand for 24 hours under slight pressure to allow the
cement-mortar lining to absorb water.
c. Expel all air from the piping system before testing and apply and maintain the specified test pressure by means of the hydraulic force pump. Valve off the piping system when the test pressure is reached and conduct the pressure test for 2 hours, reopening the isolation valve only as necessary to restore the test pressure. The pump suction shall be in a barrel or similar device, or metered so that the amount of water required to maintain the test pressure may be measured accurately. This measurement represents the leakage, which is defined as the quantity of water necessary to maintain the specified test pressure for the duration of
the test period. No pipe installation will be accepted if the leakage is greater than the number of gallons per hour as determined by the following formula:
ND?P?12
L ?
7400
In the above formula:
L = allowable leakage, in gallons per hour.
N = number of joints in the length of pipe tested. D = nominal diameter of pipe, in inches.
P = average test pressure during the leakage test, in pounds per square inch
d. Correct any leakage greater than the allowance determined under this formula.
F. Pneumatic Leak Tests:
1. Equipment - Furnish the following equipment for the pneumatic tests:
Amount Description
Pneumatic compressor separator-dryer system capable of providing oil-free
1 dry air and equipped with one or more full capacity safety relief valves set at a
pressure of not more than 105 percent of the required primary test pressure.
1 Calibrated test gauge.
2. Pneumatic testing shall be performed using accurately calibrated instruments and oil-free, dry air. Tests shall be performed only on exposed piping, but only after the piping has been completely installed, including all supports, hangers and anchors, and inspected for proper installation. All parts of the piping system shall be subjected to the test pressure specified in the Piping Schedule. The Contractor shall recognize the hazards associated with air testing and shall take all necessary precautions to protect test personnel and Owner's personnel. All piping to be ested shall be secured to prevent damage to adjacent piping and equipment in the event of a joint failure. Any appurtenant instruments or devices that could be damaged by the test shall be removed from the piping or suitably isolated before applying the test. Before starting the test, the Contractor shall notify the Engineer.
3. A preliminary pneumatic test not to exceed 25 psig shall be applied to the piping system before final leak testing, as a means of locating major leaks. Examination for leakage, detected by soap bubbles, shall be made at all joints and connections. After all visible leaks have been corrected, the pressure in the system shall gradually be increased to not more than 1/2 of the test pressure, after which the
pressure shall be increased in steps of approximately 1/10 of the test pressure until the required test pressure has been reached. The pneumatic test pressure shall be continuously maintained for a minimum time of 10 minutes and for such additional time as may be necessary to conduct a soap bubble examination for leakage. The piping system, exclusive of possible localized instances at pump or valve packing, shall show no evidence of leakage. Any visible leakage shall be corrected.
G. Initial Service Leak Tests:
1. Equipment: Equipment used for initial service leak testing may be the same as that specified under HYDROSTATIC and PNEUMATIC LEAK TESTS hereinbefore, or the pump or compressor connected to the piping system.
2. Procedure: The initial service leak test shall be performed by gradually bringing the piping system up to normal operating pressure and holding it at the normal operating pressure continuously for a minimum of 10 minutes. Examination for leakage shall be made at all joints and connections. Soap bubbles shall be used to detect leaks in pneumatically tested systems. The piping system, exclusive of possible localized instances at pump or valve packing, shall show no visual evidence of weeping or leaking. Any visible leakage shall be corrected.
H. Test Records: Records shall be made of each piping system installation during the test. These records shall include:
1. Date of test.
2. Description and identification of piping tested.
3. Test fluid.
4. Test pressure.
5. Remarks, to include such items as:
a. Leaks (type, location).
b. Repairs made on leaks.
6. Certification by Contractor and initialed acknowledgment by Engineer.
3.11 INTERIM CLEANING
A. Care shall be exercised during fabrication to prevent the accumulation of weld rod, weld spatter, pipe cuttings and filing, gravel, cleaning rags, etc. within piping sections. All piping shall be examined to assure removal of these and other foreign objects before assembly. Shop cleaning may employ any conventional commercial cleaning method if it does not corrode, deform, swell, or otherwise alter the physical properties of the material being cleaned.
