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SOF SUSTAINMENT TRAINING COMPLEX 14P1391 STONE BAY, CAMP LEJEUNE, NC EPROJECTS W.O. NO: 1294037 SECTION 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS 08/10 PART 1 GENERAL 1.1 REFERENCES The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA) AMCA 201 (2002; R 2011) Fans and Systems AMCA 210 (2007) Laboratory Methods of Testing Fans for Aerodynamic Performance Rating AMCA 300 (2008) Reverberant Room Method for Sound Testing of Fans AMCA 301 (2006; INT 2007) Methods for Calculating Fan Sound Ratings from Laboratory Test Data AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI) AHRI 260 (2011) Sound Rating of Ducted Air Moving and Conditioning Equipment AHRI 410 (2001; Addendum 1 2002; Addendum 2 2005; Addendum 3 2011) Forced-Circulation Air-Cooling and Air-Heating Coils AHRI 430 (2009) Central-Station Air-Handling Units AHRI Guideline D (1996) Application and Installation of Central Station Air-Handling Units ANSI/AHRI 1060 (2005) Performance Rating of Air-to-Air Heat Exchangers for Energy Recovery Ventilation Heat Equipment AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA) ABMA 11 (1990; R 2008) Load Ratings and Fatigue Life for Roller Bearings ABMA 9 (1990; R 2008) Load Ratings and Fatigue Life for Ball Bearings AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) ANSI S12.54 (2011) Determination of Sound Power Levels and Sound Energy Levels of Noise Sources using Sound Pressure SECTION 23 00 00 Page 1

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Page 1: P-1391 SOF SUSTAINMENT TRAINING COMPLEX

SOF SUSTAINMENT TRAINING COMPLEX 14P1391STONE BAY, CAMP LEJEUNE, NC EPROJECTS W.O. NO: 1294037

SECTION 23 00 00

AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS08/10

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA)

AMCA 201 (2002; R 2011) Fans and Systems

AMCA 210 (2007) Laboratory Methods of Testing Fans for Aerodynamic Performance Rating

AMCA 300 (2008) Reverberant Room Method for Sound Testing of Fans

AMCA 301 (2006; INT 2007) Methods for Calculating Fan Sound Ratings from Laboratory Test Data

AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI)

AHRI 260 (2011) Sound Rating of Ducted Air Moving and Conditioning Equipment

AHRI 410 (2001; Addendum 1 2002; Addendum 2 2005; Addendum 3 2011) Forced-Circulation Air-Cooling and Air-Heating Coils

AHRI 430 (2009) Central-Station Air-Handling Units

AHRI Guideline D (1996) Application and Installation of Central Station Air-Handling Units

ANSI/AHRI 1060 (2005) Performance Rating of Air-to-Air Heat Exchangers for Energy Recovery Ventilation Heat Equipment

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 11 (1990; R 2008) Load Ratings and Fatigue Life for Roller Bearings

ABMA 9 (1990; R 2008) Load Ratings and Fatigue Life for Ball Bearings

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI S12.54 (2011) Determination of Sound Power Levels and Sound Energy Levels of Noise Sources using Sound Pressure

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AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)

ASHRAE 52.2 (2012; Errata 2013) Method of Testing General Ventilation Air-Cleaning Devices for Removal Efficiency by Particle Size

ASHRAE 62.1 (2010; Errata 2011; INT 3 2012; INT 4 2012; INT 5 2013) Ventilation for Acceptable Indoor Air Quality

ASHRAE 68 (1997) Laboratory Method of Testing to Determine the Sound Power In a Duct

ASHRAE 70 (2006; R 2011) Method of Testing for Rating the Performance of Air Outlets and Inlets

ASME INTERNATIONAL (ASME)

ASME A13.1 (2007; R 2013) Scheme for the Identification of Piping Systems

ASTM INTERNATIONAL (ASTM)

ASTM A 249/A 249M (2008) Standard Specification for Welded Austenitic Steel Boiler, Superheater, Heat-Exchanger, and Condenser Tubes

ASTM A123/A123M (2012) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A167 (1999; R 2009) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A924/A924M (2010a) Standard Specification for General Requirements for Steel Sheet, Metallic-Coated by the Hot-Dip Process

ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM B766 (1986; R 2008) Standard Specification for Electrodeposited Coatings of Cadmium

ASTM C1071 (2012) Standard Specification for Fibrous Glass Duct Lining Insulation (Thermal and Sound Absorbing Material)

ASTM C553 (2011) Standard Specification for Mineral Fiber Blanket Thermal Insulation for

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Commercial and Industrial Applications

ASTM D1654 (2008) Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments

ASTM D3359 (2009; E 2010; R 2010) Measuring Adhesion by Tape Test

ASTM D520 (2000; R 2011) Zinc Dust Pigment

ASTM E2016 (2011) Standard Specification for Industrial Woven Wire Cloth

CANADIAN STANDARDS ASSOCIATION (CSA)

CSA C22.2 (2011) Safety Requirements for Electrical Equipment

INSTITUTE OF ENVIRONMENTAL SCIENCES AND TECHNOLOGY (IEST)

IEST RP-CC-001 (2009) HEPA and ULPA Filters

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2011; Errata 2012) Motors and Generators

NEMA MG 10 (2001; R 2007) Energy Management Guide for Selection and Use of Fixed Frequency Medium AC Squirrel-Cage Polyphase Induction Motors

NEMA MG 11 (1977; R 2012) Energy Management Guide for Selection and Use of Single Phase Motors

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 701 (2010) Standard Methods of Fire Tests for Flame Propagation of Textiles and Films

NFPA 90A (2012) Standard for the Installation of Air Conditioning and Ventilating Systems

SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)

SMACNA 1819 (2002) Fire, Smoke and Radiation Damper Installation Guide for HVAC Systems, 5th Edition

SMACNA 1884 (2003) Fibrous Glass Duct Construction Standards, 7th Edition

SMACNA 1966 (2005) HVAC Duct Construction Standards Metal and Flexible, 3rd Edition

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

40 CFR 82 Protection of Stratospheric Ozone

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UNDERWRITERS LABORATORIES (UL)

UL 181 (2005; Reprint Oct 2008) Factory-Made Air Ducts and Air Connectors

UL 1995 (2011) Heating and Cooling Equipment

UL 507 (1999; R 2001 thru 2007) Standard for Electric Fans

UL 555 (2006; Reprint May 2012) Standard for Fire Dampers

UL 586 (2009) Standard for High-Efficiency Particulate, Air Filter Units

UL 6 (2007; reprint Nov 2010) Electrical Rigid Metal Conduit-Steel

UL 705 (2004; Reprint Mar 2012) Standard for Power Ventilators

UL 900 (2004; Reprint Feb 2012) Standard for Air Filter Units

UL Bld Mat Dir (2012) Building Materials Directory

UL Electrical Constructn (2012) Electrical Construction Equipment Directory

UL Fire Resistance (2012) Fire Resistance Directory

1.2 SYSTEM DESCRIPTION

Furnish ductwork, piping offsets, fittings, and accessories as required to provide a complete installation. Coordinate the work of the different trades to avoid interference between piping, equipment, structural, and electrical work. Provide complete, in place, all necessary offsets in piping and ductwork, and all fittings, and other components, required to install the work as indicated and specified.

1.2.1 Mechanical Equipment Identification

The number of charts and diagrams shall be equal to or greater than the number of mechanical equipment rooms. Where more than one chart or diagram per space is required, mount these in edge pivoted, swinging leaf, extruded aluminum frame holders which open to 170 degrees.

1.2.1.1 Charts

Provide chart listing of equipment by designation numbers and capacities such as flow rates, pressure and temperature differences, heating and cooling capacities, horsepower, pipe sizes, and voltage and current characteristics.

1.2.2 Service Labeling

Label equipment, including fans, air handlers, terminal units, etc. with

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labels made of self-sticking, plastic film designed for permanent installation. Labels shall be in accordance with the typical examples below:

SERVICE LABEL AND TAG DESIGNATION

Air handling Unit Number AHU - _____

Controls CONTROL

Exhaust Fan Number EF - _____

Fan Coil Unit Number FCU - _____

Condensing Unit Number CU - _____

Rooftop Unit Number RTU - _____

Identify similar services with different temperatures or pressures. Where pressures could exceed 125 pounds per square inch, gage, include the maximum system pressure in the label. Label and arrow piping in accordance with the following:

a. Each point of entry and exit of pipe passing through walls.

b. Each change in direction, i.e., elbows, tees.

c. In congested or hidden areas and at all access panels at each point required to clarify service or indicated hazard.

d. In long straight runs, locate labels at distances within eyesight of each other not to exceed 75 feet. All labels shall be visible and legible from the primary service and operating area.

