Loading...
HomeMy WebLinkAboutCity of Russian Mission Heat Recovery Project 65% Submittal - Feb 2016 - REF Grant 705084465% SUBMITTAL PROJECT MANUAL For CITY OF RUSSIAN MISSION HEAT RECOVERY PROJECT OWNER: City of Russian Mission P.O. Box 49 Russian Mission, Alaska 99657 ENGINEER: CRW Engineering Group, LLC 3940 Arctic Boulevard, Suite 300 Anchorage, Alaska 99503 February 26, 2016 City of Russian Mission Heat Recovery Project 65% SUBMITTAL 000110 - 1 INDEX TO CONTRACT DOCUMENTS SECTION 00 01 10 INDEX TO CONTRACT DOCUMENTS SECTION TITLE PAGES DIVISION 00 and 01 PROCUREMENT & CONTRACT INFORMATION To be provided by ANTHC Contracting Department DIVISON 33 UTILITIES 33 07 00 Insulated Pipe and Fittings 18 ***See Drawings for Additional Civil, Mechanical and Electrical sheet specifications*** ATTACHMENTS DRAWINGS (under separate cover) City of Russian Mission Heat Recovery Upgrades February 2016 XX DIVISION 33 UTILITIES City of Russian Mission Heat Recovery Project 65% SUBMITTAL 330700 - 1 INSULATED PIPE AND FITTINGS SECTION 33 07 00 INSULATED PIPE AND FITTINGS This specification is based upon the standard Technical Specifications for Insulated Pressure Pipe and Fittings produced by the State of Alaska, Alaska Native Tribal Health Consortium (ANTHC) and Village Safe Water Program (VSW) as revised on January 10, 2006. Modifications to the standard specification have been made for this project. PART 1 - GENERAL 1.1 The Contractor shall supply insulated pipe and fittings for use in hydronic applications. The minimum service temperature range of all individual components and final products shall be -60 to 100°F unless otherwise specified. All pipe and fittings shall be capable of withstanding the cyclic freezing of water under its rated service pressure without breaks, leaks, gross deformities or impaired service characteristics. The pipe and fittings shall consist of an Aquatherm® Blue Pipe® MF® core pipe insulated with polyurethane insulation and protected with an outer jacket of either 16-gauge aluminum pipe, as specified in the Drawings. 1.2 REFERENCES A. The following specifications are referenced in this document and shall be considered integral to this specification: ASTM C177 Thermal transmission (guarded hot-plate apparatus) ASTM C273 Shear properties of sandwich-core materials ASTM C518 Thermal transmission (heat flow meter apparatus) ASTM D1599 Resistance to short-time hydraulic failure pressure of plastic pipe, tubing, and fittings ASTM D1621 Compressive properties of rigid cellular plastics ASTM D1622 Apparent density of rigid cellular plastics ASTM D2126 Response of rigid cellular plastics to thermal humid aging (thermal dimensional stability) ASTM D2657 Heat Joining Polyolefin Pipe and Fittings ASTM D2837 Obtaining pressure design basis for thermoplastic pipe products ASTM D2842 Water absorption of rigid cellular plastics ASTM E96 Water vapor transmission of rigid cellular plastics ASTM E398 Water vapor transmission rate of sheet materials (dynamic relative humidity measurement) ASTM F2389 Standard Specification for Pressure-rated Polypropylene (PP) Piping Systems CSA B137.11 Polypropylene (PP-R) Pipe and Fittings for Pressure Applications NSF/ANSI 14 Plastic Piping System Components and Related Materials B. Unless otherwise noted herein or on the drawings, all fittings shall be constructed utilizing core pipe of the same material, resin, and dimensions as that used for the core pipe of the straight lengths. All insulated pipe, unless otherwise noted, should be supplied in continuous 39-foot lengths. City of Russian Mission Heat Recovery Project 65% SUBMITTAL 330700 - 2 INSULATED PIPE AND FITTINGS 1.3 SUBMITTALS A. The Contractor shall furnish to the Engineer for approval one (1) electronic copy of the submittals indicated below. No work shall commence on any item until the required shop drawing submittals have been approved. The submittals shall include: 1. Prod be incorporated in the work. 2. Shop Drawings: Submit dimensionally correct (scaled) shop drawings for all items to be fabricated prior to beginning fabrication. 3. Fabrication Procedures: Submit a written description of the methods/procedures to be used in fabricating the pipe and fitting. 4. Training Certifications: Provide documentation that personnel responsible for fusing Aquatherm pipe have been certified in appropriate fusion techniques. 5. Inspections and Testing of Pipe and Fittings: a) Submit proposed hydrostatic testing procedure for review and approval before any testing is undertaken. b) Submit results of foam density tests on daily basis for all specified inspections and testing of pipe and fittings. 6. Quality Assurance program in accordance with 1.4. 