3.12 FINAL CLEANING
A. Following assembly and testing and before final acceptance, all pipelines installed under this section, except air lines and gas lines, shall be flushed with water and all accumulated construction debris and other foreign matter removed. Flushing velocities shall be a minimum of 2.5 feet per second. Cone strainers shall be inserted in the connections to attached equipment and left there until cleaning has been accomplished to the satisfaction of the Engineer. Accumulated debris shall be removed through drains 2- inch and larger or by dropping spools and valves. Immediately following drainage of flushed lines, the piping shall be air dried with compressed air.
B. Air and gas piping shall be blown clean of loose debris with compressed air.
3.13 CORROSION PROTECTION OF ATMOSPHERIC EXPOSED PIPING ACCESSORIES
A. All atmospheric exposed surfaces of black and hot-dip galvanized steel, brass, copper and bronze piping components shall be painted in accordance with Section 09900, System No. 5 or System No. 6 as described in the Paint Application Schedule.
B. Pipe support systems, except galvanized or stainless steel components, shall be painted in accordance with Section 09900, System No. 5.
3.14 CORROSION PROTECTION FOR CARBON STEEL PIPE
A. Exterior Coating For Exposed, Steel Pipe, Including Galvanized Pipe: Shop prime and finish coats in accordance with Section 09900, System No. 5 or System No. 6 as required. For insulated piping, paint shall be applied before installation of insulation.
B. Interior Lining: Carbon steel piping that is to be lined with coal-tar epoxy, as noted in the Piping Schedule shown on the Drawings, shall be as specified in Section 09900, System No. 2. Carbon steel piping that is to be cement-lined as noted on the Piping Schedule shall be in accordance with AWWA C205. Lining shall be applied by the pipe supplier.
C. Exterior Protection For Buried, Submerged or Embedded Pipe and for all Hydrants:
1. Buried steel shall be coated by hand taping with pipe tape. The pipe surface shall be solvent cleaned, SSPC-SP 1, and wire brushed, SSPC-SP 3, to remove all dirt and loose rust and mill scale, and immediately primed with the tape manufacturer's recommendations. The tape shall be spirally applied to the pipe with a 50 percent overlap minimum after the primer has thoroughly dried. Joints shall be tape wrapped or heat shrink-wrapped. Joints shall be completed above grade or a sufficient size bell hole excavated to permit joint wrapping without contamination. Tape wrapping and heat shrink-wrap are specified under PRODUCTS.
D. Exterior Protection for Buried or Submerged Piping Accessories: Exterior protection shall be in accordance with Section 09900, System No. 2.
3.15 CORROSION PROTECTION FOR COPPER PIPING
A. For Atmospheric Exposed Copper Pipe: Copper piping shall be painted in accordance with Section 09900, System No. 5 or System No. 6. Paint shall be applied before installation of insulation.
B. Exterior Coating For Buried Copper Pipe: All buried copper pipe shall be coated by hand taping with pipe tape. The pipe surface shall be solvent cleaned, SSPC-SP 1, and wire brushed, SSPC-SP 3, to remove all dirt and loose rust and mill scale, and immediately primed with the tape manufacturer's recommended primer in accordance with the manufacturer's recommendations. The tape shall be spirally applied to the pipe with a 50 percent overlap minimum after the primer has thoroughly dried. Joints shall be completed above grade or a sufficient size bell hole excavated to permit joint wrapping
without contamination. Tape wrapping and heat shrink-wrap are specified under PRODUCTS.
3.16 CORROSION PROTECTION FOR DUCTILE IRON AND CAST IRON SOIL PIPE
A. For Atmospherically Exposed Ductile Iron: Exterior protection shall be in accordance with Section 09900, System No. 5 or System No. 6 as described in the Paint Application Schedule. NOTE: Ductile iron pipe for interior use shall be provided by the Mechanical Contractor without asphaltic or bitumastic exterior coatings. This requirement applies to all ductile iron pipe except buried pipe.
B. Cement Linings: As specified in the Detail Piping Specification.
C. Exterior Protection For Buried Pipe: Buried ductile iron piping shall be wrapped with polyethylene bagging, 8 mils minimum thickness, manufactured in accordance with the latest edition of ASTM D 1248, Type I, Class C, Grade E1 and installed in accordance with ANSI A21.5/AWWA C105 and the manufacturer's recommendations.
3.17 PIPE PAINTING AND IDENTIFICATION
A. Painting of piping systems shall be as specified in Section 09900, and in accordance with the Piping Schedule.
B. Mechanical pipe identification shall be as specified in Section 15190.
END OF SECTION
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