For Bare or Insulated Pipes

for Outside Diameters of Lettering

1/2 thru 1-3/8 inch 1/2 inch

1-1/2 thru 2-3/8 inch 3/4 inch

2-1/2 inch and larger 1-1/4 inch

1.2.3 Color Coding

Color coding of all piping systems shall be in accordance with ASME A13.1.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

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Detail Drawings; G

SD-03 Product Data

Metallic Flexible DuctInsulated Nonmetallic Flexible Duct RunoutsDuct ConnectorsDuct Access Doors; GFire Dampers; GManual Balancing Dampers; GDiffusersRegistersCentrifugal FansIn-Line Centrifugal FansPanel Type Power Wall VentilatorsPropeller Type Ceiling FansCeiling Exhaust FansAir Handling Units; GEnergy Recovery Devices; GTest Procedures

SD-06 Test Reports

Performance Tests; GDamper Acceptance Test; G

SD-08 Manufacturer's Instructions

Manufacturer's Installation InstructionsOperation and Maintenance Training

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals

Manual Balancing Dampers; GCentrifugal Fans; GIn-Line Centrifugal Fans; GPanel Type Power Wall Ventilators; GPropeller Type Ceiling Fans; GCeiling Exhaust Fans; GAir Handling Units; GEnergy Recovery Devices; G

1.4 QUALITY ASSURANCE

Except as otherwise specified, approval of materials and equipment is based on manufacturer's published data.

a. Where materials and equipment are specified to conform to the standards of the Underwriters Laboratories, the label of or listing with reexamination in UL Bld Mat Dir, and UL 6 is acceptable as sufficient evidence that the items conform to Underwriters Laboratories requirements. In lieu of such label or listing, submit a written certificate from any nationally recognized testing agency, adequately equipped and competent to perform such services, stating that the items have been tested and that the units conform to the specified requirements. Outline methods of testing used by the specified

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agencies.

b. Where materials or equipment are specified to be constructed or tested, or both, in accordance with the standards of the ASTM International (ASTM), the ASME International (ASME), or other standards, a manufacturer's certificate of compliance of each item is acceptable as proof of compliance.

c. Conformance to such agency requirements does not relieve the item from compliance with other requirements of these specifications.

1.4.1 Prevention of Corrosion

Protect metallic materials against corrosion. Manufacturer shall provide rust-inhibiting treatment and standard finish for the equipment enclosures. Do not use aluminum in contact with earth, and where connected to dissimilar metal. Protect aluminum by approved fittings, barrier material, or treatment. Ferrous parts such as anchors, bolts, braces, boxes, bodies, clamps, fittings, guards, nuts, pins, rods, shims, thimbles, washers, and miscellaneous parts not of corrosion-resistant steel or nonferrous materials shall be hot-dip galvanized in accordance with ASTM A123/A123M for exterior locations and cadmium-plated in conformance with ASTM B766 for interior locations.

1.4.2 Asbestos Prohibition

Do not use asbestos and asbestos-containing products.

1.4.3 Ozone Depleting Substances Used as Refrigerants

Minimize releases of Ozone Depleting Substances (ODS) during repair, maintenance, servicing or disposal of appliances containing ODS's by complying with all applicable sections of 40 CFR 82 Part 82 Subpart F. Any person conducting repair, maintenance, servicing or disposal of appliances owned by NASA shall comply with the following:

a. Do not knowingly vent or otherwise release into the environment, Class I or Class II substances used as a refrigerant.

b. Do not open appliances without meeting the requirements of 40 CFR 82 Part 82.156 Subpart F, regarding required practices for evacuation and collection of refrigerant, and 40 CFR 82 Part 82.158 Subpart F, regarding standards of recycling and recovery equipment.

c. Only persons who comply with 40 CFR 82 Part 82.161 Subpart F, regarding technician certification, can conduct work on appliances containing refrigerant.

In addition, provide copies of all applicable certifications to the Contracting Officer at least 14 calendar days prior to initiating maintenance, repair, servicing, dismantling or disposal of appliances, including:

a. Proof of Technician Certification

b. Proof of Equipment Certification for recovery or recycling equipment.

c. Proof of availability of certified recovery or recycling equipment.

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1.4.4 Use of Ozone Depleting Substances, Other than Refrigerants

The use of Class I or Class II ODS's listed as nonessential in 40 CFR 82 Part 82.66 Subpart C is prohibited. These prohibited materials and uses include:

a. Any plastic party spray streamer or noise horn which is propelled by a chlorofluorocarbon

b. Any cleaning fluid for electronic and photographic equipment which contains a chlorofluorocarbon; including liquid packaging, solvent wipes, solvent sprays, and gas sprays.

c. Any plastic flexible or packaging foam product which is manufactured with or contains a chlorofluorocarbon, including, open cell foam, open cell rigid polyurethane poured foam, closed cell extruded polystyrene sheet foam, closed cell polyethylene foam and closed cell polypropylene foam except for flexible or packaging foam used in coaxial cabling.

d. Any aerosol product or other pressurized dispenser which contains a chlorofluorocarbon, except for those listed in 40 CFR 82 Part 82.66 Subpart C.

Request a waiver if a facility requirement dictates that a prohibited material is necessary to achieve project goals. Submit the waiver request in writing to the Contracting Officer. The waiver will be evaluated and dispositioned.

1.4.5 Detail Drawings

Submit detail drawings showing equipment layout, including assembly and installation details and electrical connection diagrams; ductwork layout showing the location of all supports and hangers, typical hanger details, gauge reinforcement, reinforcement spacing rigidity classification, and static pressure and seal classifications. Include any information required to demonstrate that the system has been coordinated and functions properly as a unit on the drawings and show equipment relationship to other parts of the work, including clearances required for operation and maintenance. Submit drawings showing bolt-setting information, and foundation bolts prior to concrete foundation construction for all equipment indicated or required to have concrete foundations. Submit function designation of the equipment and any other requirements specified throughout this Section with the shop drawings.

1.4.6 Test Procedures

Submit proposed test procedures and test schedules for the ductwork leak test, and performance tests of systems, at least 2 weeks prior to the start of related testing.

1.5 DELIVERY, STORAGE, AND HANDLING

Protect stored equipment at the jobsite from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Additionally, cap or plug all pipes until installed.

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PART 2 PRODUCTS

2.1 STANDARD PRODUCTS

Except for the fabricated duct, plenums and casings specified in paragraphs "Metal Ductwork" and "Plenums and Casings for Field-Fabricated Units", provide components and equipment that are standard products of manufacturers regularly engaged in the manufacturing of products that are of a similar material, design and workmanship. This requirement applies to all equipment, including diffusers, registers, fire dampers, and balancing dampers.

a. Standard products are defined as components and equipment that have been in satisfactory commercial or industrial use in similar applications of similar size for at least two years before bid opening.

b. Prior to this two year period, these standard products shall have been sold on the commercial market using advertisements in manufacturers' catalogs or brochures. These manufacturers' catalogs, or brochures shall have been copyrighted documents or have been identified with a manufacturer's document number.

c. Provide equipment items that are supported by a service organization. Where applicable, provide equipment that is an ENERGY STAR Qualified product or a Federal Energy Management Program (FEMP) designated product.

2.2 IDENTIFICATION PLATES

In addition to standard manufacturer's identification plates, provide engraved laminated phenolic identification plates for each piece of mechanical equipment. Identification plates are to designate the function of the equipment. Submit designation with the shop drawings. Identification plates shall be three layers, black-white-black, engraved to show white letters on black background. Letters shall be upper case. Identification plates 1-1/2-inches high and smaller shall be 1/16-inch thick, with engraved lettering 1/8-inch high; identification plates larger than 1-1/2-inches high shall be 1/8-inch thick, with engraved lettering of suitable height. Identification plates 1-1/2-inches high and larger shall have beveled edges. Install identification plates using a compatible adhesive.

2.3 EQUIPMENT GUARDS AND ACCESS

Fully enclose or guard belts, pulleys, chains, gears, couplings, projecting setscrews, keys, and other rotating parts exposed to personnel contact according to OSHA requirements. Properly guard or cover with insulation of a type specified, high temperature equipment and piping exposed to contact by personnel or where it creates a potential fire hazard. The requirements for catwalks, operating platforms, ladders, and guardrails are specified in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.

2.4 ELECTRICAL WORK

a. Provide motors, controllers, integral disconnects, contactors, and controls with their respective pieces of equipment, except controllers indicated as part of motor control centers. Provide electrical equipment, including motors and wiring, as specified in Section 26 20 00INTERIOR DISTRIBUTION SYSTEM. Provide manual or automatic control and

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protective or signal devices required for the operation specified and control wiring required for controls and devices specified, but not shown. For packaged equipment, include manufacturer provided controllers with the required monitors and timed restart.

b. For single-phase motors, provide high-efficiency type, fractional-horsepower alternating-current motors, including motors that are part of a system, in accordance with NEMA MG 11. Integral size motors shall be the premium efficiency type in accordance with NEMA MG 1.

c. For polyphase motors, provide squirrel-cage medium induction motors, including motors that are part of a system , and that meet the efficiency ratings for premium efficiency motors in accordance with NEMA MG 1. Select premium efficiency polyphase motors in accordance with NEMA MG 10.

d. Provide motors in accordance with NEMA MG 1 and of sufficient size to drive the load at the specified capacity without exceeding the nameplate rating of the motor. Provide motors rated for continuous duty with the enclosure specified. Provide motor duty that allows for maximum frequency start-stop operation and minimum encountered interval between start and stop. Provide motor torque capable of accelerating the connected load within 20 seconds with 80 percent of the rated voltage maintained at motor terminals during one starting period. Provide motor starters complete with thermal overload protection and other necessary appurtenances. Fit motor bearings with grease supply fittings and grease relief to outside of the enclosure.

e. Where two-speed or variable-speed motors are indicated, solid-state variable-speed controllers are allowed to accomplish the same function. Use solid-state variable-speed controllers for motors rated 10 hp or less and adjustable frequency drives for larger motors. Provide variable frequency drives for motors as specified in Section 26 29 23 VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS.