7. Laboratory Testing Results: a) K-factor testing of insulation. b) Core pipe/insulation bond c) Density of insulation d) Testing frequency shall be a minimum of one set of tests per 400 linear feet of pipe. City of Russian Mission Heat Recovery Project 65% SUBMITTAL 330700 - 3 INSULATED PIPE AND FITTINGS 1.4 QUALITY ASSURANCE A. The manufacturer shall be experienced and regularly engaged in the production of pre-insulated piping systems. The manufacturer shall understand the system design and its intent and shall produce components suitable to accomplish that intent. Any deficiencies in the Drawings or these Specifications which may jeopardize the performance of the system shall be brought to the immediate attention of the Engineer, prior to submittal of product description and information for acceptance, whenever possible. B. Engineer shall have open access to the fabrication facility and any sub-tier suppliers to assure conformance with the Specifications and quality of workmanship. C. The Contractor shall submit to the Engineer for approval a Quality Assurance program which incorporates as a minimum the following: 1. A description of the method of manufacture. 2. Shop Drawings (for review). D. The Contractor shall implement the Quality Assurance program to assure compliance with all requirements of this Specification. E. A record of all tests which were performed shall be provided to the Engineer as required. (As a minimum, all test reports shall be submitted to the Engineer upon completion of work). F. Where a method of testing has not been specified, the Contractor shall submit detailed test procedures for approval by the Engineer. G. Any deficiency found in a stick of pipe shall be cause for rejection of the entire stick of pipe. All rejected pipe shall be replaced by the Contractor at no additional cost to the Owner. H. All insulated pipe and fittings supplied under this specification shall utilize the same manufacturer of core pipe. Contractor shall identify the core pipe manufacturer with his submittal. PART 2 - PRODUCTS 2.1 PIPE AND PIPING PRODUCTS A. Pipe shall be manufactured from a PR-R resin (Fusiolen) meeting the short-term properties and long-term strength requirements of ASTM F 2389 or CSA B137.11. The pipe shall contain no rework or recycled n plant from resin of the same specification from the same raw material. All pipe shall be made in an extrusion process. Hydronic hot water and heating piping shall contain a fiber layer (FASER) to restrict thermal expansion. All pipe shall comply with the rated pressure requirements of ASTM F 2389 or CSA B137.11. All pipe shall be certified by NSF International as complying with NSF 14, and ASTM F 2389 or CSA B137.11. B. Pipe shall be Aquatherm® Blue Pipe® MF®, available from Aquatherm, NA. 2.2 FITTINGS City of Russian Mission Heat Recovery Project 65% SUBMITTAL 330700 - 4 INSULATED PIPE AND FITTINGS A. Fittings shall be manufactured from a PP-R resin (Fusiolen)meeting the short-term properties and long-term strength requirements of ASTM F2389. The Fittings shall contain no rework or recycled materials except from resin of the same specification from the same raw material. All fittings shall be certified by NSF International as complying with NSF 14, and ASTM F 2389 or CSA B137.11. B. Fittings shall be Aquatherm® Blue Pipe® MF®, available from Aquatherm, NA. 2.3 WARRANTY A. Manufacturer shall warrant pipe and fittings for 10 years to be free of defects in materials or manufacturing. B. Warranty shall cover labor and material costs of repairing and/or replacing defective materials and repairing any incidental damage caused by failure of the piping system due to defects in materials or manufacturing. C. Warranty shall be in effect only upon submission by the contractor to the manufacturer valid pressure/leak test documentation indicating that the system was tested and pass pressure/leak test. 2.4 FUSION A. All fusion of Aquatherm pipe shall be socket fusion. If socket fusion is not feasible due to space constraints at specific joints, Contractor shall request authorization from the Engineer to allow for electrofustion couplings to be used. B. All fusion- product standards. C. Fusion-weld tooling and welding machines shall be as specified by the pipe and fittings manufacturer. D. Prior to joining, the pipe and fittings shall be prepared in accordance with ASTM F 2389 and the E. Joint preparation, setting and alignment, fusion process, cooling times and working pressure shall be in acco 2.5 INSULATION A. Insulation between core pipe and outer jacket of all pipe and fittings shall be low-density rigid closed-cell urethane insulation with a nominal thickness as shown on the drawings. It shall be applied and cured in strict accordance with the manufacturer's recommendations and good commercial practices such that the resulting insulation completely fills the annular space between core pipe and outer jacket and is free of defects affecting its intended purpose. B. Urethane insulation shall exhibit the following