2.5 ANCHOR BOLTS

Provide anchor bolts for equipment placed on concrete equipment pads or on concrete slabs. Bolts to be of the size and number recommended by the equipment manufacturer and located by means of suitable templates. Installation of anchor bolts shall not degrade the surrounding concrete.

2.6 PAINTING

Paint equipment units in accordance with approved equipment manufacturer's standards unless specified otherwise. Field retouch only if approved. Otherwise, return equipment to the factory for refinishing.

2.7 INDOOR AIR QUALITY

Provide equipment and components that comply with the requirements of ASHRAE 62.1 unless more stringent requirements are specified herein.

2.8 DUCT SYSTEMS

2.8.1 Metal Ductwork

Provide metal ductwork construction, including all fittings and components, that complies with SMACNA 1966, as supplemented and modified by this

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specification.

a. Ductwork shall be constructed meeting the requirements for the duct system static pressure specified in APPENDIX D of Section 23 05 93 TESTING, ADJUSTING AND BALANCING FOR HVAC.

b. Provide radius type elbows with a centerline radius of 1.5 times the width or diameter of the duct where space permits. Otherwise, elbows having a minimum radius equal to the width or diameter of the duct or square elbows with factory fabricated turning vanes are allowed.

c. Provide ductwork that meets the requirements of Seal Class A. Provide ductwork in VAV systems upstream of the VAV boxes that meets the requirements of Seal Class A.

d. Provide sealants that conform to fire hazard classification specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS and are suitable for the range of air distribution and ambient temperatures to which it is exposed. Do not use pressure sensitive tape as a sealant.

e. Make spiral lock seam duct, and flat oval with duct sealant and lock with not less than 3 equally spaced drive screws or other approved methods indicated in SMACNA 1966. Apply the sealant to the exposed male part of the fitting collar so that the sealer is on the inside of the joint and fully protected by the metal of the duct fitting. Apply one brush coat of the sealant over the outside of the joint to at least 2 inch band width covering all screw heads and joint gap. Dents in the male portion of the slip fitting collar are not acceptable. Fabricate outdoor air intake ducts and plenums with watertight soldered or brazed joints and seams.

2.8.1.1 Metallic Flexible Duct

a. Provide duct that conforms to UL 181 and NFPA 90A with factory-applied insulation, vapor barrier, and end connections. Provide duct assembly that does not exceed 25 for flame spread and 50 for smoke developed. Provide ducts designed for working pressures of 2 inches water gauge positive and 1.5 inches water gauge negative. Provide flexible round duct length that does not exceed 5 feet. Secure connections by applying adhesive for 2 inches over rigid duct, apply flexible duct 2 inches over rigid duct, apply metal clamp, and provide minimum of three No. 8 sheet metal screws through clamp and rigid duct.

b. Inner duct core: Provide interlocking spiral or helically corrugated flexible core constructed of zinc-coated steel, aluminum, or stainless steel; or constructed of inner liner of continuous galvanized spring steel wire helix fused to continuous, fire-retardant, flexible vapor barrier film, inner duct core.

c. Insulation: Provide inner duct core that is insulated with mineral fiber blanket type flexible insulation, minimum of 1 inch thick. Provide insulation covered on exterior with manufacturer's standard fire retardant vapor barrier jacket for flexible round duct.

2.8.1.2 Insulated Nonmetallic Flexible Duct Runouts

Use flexible duct runouts only where indicated. Runout length is indicated on the drawings, and is not to exceed 5 feet. Provide runouts that are preinsulated, factory fabricated, and that comply with NFPA 90A and UL 181.

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Provide either field or factory applied vapor barrier. Provide not less than 20 ounce glass fabric duct connectors coated on both sides with neoprene. Where coil induction or high velocity units are supplied with vertical air inlets, use a streamlined, vaned and mitered elbow transition piece for connection to the flexible duct or hose. Provide a die-stamped elbow and not a flexible connector as the last elbow to these units other than the vertical air inlet type. Insulated flexible connectors are allowed as runouts. Provide insulated material and vapor barrier that conform to the requirements of Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. Do not expose the insulation material surface to the air stream.

2.8.1.3 General Service Duct Connectors

Provide a flexible duct connector approximately 6 inches in width where sheet metal connections are made to fans or where ducts of dissimilar metals are connected. For round/oval ducts, secure the flexible material by stainless steel or zinc-coated, iron clinch-type draw bands. For rectangular ducts, install the flexible material locked to metal collars using normal duct construction methods. Provide a composite connector system that complies with NFPA 701 and is classified as "flame-retardent fabrics" in UL Bld Mat Dir.

2.8.2 Duct Access Doors

Provide hinged access doors conforming to SMACNA 1966 in ductwork and plenums where indicated and at all air flow measuring primaries, automatic dampers, fire dampers, coils, thermostats, and other apparatus requiring service and inspection in the duct system. Provide access doors upstream and downstream of air flow measuring primaries and heating and cooling coils. Provide doors that are a minimum 15 by 18 inches, unless otherwise shown. Where duct size does not accommodate this size door, make the doors as large as practicable. Equip doors 24 by 24 inches or larger with fasteners operable from inside and outside the duct. Use insulated type doors in insulated ducts.

2.8.3 Fire Dampers

Use 1.5 hour rated fire dampers unless otherwise indicated. Provide fire dampers that conform to the requirements of NFPA 90A and UL 555. Perform the fire damper test as outlined in NFPA 90A. Provide a pressure relief door upstream of the fire damper. If the ductwork connected to the fire damper is to be insulated then provide a factory installed pressure relief damper. Provide automatic operating fire dampers with a dynamic rating suitable for the maximum air velocity and pressure differential to which it is subjected. Provide fire dampers approved for the specific application, and install according to their listing. Equip fire dampers with a steel sleeve or adequately sized frame installed in such a manner that disruption of the attached ductwork, if any, does not impair the operation of the damper. Equip sleeves or frames with perimeter mounting angles attached on both sides of the wall or floor opening. Construct ductwork in fire-rated floor-ceiling or roof-ceiling assembly systems with air ducts that pierce the ceiling of the assemblies in conformance with UL Fire Resistance. Provide curtain type with damper blades out of the air stream or multi-blade type fire dampers. Install dampers that do not reduce the duct or the air transfer opening cross-sectional area. Install dampers so that the centerline of the damper depth or thickness is located in the centerline of the wall, partition or floor slab depth or thickness. Unless otherwise indicated, comply with the installation details given in

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SMACNA 1819 and in manufacturer's instructions for fire dampers. Perform acceptance testing of fire dampers according to paragraph Fire Damper Acceptance Test and NFPA 90A.

2.8.4 Manual Balancing Dampers

a. Furnish manual balancing dampers with accessible operating mechanisms. Use chromium plated operators (with all exposed edges rounded) in finished portions of the building. Provide manual volume control dampers that are operated by locking-type quadrant operators.

b. Unless otherwise indicated, provide opposed blade type multileaf dampers with maximum blade width of 12 inches. Provide access doors or panels for all concealed damper operators and locking setscrews. Provide access doors or panels in hard ceilings, partitions and walls for access to all concealed damper operators and damper locking setscrews. Coordinate location of doors or panels with other affected contractors.

c. Provide stand-off mounting brackets, bases, or adapters not less than the thickness of the insulation when the locking-type quadrant operators for dampers are installed on ducts to be thermally insulated, to provide clearance between the duct surface and the operator. Stand-off mounting items shall be integral with the operator or standard accessory of the damper manufacturer.

2.8.4.1 Square or Rectangular Dampers

a. Duct Height 12 inches and Less

(1) Frames

Width Height Galvanized Steel Thickness

Length

Maximum 19 inches

Maximum 12 inches

Minimum 20 gauge

Minimum 3 inches

More than 19 inches

Maximum 12 inches

Minimum 16 gauge

Minimum 3 inches

(2) Single Leaf Blades

Width Height Galvanized Steel Thickness

Length

Maximum 19 inches

Maximum 12 inches

Minimum 20 gauge

Minimum 3 inches

More than 19 inches

Maximum 12 inches

Minimum 16 gauge

Minimum 3 inches

(3) Blade Axles: To support the blades of round dampers, provide

galvanized steel shafts supporting the blade the entire duct diameter frame-to-frame. Axle shafts shall extend through standoff bracket and hand quadrant.

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Width Height Material Square Shaft

Maximum 19 inches

Maximum 12 inches

Galvanized Steel Minimum 3/8 inch

More than 19 inches

Maximum 12 inches

Galvanized Steel Minimum 1/2 inch

(4) Axle Bearings: Support the shaft on each end at the frames with shaft bearings. Shaft bearings configuration shall be a pressed fit to provide a tight joint between blade shaft and damper frame.

Width Height Material

Maximum 19 inches Maximum 12 inches solid nylon, or equivalent solid plastic, or oil-impregnated

More than 19 inches Maximum 12 inches oil-impregnated bronze

(5) Control Shaft/Hand Quadrant: Provide dampers with accessible locking-type control shaft/hand quadrant operators.

Provide stand-off mounting brackets, bases, or adapters for the locking-type quadrant operators on dampers installed on ducts to be thermally insulated. Stand-off distance shall be a minimum of 50 mm 2 inches off the metal duct surface. Stand-off mounting items shall be integral with the operator or standard accessory of the damper manufacturer.

(6) Finish: Mill Galvanized

b. Duct Height Greater than 12 inches

(1) Provide dampers with multi-leaf opposed-type blades.

(2) Frames: Maximum 48 inches in height; maximum48 inches in width; minimum of 16 gauge galvanized steel,minimum of 5.5 inches long.

(2) Blades: Minimum of 16 gauge galvanized steel; 6 inch nominal width.

(3) Blade Axles: To support the blades of round dampers, provide

galvanized square steel shafts supporting the blade the entire duct diameter frame-to-frame. Axle shafts shall extend through standoff bracket and hand quadrant.

(4) Axle Bearings: Support the shaft on each end at the frames with shaft bearings constructed of oil-impregnated bronze, or solid nylon, or a solid plastic equivalent to nylon. Shaft bearings configuration shall be a pressed fit to provide a tight joint between blade shaft and damper frame.

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(5) Blade Actuator: Minimum 1/2 inch diameter galvanized steel.

(6) Blade Actuator Linkage: Mill Galvanized steel bar and crank plate with stainless steel pivots.

(7) Control Shaft/Hand Quadrant: Provide dampers with accessible

locking-type control shaft/hand quadrant operators.

Provide stand-off mounting brackets, bases, or adapters for the locking-type quadrant operators on dampers installed on ducts to be thermally insulated. Stand-off distance shall be a minimum of 50 mm 2 inches off the metal duct surface. Stand-off mounting items shall be integral with the operator or standard accessory of the damper manufacturer.

(8) Finish: Mill Galvanized

2.8.4.2 Round Dampers

a. Frames

Size Galvanized Steel Thickness

Length

4 to 20 inches Minimum 20 gauge Minimum 10 inches

22 to 30 inches Minimum 20 gauge Minimum 10 inches

32 to 40 inches Minimum 16 gauge Minimum 10 inches

b. Blades

Size Galvanized Steel Thickness

4 to 20 inches Minimum 20 gauge

22 to 30 inches Minimum 16 gauge

32 to 40 inches Minimum 10 gauge

c. Blade Axles: To support the blades of round dampers, provide galvanized steel shafts supporting the blade the entire duct diameter frame-to-frame. Axle shafts shall extend through standoff bracket and hand quadrant.

Size Shaft Size and Shape

4 to 20 inches Minimum 3/8 inch square

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Size Shaft Size and Shape

22 to 30 inches Minimum 1/2 inch square

32 to 40 inches Minimum 3/4 inch square

d. Axle Bearings: Support the shaft on each end at the frames with shaft bearings constructed of oil-impregnated bronze, or solid nylon, or a solid plastic equivalent to nylon. Shaft bearings configuration shall be a pressed fit to provide a tight joint between blade shaft and damper frame.

Size Material

4 to 20 inches solid nylon, or equivalent solid plastic, or oil-impregnated bronze

22 to 30 inches solid nylon, or equivalent solid plastic, or oil-impregnated bronze

32 to 40 inches oil-impregnated bronze, or stainless steel sleeve bearing

e. Control Shaft/Hand Quadrant:Provide dampers with accessible locking-type control shaft/hand quadrant operators.

Provide stand-off mounting brackets, bases, or adapters for the locking-type quadrant operators on dampers installed on ducts to be thermally insulated. Stand-off distance shall be a minimum of 2 inches off the metal duct surface. Stand-off mounting items shall be integral with the operator or standard accessory of the damper manufacturer.

f. Finish: Mill Galvanized

2.8.5 Automatic Balancing Dampers

Provide dampers as specified in paragraph SUPPLEMENTAL COMPONENTS/SERVICES, subparagraph CONTROLS.

2.8.6 Plenums and Casings for Field-Fabricated Units

2.8.6.1 Plenum and Casings

Fabricate and erect plenums and casings as shown in SMACNA 1966, as applicable. Construct system casing of not less than 16 gauge galvanized sheet steel. Furnish cooling coil drain pans with 1 inch threaded outlet to collect condensation from the cooling coils. Fabricate drain pans from not lighter than 16 gauge steel, galvanized after fabrication or of 18 gauge corrosion-resisting sheet steel conforming to ASTM A167, Type 304, welded and stiffened. Thermally insulate drain pans exposed to the atmosphere to prevent condensation. Coat insulation with a flame resistant waterproofing material. Provide separate drain pans for each vertical coil section, and a separate drain line for each pan. Size pans to ensure capture of entrained moisture on the downstream-air side of the coil. Seal openings in the casing, such as for piping connections, to prevent air leakage.

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Size the water seal for the drain to maintain a pressure of at least 2 inch water gauge greater than the maximum negative pressure in the coil space.

2.8.6.2 Casing

Terminate casings at the curb line and bolt each to the curb using galvanized angle, as indicated in SMACNA 1966.

2.8.6.3 Access Doors

Provide access doors in each section of the casing. Weld doorframes in place, gasket each door with neoprene, hinge with minimum of two brass hinges, and fasten with a minimum of two brass tension fasteners operable from inside and outside of the casing. Where possible, make doors 36 by 18 inches and locate them 18 inches above the floor. Where the space available does not accommodate doors of this size, use doors as large as the space accommodates. Swing doors so that fan suction or pressure holds doors in closed position, airtight. Provide a push-button station, located inside the casing, to stop the supply.

2.8.6.4 Factory-Fabricated Insulated Sheet Metal Panels

Factory-fabricated components are allowed for field-assembled units, provided all requirements specified for field-fabricated plenums and casings are met. Provide panels of modular design, pretested for structural strength, thermal control, condensation control, and acoustical control. Seal and insulate panel joints. Provide and gasket access doors to prevent air leakage. Provide panel construction that is not less than 20 gauge galvanized sheet steel, assembled with fasteners treated against corrosion. Provide standard length panels that deflect not more than 1/2 inch under operation. Construct details, including joint sealing, not specifically covered, as indicated in SMACNA 1966. Construct the plenums and casings to withstand the specified internal pressure of the air systems.

2.8.6.5 Duct Liner

Unless otherwise specified, duct liner is not permitted.

2.8.7 Louvers

Provide louvers for installation in exterior walls that are associated with the air supply and distribution system as specified in Section 13 34 19 METAL BUILDING SYSTEMS.

2.8.8 Diffusers, Registers, and Grilles

Provide factory-fabricated units of steel or aluminum that distribute the specified quantity of air evenly over space intended without causing noticeable drafts, air movement faster than 50 fpm in occupied zone, or dead spots anywhere in the conditioned area. Provide outlets for diffusion, spread, throw, and noise level as required for specified performance. Certify performance according to ASHRAE 70. Provide sound rated and certified inlets and outlets according to ASHRAE 70. Provide sound power level as indicated. Provide diffusers and registers with volume damper with accessible operator, unless otherwise indicated; or if standard with the manufacturer, an automatically controlled device is acceptable. Provide opposed blade type volume dampers for all diffusers and registers, except linear slot diffusers. Provide linear slot diffusers with round or elliptical balancing dampers. Where the inlet and outlet

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openings are located less than 7 feet above the floor, protect them by a grille or screen according to NFPA 90A.

2.8.8.1 Diffusers

Provide diffuser types indicated. Furnish ceiling mounted units with anti-smudge devices, unless the diffuser unit minimizes ceiling smudging through design features. Provide diffusers with air deflectors of the type indicated. Provide air handling troffers or combination light and ceiling diffusers conforming to the requirements of UL Electrical Constructn for the interchangeable use as cooled or heated air supply diffusers or return air units. Install ceiling mounted units with rims tight against ceiling. Provide sponge rubber gaskets between ceiling and surface mounted diffusers for air leakage control. Provide suitable trim for flush mounted diffusers. For connecting the duct to diffuser, provide duct collar that is airtight and does not interfere with volume controller. Provide return or exhaust units that are similar to supply diffusers.

2.8.8.2 Registers

Double-deflection supply registers. Provide manufacturer-furnished volume dampers. Provide volume dampers of the group-operated, opposed-blade type and key adjustable by inserting key through face of register. Operating mechanism shall not project through any part of the register face. Automatic volume control devices are acceptable. Provide exhaust and return registers as specified for supply registers, except provide exhaust and return registers that have a single set of nondirectional face bars or vanes having the same appearance as the supply registers. Set face bars or vanes at 45 degrees.

2.8.9 Bird Screens and Frames

Provide bird screens that conform to ASTM E2016, No. 2 mesh, aluminum or stainless steel. Provide "medium-light" rated aluminum screens. Provide "light" rated stainless steel screens. Provide removable type frames fabricated from either stainless steel or extruded aluminum.