properties and characteristics specified by the referenced ASTM tests below. City of Russian Mission Heat Recovery Project 65% SUBMITTAL 330700 - 5 INSULATED PIPE AND FITTINGS ASTM C518 or C177 Maximum K-factor, as produced 0.15 btu-in/hr-ft 2-°F ASTM D1622 Core Density Range 3.0 to 4.0 lbs/ft3 ASTM D1621 Minimum Compressive Strength 35 psi (parallel and perpendicular to pipe axis) ASTM D2842 Maximum Water Absorption 0.05 lb/ft3 ASTM D2126 Dimensional Stability 1% at -20°F (Maximum Linear Change) 3% at +100°F C. Exposed urethane insulation faces at pipe and fitting ends shall be coated to protect against physical abuse, UV exposure during shipping and storage, and against water intrusion in service. The coating shall be suitable for direct application over urethane insulation with no deleterious effects to the insulation or coating. The coating shall be formulated for long-term service and retained flexibility over extended periods of exposure to sunlight, harsh weather, and saltwater spray. The strength of the adhesive bond of the coating to the insulation shall be greater than the tensile strength of the coating. In the event the coating is nicked or an edge is rolled up in handling, the coating that has been dislodged shall tear free from the coating still adhering to the insulation rather than pull the balance of the coating off as a sheet. D. The coating shall be applied and cured in strict accordance with the manufacturer's recommendations and good commercial practice such that the finished product is free of defects affecting its intended purpose. E. The coating material shall exhibit the following properties and characteristics: ASTM E398 or E96 Maximum Water Vapor Permeance 1.0 perm Dry Film Thickness Range: 15 to 63 mils 2.6 METAL OUTER JACKET A. Metal outer jackets for pipe and fittings shall be constructed of 16-gauge internal helical lock-seam corrugated aluminum pipe with a nominal diameter as shown on the drawings. Aluminum alloy material shall be 3004-H34 with a 7072 coating on the outside of the jacket or 5052-H32. All helical seams shall be continuous, tightly locked and folded. The outer jacket of all pipe and fittings shall be watertight under a five-foot head of water. B. The outer jacket corrugations shall be between 3/16-inch and 3/8-inch deep as measured from the flat area between corrugations to the bottom of the corrugation on the outside of the jacket and shall be spaced no more than 2 2/3-inches apart and formed diagonally around the pipe, resulting in not less than 2 nor more than 10 complete corrugat -section. C. The nominal diameter shall be the inside diameter as measured between the innermost portion of the corrugations, with a dimensional tolerance of + D. All joints in the aluminum outer jacket fabricated around fittings shall be welded with a continuous bead, resulting in a finished jacket that is watertight per the requirements of section 2.3A. E. The Contractor shall provide company name and production date (month and year) on the outer jacket of each pipe and fitting. Information shall be engraved on aluminum jackets with 1/8-inch to ¼-inch high City of Russian Mission Heat Recovery Project 65% SUBMITTAL 330700 - 6 INSULATED PIPE AND FITTINGS F. All surfaces of the outer jacket, including end-cuts and welds, shall be finished such that no jagged edges exist that could cause personal injury. G. The interior of the jacket shall be free of oils, grease, or other residue that could interfere with the adhesion of insulation to the outer jacket. 2.7 JOINT KITS A. Joint kits shall consist of an aluminum metal band and associated hardware as shown in the drawings with 2- part foam mixing chemicals in sufficient quantity to field pour polyurethane foam within the aluminum band. B. Field Poured Polyurethane Foam: 1. Two part foam mixing chemicals shall be provided and shipped in separate containers of 50 gallons or less each. 2. Contractor shall provide foam mixing chemicals in quantities sufficient for 110% of joint kits as specified in the Bid Schedule(s). Basis for calculation of chemical quantity shall be provided to Engineer for acceptance. 3. Contractor shall provide 750mL containers for use in Contractor provided pneumatically driven foam dispensing gun. Chemicals shall be combined in a disposable mixer element immediately prior to application. 