2.9 AIR SYSTEMS EQUIPMENT

2.9.1 Fans

Test and rate fans according to AMCA 210. Calculate system effect on air moving devices in accordance with AMCA 201 where installed ductwork differs from that indicated on drawings. Install air moving devices to minimize fan system effect. Where system effect is unavoidable, determine the most effective way to accommodate the inefficiencies caused by system effect on the installed air moving device. The sound power level of the fans shall not exceed 85 dBA when tested according to AMCA 300 and rated in accordance with AMCA 301. Provide all fans with an AMCA seal. Connect fans to the motors either directly or indirectly with V-belt drive. Use V-belt drives designed for not less than 120 percent of the connected driving capacity. Provide variable pitch motor sheaves for 15 hp and below, and fixed pitch as defined by AHRI Guideline D (A fixed-pitch sheave is provided on both the fan shaft and the motor shaft. This is a non-adjustable speed drive.). Select variable pitch sheaves to drive the fan at a speed which can produce the specified capacity when set at the approximate midpoint of the sheave adjustment. When fixed pitch sheaves are furnished, provide a replaceable sheave when needed to achieve system air balance. Provide motors for V-belt drives with adjustable rails or bases. Provide removable metal

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guards for all exposed V-belt drives, and provide speed-test openings at the center of all rotating shafts. Provide fans with personnel screens or guards on both suction and supply ends, except that the screens need not be provided, unless otherwise indicated, where ducts are connected to the fan. Provide fan and motor assemblies with vibration-isolation supports or mountings as indicated. Use vibration-isolation units that are standard products with published loading ratings. Select each fan to produce the capacity required at the fan static pressure indicated. Provide sound power level as indicated. Obtain the sound power level values according to AMCA 300. Provide standard AMCA arrangement, rotation, and discharge as indicated. Provide power ventilators that conform to UL 705 and have a UL label.

2.9.1.1 Centrifugal Fans

Provide fully enclosed, single-width single-inlet, or double-width double-inlet centrifugal fans, with AMCA Pressure Class I, II, or III as required or indicated for the design system pressure. Provide impeller wheels that are rigidly constructed and accurately balanced both statically and dynamically. Provide forward curved or backward-inclined airfoil design fan blades in wheel sizes up to 30 inches. Provide backward-inclined airfoil design fan blades for wheels over 30 inches in diameter. Provide fan wheels over 36 inches in diameter with overhung pulleys and a bearing on each side of the wheel. Provide fan wheels 36 inches or less in diameter that have one or more extra long bearings between the fan wheel and the drive. Provide sleeve type, self-aligning and self-oiling bearings with oil reservoirs, or precision self-aligning roller or ball-type with accessible grease fittings or permanently lubricated type. Connect grease fittings to tubing for serviceability from a single accessible point. Provide L50 rated bearing life at not less than 200,000 hours as defined by ABMA 9 and ABMA 11. Provide steel, accurately finished fan shafts, with key seats and keys for impeller hubs and fan pulleys. Provide fan outlets of ample proportions, designed for the attachment of angles and bolts for attaching flexible connections. Unless otherwise indicated, provide motors that do not exceed 1800 rpm and have totally enclosed enclosures. Provide manual across-the-line type motor starters with weather-resistant enclosure. Provide remote manual switch with pilot indicating light where indicated.

2.9.1.2 In-Line Centrifugal Fans

Provide in-line fans with centrifugal backward inclined blades, stationary discharge conversion vanes, internal and external belt guards, and adjustable motor mounts. Mount fans in a welded tubular casing. Provide a fan that axially flows the air in and out. Streamline inlets with conversion vanes to eliminate turbulence and provide smooth discharge air flow. Enclose and isolate fan bearings and drive shafts from the air stream. Provide precision, self aligning ball or roller type fan bearings that are sealed against dust and dirt and are permanently lubricated. Provide L50 rated bearing life at not less than 200,000 hours as defined by ABMA 9 and ABMA 11. Provide motors with open enclosure unless otherwise noted on drawings. Provide magnetic motor starters across the line with general purpose enclosures where located indoors, and weather-resistant enclosures where located outdoors.

2.9.1.3 Panel Type Power Wall Ventilators

Provide direct driven centrifugal type fans with backward inclined, non-overloading wheel. Provide removable and weatherproof motor housing.

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Provide unit housing that is designed for sealing to building surface and for discharge and condensate drippage away from building surface. Construct housing of heavy gauge aluminum. Equip unit with an aluminum or plated steel wire discharge bird screen, disconnect switch, anodized aluminum wall grille, manufacturer's standard gravity damper, an airtight and liquid-tight metallic wall sleeve. Provide totally enclosed fan cooled type motor enclosure. Use only lubricated bearings.

2.9.1.4 Propeller Type Ceiling Fans

2.9.1.4.1 Complete Unit

The entire fan assembly shall be ETL-certified and built pursuant to construction guidelines set forth by UL 507 and CSA C22.2. The fan shall be designed to move an effective amount of air for cooling and destratification in large industrial applications over an extended life. The fan and components shall be designed specifically for high volume, low speed fans to ensure lower operational noise. The sound levels from the fan operating at maximum speed measured in a laboratory setting shall not exceed 55 dBA (measured 20 feet below the airfoils and 20 feet horizontally from the center of the fan). Actual results of sound measurements in the field may vary due to sound reflective surfaces and environmental conditions.

2.9.1.4.2 Airfoil System

The fan shall be equipped with eight (8) Powerfoil Plus airfoils of precision extruded aluminum alloy. The airfoils shall be connected by means of two (2) high strength locking bolts per airfoil. The airfoils shall be connected to the hub and interlocked with zinc plated steel retainers. As an option, airfoils may be powder coated as specified by the architect or owner.

The fan shall be equipped with eight (8) Powerfoil Plus winglets on the end of the airfoils and eight (8) AirFences™ positioned on the airfoils at the optimum location for performance. The winglets shall be attached at the tip of each airfoil. The winglets and AirFences shall be molded of high density polypropylene. The standard color of the winglets and AirFences shall be "Safety Yellow".

2.9.1.4.3 Motor and Gearbox

The fan motor shall be an AC induction type inverter rated at 1725 RPM, 230/460 VAC, and 60 Hz for 3 phase and 1725 RPM, 208 VAC, and 60 Hz for 1 phase. The motor shall be totally enclosed, fan cooled (TEFC) with an IP55 NEMA classification. The motor shall be manufactured with a double baked Class F insulation and be capable of continuous operation in -30 degrees F to 122 degrees F ambient conditions.

The gearbox shall be a helical gear reducer. The gear box shall be precision finished from hardened steel for low noise and long service life with double lip seals to keep oil in and contaminants out. The gear box shall be lubricated for life. The gear reducer shall have a standard backlash of less than 25 arc minutes and be equipped with a 17-4 stainless steel shaft of 1-1/4 inches diameter.

2.9.1.4.4 Motor Frame

The motor frame and mount shall be constructed of steel and powder coated

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for corrosion resistance and appearance. Non visible, steel, threaded rods in each structural member of the motor frame shall provide a redundant safety feature in the event of a catastrophic event.

2.9.1.4.5 Hub

The fan hub shall be made of laser cut aluminum for high strength and light weight. The hub shall consist of two aluminum plates, eight (8) aluminum spars and one (1) spacer fastened with a pin and collar rivet system. The hub shall be secured to the output shaft of the gearbox by means of a steel coupling interface. The hub shall incorporate four (4) safety retaining clips made of 1/4 inch thick steel that shall restrain the hub/airfoil assembly.

2.9.1.4.6 Mounting System

The fan mounting system shall be designed for quick and secure installation from a structural support beam. All components in the mounting system shall be of welded construction using low carbon steel no less than 3/16 inch thick and be powder coated for appearance and resistance to corrosion. All mounting bolts shall be SAE Grade 8 or equivalent. As an option, mounting components may be colored as specified by the architect or owner.

2.9.1.4.7 Safety Cable

The fan shall be equipped with a safety cable that provides an additional means of securing the fan assembly to the building structure. The safety cable shall be 3/8 inch to 1/4 inch diameter and fabricated out of 7 x 19 stranded galvanized steel. The loops shall be secured with swaged Nicopress fittings, pre-loaded and tested to 3,000 lbs f.

Field construction of safety cables is not permitted.

2.9.1.4.8 Wall Controller

The fan controller shall be constructed using a NEMA 4X, Variable Speed Drive (VSD) that is mounted to the wall at ground-level and factory programmed to minimize the starting and braking torques, for smooth and efficient operation. The wall control shall be equipped with touchpad controls and an LED display for controlling the fan's direction, operation, speed, and programming. The wall controller shall provide 100% control of all fan functions. The wall control shall be equipped with an EMI/RFI filter to limit interference with other electronic equipment and a rotary switch disconnect for lock-out/tag-out requirements.

The fan shall be mounted to an angle iron or I-beam structure. The fan installation area shall be free of obstructions such as lights, cables, sprinklers or other building structures; with the airfoils at least 2 feet clear of all obstructions. The fan should not be installed where it will be continuously subjected to wind gusts or in close proximity to the outputs of HVAC systems. The design criteria for the fan mounting system shall be capable of handling 300 feet-lbs of torque.

2.9.1.5 Ceiling Exhaust Fans

Provide centrifugal type, direct driven suspended cabinet-type ceiling exhaust fans. Provide fans with acoustically insulated housing. Provide chatter-proof backdraft damper. Provide egg-crate design or louver design

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integral face grille. Mount fan motors on vibration isolators. Furnish unit with mounting flange for hanging unit from above. Provide U.L. listed fans.

2.9.2 Coils

Provide fin-and-tube type coils constructed of seamless copper tubes and aluminum fins mechanically bonded or soldered to the tubes. Provide copper tube wall thickness that is a minimum of 0.016 inches. Provide aluminum fins that are 0.0055 inch minimum thickness. Provide casing and tube support sheets that are not lighter than 16 gauge galvanized steel, formed to provide structural strength. When required, provide multiple tube supports to prevent tube sag. Test each coil at the factory under water at not less than 400 psi air pressure and make suitable for 200 psi working pressure and 300 degrees F operating temperature unless otherwise stated. Mount coils for counterflow service. Rate and certify coils to meet the requirements of AHRI 410.

2.9.2.1 Heat Recovery Glycol Coils

Install heat recovery glycol coils with a pitch of not less than 1/8 inch/foot of the tube length toward the drain end. Use headers constructed of cast iron, welded steel or copper. Furnish each coil with a plugged vent and drain connection extending through the unit casing. Provide removable water coils with drain pans.

2.9.2.2 Eliminators

Equip each cooling coil having an air velocity of over 400 fpm through the net face area with moisture eliminators, unless the coil manufacturer guarantees, over the signature of a responsible company official, that no moisture can be carried beyond the drip pans under actual conditions of operation. Construct of minimum 24 gage copper, removable through the nearest access door in the casing or ductwork. Provide eliminators that have not less than two bends at 45 degrees and are spaced not more than 2-1/2 inches center-to-center on face. Provide each bend with an integrally formed hook as indicated in the SMACNA 1884.

2.9.2.3 Corrosion Protection for Coastal Installations

Provide corrosion protection for all exterior HVAC equipment, including air handling units, heat exchanger coil surfaces, equipment casings, air cooled condensing units, air conditioning units that are exposed to the weather. Corrosion protection shall meet or exceed the requirements of a 3000 hour salt spray test in accordance with ASTM B117. The specified capacities on the plans and specifications shall be the capacities after the required corrosion protection coatings are applied. This corrosion protection is also required on HVAC equipment within buildings that are subject to the outside weather conditions. Specifically, equipment requiring protection is defined as the first HVAC equipment (excluding louvers) met by the outside air in the supply air ductwork system. Provide manufacturer's standard off-the-shelf anti-corrosion options for "coastal" or "sea coast" installations that meet or exceed the requirements stated above.

2.9.3 Air Filters

List air filters according to requirements of UL 900, except list high efficiency particulate air filters of 99.97 percent efficiency by the DOP Test method under the Label Service to meet the requirements of UL 586.

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2.9.3.1 Extended Surface Pleated Panel Filters

Provide 2 inch depth, sectional, disposable type filters of the size indicated with a MERV of 8 when tested according to ASHRAE 52.2. Provide initial resistance at 500 fpm that does not exceed 0.36 inches water gauge. Provide UL Class 2 filters, and nonwoven cotton and synthetic fiber mat media. Attach a wire support grid bonded to the media to a moisture resistant fiberboard frame. Bond all four edges of the filter media to the inside of the frame to prevent air bypass and increase rigidity.

2.9.3.2 High-Efficiency Particulate Air (HEPA) Filters

Provide HEPA filters that meet the requirements of IEST RP-CC-001 and are individually tested and certified to have an efficiency of not less than 99.97 percent, and an initial resistance at 800 fpm that does not exceed 5.0 inches water gauge. Provide filters that are constructed by pleating a continuous sheet of filter medium into closely spaced pleats separated by corrugated aluminum or mineral-fiber inserts, strips of filter medium, or by honeycomb construction of the pleated filter medium. Provide interlocking, dovetailed, molded neoprene rubber gaskets of 5-10 durometer that are cemented to the perimeter of the upstream face of the filter cell sides. Provide self-extinguishing rubber-base type adhesive or other materials conforming to fire hazard classification specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. Provide filter cell sides that are galvanized steel assembled in a rigid manner. Provide overall cell side dimensions that are correct to 1/16 inch, and squareness that is maintained to within 1/8 inch. Provide holding frames that use spring loaded fasteners or other devices to seal the filter tightly within it and that prevent any bypass leakage around the filter during its installed life. Provide air capacity and the nominal depth of the filter as indicated. Install each filter in a factory preassembled side access housing or a factory-made sectional supporting frame as indicated. Provide prefilters of the type, construction and efficiency indicated.

2.9.3.3 Holding Frames

Fabricate frames from not lighter than 16 gauge sheet steel with rust-inhibitor coating. Equip each holding frame with suitable filter holding devices. Provide gasketed holding frame seats. Make all joints airtight.

2.9.3.4 Filter Gauges

Provide dial type filter gauges, diaphragm actuated draft for all filter stations, including those filters which are furnished as integral parts of factory fabricated air handling units. Gauges shall be at least 3-7/8 inches in diameter, with white dials with black figures, and graduated in 0.01 inch of water, with a minimum range of 1 inch of water beyond the specified final resistance for the filter bank on which each gauge is applied. Provide each gauge with a screw operated zero adjustment and two static pressure tips with integral compression fittings, two molded plastic vent valves, two 5 foot minimum lengths of 1/4 inch diameter aluminum tubing, and all hardware and accessories for gauge mounting.

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2.10 AIR HANDLING UNITS

2.10.1 Factory-Fabricated Air Handling Units

Provide single-zone draw-through type or single-zone blow-through type units as indicated. Units shall include fans, coils, airtight insulated casing, prefilters, secondary filter sections, adjustable V-belt drives, belt guards for externally mounted motors, access sections where indicated, mixing box vibration-isolators, and appurtenances required for specified operation. Provide vibration isolators as indicated. Physical dimensions of each air handling unit shall be suitable to fit space allotted to the unit with the capacity indicated. Provide air handling unit that is rated in accordance with AHRI 430 and AHRI certified for cooling.

2.10.1.1 Casings

Provide the following:

a. Casing sections 2 inch double wall type, constructed of a minimum 18 gauge galvanized steel, or 18 gauge corrosion-resisting sheet steel conforming to ASTM A167, Type 304. Inner casing of double-wall units that are a minimum 20 gauge solid galvanized steel or corrosion-resisting sheet steel conforming to ASTM A167, Type 304. Design and construct casing with an integral insulated structural galvanized steel frame such that exterior panels are non-load bearing.

b. Individually removable exterior panels with standard tools. Removal shall not affect the structural integrity of the unit. Furnish casings with access sections, according to paragraph AIR HANDLING UNITS, inspection doors, and access doors, all capable of opening a minimum of 90 degrees, as indicated.

c. Insulated, fully gasketed, double-wall type inspection and access doors, of a minimum 18 gauge outer and 20 gauge inner panels made of either galvanized steel or corrosion-resisting sheet steel conforming to ASTM A167, Type 304. Doors shall be rigid and provided with heavy duty hinges and latches. Inspection doors shall be a minimum 12 inches wide by 12 inches high. Access doors shall be a minimum 24 inches wide, the full height of the unit casing or a minimum of 6 foot, whichever is less.

d. Double-wall insulated type drain pan (thickness equal to exterior casing) constructed of 16 gauge corrosion resisting sheet steel conforming to ASTM A167, Type 304, conforming to ASHRAE 62.1. Construct drain pans water tight, treated to prevent corrosion, and designed for positive condensate drainage. When 2 or more cooling coils are used, with one stacked above the other, condensate from the upper coils shall not flow across the face of lower coils. Provide intermediate drain pans or condensate collection channels and downspouts, as required to carry condensate to the unit drain pan out of the air stream and without moisture carryover. Construct drain pan to allow for easy visual inspection, including underneath the coil without removal of the coil and to allow complete and easy physical cleaning of the pan underneath the coil without removal of the coil. Coils shall be individually removable from the casing.

e. Casing insulation that conforms to NFPA 90A. Single-wall casing sections handling conditioned air shall be insulated with not less than 1 inch thick, 1-1/2 pound density coated fibrous glass material having

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a thermal conductivity not greater than 0.23 Btu/hr-sf-F. Double-wall casing sections handling conditioned air shall be insulated with not less than 2 inches of the same insulation specified for single-wall casings. Foil-faced insulation is not an acceptable substitute for use with double wall casing. Double wall insulation shall be completely sealed by inner and outer panels.

f. Factory applied fibrous glass insulation that conforms to ASTM C1071, except that the minimum thickness and density requirements do not apply, and that meets the requirements of NFPA 90A. Make air handling unit casing insulation uniform over the entire casing. Foil-faced insulation is not an acceptable substitute for use on double-wall access doors and inspections doors.

g. A latched and hinged inspection door, in the fan and coil sections. Plus additional inspection doors, access doors and access sections.

2.10.1.2 Heating and Cooling Coils

Provide coils as specified in paragraph AIR SYSTEMS EQUIPMENT.

2.10.1.3 Air Filters

Provide air filters as specified in paragraph AIR SYSTEMS EQUIPMENT for types and thickness indicated.