2.8 MANUFACTURING AND DIMENSIONAL TOLERANCES A. Allowable offset of the centerline of the outer jacket and core pipe shall be not more than 1/4-inch at the pipe ends. Elsewhere along pipe lengths the centerline offset shall not be greater than 3/8-inch. B. The minimum temperature of all components used to manufacture pipe and fittings shall be 50 °F at the start of fabrication. The fabricated pipe shall be placed in a facility maintained at a temperature of 50 °F or greater for a minimum of 12 hours after fabrication. C. All elbows shall have a bend radius as specified in the drawings with a tolerance of + 2 degrees without reversion. All elbows must maintain normal outside diameters along their entire length without tolerance as per ASTM-F714. D. All branches of fabricated fittings must lie in a single plane with a maximum deviation of + 2 degrees. E. The length of core pipe protruding from the insulation on the ends shall be 12 inches + 1/4 -inch. The core pipe ends shall be smooth and oriented perpendicularly to the core pipe longitudinal axis + 1/8-inch. F. The outer jacket shall be cut in one pass perpendicular to the length of the jacket + 1 degree. The insulation profile of the coated ends shall not exceed a relief deviance of + 1/4-inch across the face. 2.9 FABRICATED FITTINGS A. All fusion joints used in fabricated fittings shall be documented by a computer that records pressure and temperature applied at each fused joint. Computer printouts and electronic data for each fitting shall be made available to the Engineer upon request. The Contractor shall ensure that each joint is fused at the City of Russian Mission Heat Recovery Project 65% SUBMITTAL 330700 - 7 INSULATED PIPE AND FITTINGS temperature and pressure recommended by the pipe manufacturer in order to achieve the maximum pressure rating for that joint. B. All fittings for each project shall be labeled with a unique identifier that corresponds with the fusion computer printouts for each fitting. 2.10 INSULATING A. All Federal and State regulations applicable to the type of insulation and its use shall be strictly adhered to. B. Insulation shall be placed into the pipe by a single injection application. Fittings may be manufactured using one insulation injection for each open end of the fitting. In no case shall the jacket be drilled to perform, monitor, or inspect the injection. C. The maximum allowable void size is 0.05 in3 -inch cube is .05 in3). D. Insulation and chemicals shall be prevented from coming in contact with the end or inside of the exposed core pipe. 2.11 CORE PIPE/INSULATION BOND A. Core pipe and fittings shall be bonded to the insulation with a minimum shear bond strength of 15 psi, or in such a manner as to produce insulation-to-insulation separation when a sample is tested in shear. B. The core pipe surface preparation will be performed in a manner that does not leave foreign material imbedded in the plastic. Gouges or scratches in the pipe surface that exceed the tolerance specified by the pipe manufacturer for the pipe pressure rating shall be cause for rejection. 2.12 PRODUCTION TESTING AND INSPECTION A. Only finished pipe lengths and fittings that meet the requirements of these specifications and drawings shall be used for destructive testing. Should any product fail to meet the visual quality control specifications listed below, that product shall be either re-built to meet the specifications or rejected. Only those products that meet all visual quality control specifications shall be considered final products suitable for receipt by the Owner or for laboratory or other destructive testing. 1. VISUAL QUALITY CONTROL: a. FUSION JOINTS: All fusion joints on elbow and fitting extensions shall be examined before the core pipe assembly is installed into the outer jacket. Elbow and fitting extension fusion joints shall meet all the requirements of the pipe manufacturer and the following minimum requirements: 1) On both sides, the double bead shall be rolled over to the surface and be uniformly rounded and consistent in size throughout the entire circumference of the joint. 2) The gap between the two beads must not be below the fusion surface throughout the entire circumference of the joint. City of Russian Mission Heat Recovery Project 65% SUBMITTAL 330700 - 8 INSULATED PIPE AND FITTINGS 3) The displacement (perpendicular to the pipe centerline) between the fused ends must not exceed 10% of the pipe minimum wall thickness. 4) The width of the combined two beads for SDR 11 pipe shall be as follows: Pipe Dia. Minimum Bead Width Maximum Bead Width 3/16-inch 5/16-inch 9/32-inch 3/8-inch 5/16-inch 7/16-inch 3/8-inch 9/16-inch 1/2-inch 11/16-inch 5) Both beads of each fusion joint shall be of a uniform size and shape. The ratio of the difference in individual bead widths divided by the total width of both beads shall not exceed 10%. b. DIMENSIONAL TOLERANCE: Each length of pipe and each fitting will be examined by the Contractor for off-set tolerances, insulation cut-back distances, exposed insulation face alignment and relief profile, and alignment and smoothness of core pipe ends. c. INSULATION INTEGRITY: Completed pipe and fitting ends shall be inspected for voids in excess of 0.05 in3 or discontinuities by the Contractor prior to coating. Any glazing left on the uncoated pipe end from the forms used during the insulating operation shall be removed before coating. d. AQUATHERM CARRIER PIPE: The surface of the AQUATHERM carrier pipe shall be free of nicks, cuts, or gouges as outlined in Section 2.1 of this document. 