2.10.1.4 Fans

Provide the following:

a. Fans that are double-inlet, centrifugal type with each fan in a separate scroll. Dynamically balance fans and shafts prior to installation into air handling unit, then after it has been installed in the air handling unit, statically and dynamically balance the entire fan assembly. Mount fans on steel shafts, accurately ground and finished.

b. Fan bearings that are sealed against dust and dirt and are precision self-aligning ball or roller type, with L50 rated bearing life at not less than 200,000 hours as defined by ABMA 9 and ABMA 11. Bearings shall be permanently lubricated or lubricated type with lubrication fittings readily accessible at the drive side of the unit. Support bearings by structural shapes, or die formed sheet structural members, or support plates securely attached to the unit casing. Do not fasten bearings directly to the unit sheet metal casing. Furnish fans and scrolls with coating indicated.

c. Fans that are driven by a unit-mounted, or a floor-mounted motor connected to fans by V-belt drive complete with belt guard for externally mounted motors. Furnish belt guards that are the three-sided enclosed type with solid or expanded metal face. Belt drives shall be designed for not less than a 1.3 service factor based on motor nameplate rating.

d. Where fixed sheaves are required, the use of variable pitch sheaves is allowed during air balance, but replace them with an appropriate fixed sheave after air balance is completed. Select variable pitch sheaves to drive the fan at a speed that produces the specified capacity when set at the approximate midpoint of the sheave adjustment. Furnish

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motors for V-belt drives with adjustable bases, and with open, splashproof enclosures.

e. Motor starters of magnetic type with weather-resistant enclosure. Select unit fan or fans to produce the required capacity at the fan static pressure with sound power level as indicated. Obtain the sound power level values according to AMCA 300, ASHRAE 68, or AHRI 260.

2.10.1.5 Access Sections and Filter/Mixing Boxes

Provide access sections where indicated and furnish with access doors as shown. Construct access sections and filter/mixing boxes in a manner identical to the remainder of the unit casing and equip with access doors. Design mixing boxes to minimize air stratification and to promote thorough mixing of the air streams.

2.11 ROOFTOP AIR HANDLING UNITS

All units shall be factory assembled, internally wired, and 100 Percent run tested to check operation, fan/blower rotation and control sequence before leaving the factory. Wiring internal to the unit shall be numbered for simplified identification. Units shall be ETL listed and labeled, classified in accordance with UL 1995 / CSA C22.2. Unit(s) shall be complete with all components and accessories as specified.

2.11.1 Quality Assurance

All unit(s) shall be factory run tested before shipping. A proof copy of the test shall be placed in the unit electrical power & control panel. Unit(s) shall bear the ETL label, tested in accordance to UL 1995. Electrical components shall be UL listed; fans shall be tested in an AMCA certified laboratory; insulation shall comply with NFPA 90A; coils shall tested in accordance to AHRI 410 ; energy recovery exchangers shall be in accordance to ANSI/AHRI 1060, "Rating Air-to-Air Energy Recovery Equipment"; filters shall be tested in accordance to ASHRAE 52.2. The unit manufacturer shall have an independent testing agency test the air leakage, panel deflection and sound pressure levels for a typical unit providing at minimum the supply airflow of units in question and not exceeding 20,000 CFM. The air leakage of the unit(s) shall not exceed 1 Percent at 8" inches H2O positive static pressure and a copy of the report must be submitted upon request. Unit shall be constructed to limit frame and panel deflection to 1/250th of the panel length at 8" inches H2O positive static pressure and a copy of the report must be submitted upon request. The unit shall also be tested in accordance with ANSI S12.54 and instrumentation used must be in compliance with the requirements of AMCA 300 for sound readings. The sound tests conducted shall report overall sound power and pressure readings for supply air outlet, return air inlet and casing radiated.

2.11.1.1 Housing

The unit housing shall be constructed from a frame, base and panel assembly. Unit shall be completely factory assembled and shipped in one piece as shown on drawings. The frame shall consist of die cast corners and extruded aluminum profiles welded together for reinforcement. The base structure shall be fully welded with formed heavy gauge galvanized steel. Double lined heavy duty galvanized steel, G-90 floor insulated with R12 foam shall be mechanically fastened to the base structure which shall consist of an anti-vibration gasket to diminish the metal to metal

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contact. Base structure shall have galvanized lifting lugs. All roof and wall panels shall be made from G-90 galvanized steel, minimum 18-gauge exterior and 20 gauge interior. All panels and access doors shall be double wall construction with (R-8.6) two-inch thick, minimum 1.8 PCF fiberglass insulation. Panels shall be fastened from the interior and gasketed along the frame to reduce thermal transmission. Fixed panels shall be removable without affecting the housing integrity. Access doors shall be provided to all major components to facilitate quick and easy access.

If access doors do not open against unit operating pressure, provide safety latches that allow access doors to partially open after first handle movement and fully open after second handle movement. Removable panels provided for equipment pull out for coil(s), heat exchanger(s) and fan intake section(s) shall have key tooled threaded insert fasteners. Hinges shall be aluminum butt hinges designed to open 180 degrees. Access doors shall be sealed with a full "U-Shaped" gasket for tightness along the door edge. Bulb type gaskets shall not be acceptable. The airflow separation wall between the outside air intake and exhaust air outlet shall be a one inch double wall insulated. Floor openings shall be covered with safety walk on gratings. All roof and side wall seams shall be positively sealed to prevent water and air leakage. Outdoor units shall have a rain gutter above each access door and a watertight roof shall be provided with a UV-reflective membrane. Outdoor units shall have the entire exterior finished with (2) two coats of acrylic urethane enamel. Paint shall pass ASTM B117 3000-hour salt fog resistance test.

2.11.1.2 Weather Hood(s)

Intake hood shall include an aluminum frame to hold 2 inch pleated filters. Hood shall be designed with an angle and include a removable louver for access to OA Pre-Filters and be designed for maximum 450 FPM air velocity.

2.11.1.3 Fans

The fans shall be carefully positioned and installed at an optimal distance to respect uniform airflow across the heat exchanger & coil(s).

Plug Fans: Fans shall be direct drive radial centrifugal fans with free running impeller. No fan belts will be acceptable for this application. Fans shall be compact, optimized and construction made of galvanized sheet steel with backward curved high efficiency impeller, protected by an epoxy powder coating. The single inlet shall be mounted onto constant speed direct drive motor, equipped with an air flow optimized inlet cone from galvanized sheet steel. Fans will require to be operated by a Variable speed drive.

The fan housing and motor assembly shall be isolated from the unit cabinetry with a minimum 95 Percent efficient isolators. Fan(s) shall have flexible duct canvas and galvanized spring isolators. Painted isolators are unacceptable.

2.11.1.4 Fan Motors

The fan motors shall meet NEMA standard dimensions and comply with the Energy policy Act of 1997. Motors shall have high efficiencies with low noise and vibration output. Motors shall have ODP enclosure with Premium efficiency performance. Units shall be designed for constant application.

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Please refer to the unit schedule for the application type. Option: A shaft grounding brush kit will be provided to prevent electrical damage to motor bearings by safely channeling harmful shaft currents to ground.

2.11.1.5 Variable Frequency Drive (VFD)

Refer to Specification Section 26 29 23 VARIABLE FREQUENCY DRIVES for VFD requirements. VFDs will be installed without a by-pass.

2.11.1.6 Pre-Filters

Filters shall be factory installed upstream of the heat exchanger and coils, in both airstreams. The filters shall be MERV 8. Each filter shall consist of 100 Percent synthetic media, expanded metal on the downstream and enclosing with high wet-strength beverage board with diagonal support bonded on air entering and air exiting side of each pleat.

2.11.1.7 Dampers Non-Insulated

Dampers shall be installed where shown on the drawings. Dampers shall be low leak type with rubber edges, opposed or parallel blades, and constructed from extruded aluminum. Galvanized dampers will not be acceptable. The exhaust air outlet shall have a standard aluminum gravity type damper, unless otherwise noted below.

Dampers shall be installed in the compartments (as shown on the drawings) with linkage rod for actuators:

Actuators shall be 24V factory installed; two-position or modulating type (please refer to the control diagrams). All actuators shall have spring return mechanism and auxiliary switches. Dampers will be installed in the failed close position unless otherwise noted.

2.11.1.8 Dehumidification Section with Variable Air Cooled Condensers

Provide integral variable capacity through variable speed compressor air cooled condensing section. The condensing unit shall be factory piped, wired, and ready for field installation and charge with R-410A refrigerant. Each compressor shall be equipped with a crankcase heater function, anti-short cycling and a variable frequency drive (VFD) which includes a built-in phase loss detector. Compressors shall be variable speed scroll type. Each condenser fan banks shall be equipped with a variable frequency drive (VFD). Protective guards shall be included. All condenser fans shall have an asynchronous external motor type, insulation class F, IP54 and 100 Percent variable speed. Exterior cabinet shall be capable of withstanding 3000 hour salt spray exposure per ASTM B117. Compressors shall be mounted on rubber and shear vibration insulators. Condenser Coil construction shall consist of aluminum alloys for the fins, tubes and manifolds or Copper coils with aluminum fins. Assembled condenser coils shall be leak tested and pressure tested at 650 psig. Condenser fans shall modulate to reach minimal energy consumption while meeting the cooling load required by the associated air handling unit.The following components are compulsory and must be included in the ACCU: liquid line filter/dryer, vertical receiver with temperature relief device, hi pressure switch, hi and low pressure transducers, hi/low pressure gauges, suction and liquid lines shutoff valves, suction line accumulators.