2. LABORATORY TESTING a. All completed arctic pipe fittings shall be pressure tested to a test pressure of 150 psi, in accordance with published Aquatherm test procedures (see attached documention). Failure of fittings to maintain pressure during test shall be cause for rejection of fittings. Documentation of testing shall be forwarded to Engineer for review. b. Laboratory testing as identified in section 2.2B shall be conducted to verify the quality of the finished product. The density and K-factor shall be measured on insulation specimens of the appropriate size and under the specified conditions as set forth in the applicable ASTM test. Insulation specimens shall be retrieved by cutting a 12-inch section of insulated pipe from a production sample. The remaining length shall be trimmed to the dimensional tolerances of this specification to allow Owner use of that pipe section. c. Should the Contractor choose to test the "K" factor as outlined in ASTM C518, the testing apparatus shall be calibrated within 24 hours of the test using a calibration standard certified accurate by the National Bureau of Standards (NBS). The "K" factor test sample shall be removed from the insulated pipe, prepared for testing, and left open to the atmosphere at 70°F for a minimum of 24 hours prior to testing. c. In addition to the testing identified in section 2.2B, the following tests shall be performed to verify the quality of the finished product: City of Russian Mission Heat Recovery Project 65% SUBMITTAL 330700 - 9 INSULATED PIPE AND FITTINGS 1) Core pipe/insulation bond: a) Two 6-inch lengths of cured insulated pipe shall be cut from one uncoated insulation face end of completed pipe length. The remaining length shall be trimmed according to the dimensional tolerances of this specification and coated to allow Owner use of that pipe section. b) One specimen shall be tested at +70°F. The other specimen shall be brought to -60°F in 4 hours or less, and remain there for at least 24 hours before testing. Acceptance will be indicated by a minimum shear bond strength of 15 psi and insulation-to-insulation (or insulation-to-insulation pipe surface film) separation or tearing. 2.13 FINAL INSPECTION A. After completion of the quantity of pipe and fittings contracted for, the Owner may perform a final inspection at the fabrication point, prior to the pipe and fittings being prepared for shipment . The Contractor must provide one (1) week notice prior to the completion of the order to allow for travel arrangements to be made to point of fabrication. The certified results of all required laboratory tests made during production by the Contractor shall be made available in report form at this time. PART 3 - EXECUTION 3.1 CORE PIPE FUSION A. All fusion of Aquatherm pipe shall be socket fusion. If socket fusion is not feasible due to space constraints at specific joints, Contractor shall request authorization from the Engineer to allow for electrofustion couplings to be used. B. All fusion-d product standards. C. Fusion-weld tooling and welding machines shall be as specified by the pipe and fittings manufacturer. D. Prior to joining, the pipe and fittings shall be prepared in accordance with ASTM F 2389 and the E. Joint preparation, setting and alignment, fusion process, cooling times and working pressure shall be in 3.2 JOINT INSULATION KITS A. Construct all piping before installing joint insulation kits. B. Joint insulation kits shall only be installed on piping that has passed hydrostatic pressure test. C. Apply release agent to inside of removable coupling bands prior to application of foam. City of Russian Mission Heat Recovery Project 65% SUBMITTAL 330700 - 10 INSULATED PIPE AND FITTINGS D. Inject 2-part foam insulation in liquid form through one hole in top of aluminum coupling band. E. Remove band and inspect foam insulation at joint for void space. a. Fill small voids (less than 2-inches in diameter) with spray foam insulation, DOW Great Stuff, or equal. b. Fill large voids (greater than 2-inches in diameter) by re-installing aluminum joint kit band and injecting additional foam insulation. Cut out cured foam as necessary to apply new foam to void area. c. Remove aluminum band and re-inspect foam. Repeat above steps if required. F. Install permanent aluminum joint kit band. 3.3 PRESSURE TESTING A. After all fusion is complete, all Aquatherm pipe shall be tested as a complete system in accordance with Aquatherm standard pressure testing procedure requirements (attached for reference). Standard Aquatherm testing shall be adhered to ensure full warranty coverage of the system. Submit all pressure testing forms to Engineer for review. END OF SECTION