The following safety devices are also compulsory and must be included in

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the ACCU:

Compressor lockout protection for internal or external overload, low pressure protection, high pressure protection and compressor reverse rotation protection.

Controls shall include: automatic compressor lead/lag control, compressor minimum off time (5 min), capacity control with variable speed compressors and alarm relay out to indicate when the unit is in alarm condition. All refrigeration parts, including compressors shall be installed in a closed vented service compartment separate from the condenser coil airflow. Each refrigeration system shall be factory tested. Minimum (5) five year compressor warranties shall be provided.

2.11.1.9 DX Coils

Coils shall be factory installed in the unit. Coils shall be designed with respective circuits to match the design requirements. All coils shall have a distributor per circuit connection. Primary surface shall be round seamless copper tube. Secondary surface shall consist of aluminum plate fins. Tubes shall be mechanically expanded into the fins to provide a continuous primary to secondary compression bond over the entire finned length for maximum heat transfer rates. Casing shall be constructed of continuous galvanized steel. Coils shall be circuited for counter-flow heat transfer. The complete coil shall be tested with 315 pounds air pressure and be suitable for operation at 250 psig working pressures. Maximum finned coil height shall be 60 inches and shall not exceed 500 FPM face velocity. Drain pan shall be provided on cooling coils. Cooling coils shall sit on stainless steel support rails, which shall stand a minimum of (2) two inchesabove the highest point of the floor drain pan. Stacked coils shall be provided for larger airflows and intermediate drain pans shall be provided for each coil bank. Drain pans shall be stainless steel with stainless steel drain connections on one side only. Pan shall be sloped in two planes. All coils shall be certified in accordance with AHRI 410.

2.11.1.10 Water Coils

Coils shall be are factory installed in the unit. Primary surface shall be round seamless copper tube. Secondary surface shall consist of aluminum plate fins for higher capacity and structural strength. Fins shall have full drawn collars to provide a continuous surface cover over the entire tube for maximum heat transfer. Tubes shall be mechanically expanded into the fins to provide a continuous primary to secondary compression bond over the entire finned length for maximum heat transfer rates. Casing shall be constructed of continuous galvanized steel. Coils shall be circuited for counter-flow heat transfer. The complete coil shall be tested with 315 pounds air pressure and be suitable for operation at 250 psig working pressures. Maximum finned coil height shall be 60 inches and shall not exceed 500 FPM face velocity. Drain pan shall be provided for cooling coils. Cooling coils shall sit on stainless steel support rails, which shall stand a minimum of (2) two inches above the highest point of the floor drain pan. Stacked coils shall be provided for larger airflows and intermediate drain pans shall be provided for each coil bank. Drain pans shall be stainless steel with stainless steel drain connections on one side only. Pan shall be sloped in two planes. All coils shall be certified in accordance with AHRI 410.

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2.11.1.11 Indirect Gas Fired Duct Furnace

Furnish and install where shown on plans Gas-fired Duct Furnace Heat Module(s). The module shall be a Recognized Component by (UL / ETL). All modules will have a minimum thermal efficiency of 80 Percent. The module shall employ a tubular heat exchanger and a draft inducer assembly to provide for positive venting of flue gases. Burner assemblies shall employ in-shot type burners constructed of aluminized steel body and sintered metal flame holder with integral carryover plenum. The ignition system will include a Igniter and flame rod detection. Ceramic hot surface ignition systems are unacceptable. Gas-fired duct furnace(s) provided shall employ a tubular heat exchanger constructed of 18-gauge minimum, type 409 stainless steel, and having a minimum wall thickness of 0.047 inch. Tubes shall be produced to ASTM A 249/A 249M standards for heat exchanger application. Tubes shall employ restrictors to eliminate noise associated with expansion and contraction of internal baffles during heating cycles, and to provide for unobstructed drainage of condensate that occurs in the tubes during cooling operation. Drainage shall be configured so that burners and burner surfaces are not exposed to condensate during cooling system operation. Full Modulation control shall be provided. On a call for heat and subsequent safe burner light OFF, the burner firing rate is controlled between 20 Percent and 100 Percent of full rated capacity. The modulation will be continuous between 20 Percent and 100 Percent; "stepped" modulation is not acceptable. Controls shall include an ignition control with alarm capable contact and one hour auto reset on lockout, roll out switch, high limit switch and a proving switch of loss of the induced draft fan. Additionally, on modulating and 2-stage systems all timing and switching functions shall be controlled through an electronic timer relay control. Staging controller available for 0 to 10VDC or 4 to 20mA input signals from building management control. Burners will use Natural Gas (with gas pressure min 7 inches-max 14 inches wc) unless otherwise specified.

2.11.1.12 Roof Curb

A non-insulated, pre-fabricated roof curb shall be provided. The roof curb will be made of 16-gauge galvanized steel.

2.11.1.13 Power & Safety Control

The power and control center shall be integral to the unit housing and rated equivalent to NEMA 3R. Panels that are externally mounted to the unit shall not be accepted, regardless of the NEMA rating they may have. A separate access door shall be provided with an approved locking device. All electrical components contained in the panel shall be UL certified and labeled. The unit shall be complete with VFDs, fuses, cascading overloads (without VFD's or 2 motors on same VFD), relays, phase protection for compressorized units, terminals for main ON/OFF and step-down transformer. All components shall be factory wired for single point power connection by the manufacturer of the unit. A non-fused safety disconnect switch shall be factory installed for ON/OFF servicing. Any power or control wiring that is field installed shall not be accepted under any circumstances. The Short Circuit Current Rating (SCCR) is 5kA rms symmetrical, 600V Maximum.

2.11.1.14 Service Power & Lighting

GFI, lights, and switches shall be factory installed and wired to a common junction box. A separate power connection 120V/1 will be required (powered by others).

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2.11.1.15 Air Temperature Control Package

The unit shall be delivered with factory installed control system. Under no circumstances shall control be provided by other than the manufacturer of the equipment. Field installed control package by the ATC will not be acceptable. The control system shall consist of a microprocessor with LCD display, 7 day time clock, 20 day holiday schedule, occupied/unoccupied mode switch, warm up mode, cool down mode, hi-lo limit discharge control, fan status, dirty filter status, temperature and humidity sensors, and alarm history. The control system main purpose will be as specified on the Sequence of Operation. Space temperature and humidity wall mount sensors shall be field mounted. Indoor installed units shall have Outdoor Air temperature and humidity sensors field mounted. Terminals for remote control shall be provided for entire unit ON/OFF, OCCUPIED/UNOCCUPIED mode selection and alarm contact. Refer to the Sequence of Operation and control schematic for detailed description and options.

2.11.1.16 Communication Interface Card

The microprocessor shall be capable of communicating with the following protocol BACnet MS/TP RS-485.

2.11.1.17 Remote Control LCD Display Panel

Remote control panel shall be wall mount type. The panel shall have an LCD display and scroll buttons to allow change set-points and view status of unit. In addition, the remote panel shall have a built in buzzer which will sound upon alarm status.

2.12 ENERGY RECOVERY DEVICES

2.12.1 Run-Around-Coil

Provide assembly that is air-to-liquid-to-air energy recovery system for transfer of sensible heat from exhaust air to supply air stream and that delivers an energy transfer effectiveness not less than that indicated without cross-contamination with maximum energy recovery at minimum life cycle cost. Computer optimize components for capacity, effectiveness, number of coil fins per inch, number of coil rows, flow rate, heat transfer rate of 60 percent by volume of propylene glycol solution, and frost control. Provide coils that conform to paragraph AIR HANDLING UNITS. Provide related pumps, and piping specialties.

2.13 FACTORY PAINTING

Factory paint new equipment, which are not of galvanized construction. Paint with a corrosion resisting paint finish according to ASTM A123/A123M or ASTM A924/A924M. Clean, phosphatize and coat internal and external ferrous metal surfaces with a paint finish which has been tested according to ASTM B117, ASTM D1654, and ASTM D3359. Submit evidence of satisfactory paint performance for a minimum of 125 hours for units to be installed indoors and 3,000 hours for units to be installed outdoors. Provide rating of failure at the scribe mark that is not less than 6, average creepage not greater than 1/8 inch. Provide rating of the inscribed area that is not less than 10, no failure. On units constructed of galvanized steel that have been welded, provide a final shop docket of zinc-rich protective paint on exterior surfaces of welds or welds that have burned through from the interior according to ASTM D520 Type I.

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Factory painting that has been damaged prior to acceptance by the Contracting Officer shall be field painted in compliance with the requirements of paragraph FIELD PAINTING OF MECHANICAL EQUIPMENT.

2.14 SUPPLEMENTAL COMPONENTS/SERVICES

2.14.1 Heat Recovery Glycol Piping

The requirements for heat recovery glycol piping are specified in Section 23 05 15 COMMON PIPING FOR HVAC.

2.14.2 Refrigerant Piping

The requirements for refrigerant piping are specified in Section 23 23 00 REFRIGERANT PIPING.

2.14.3 Condensate Drain Lines

Provide and install condensate drainage for each item of equipment that generates condensate in accordance with Section 22 00 00 PLUMBING, GENERAL PURPOSE except as modified herein.

2.14.4 Backflow Preventers

The requirements for backflow preventers are specified in Section 22 00 00 PLUMBING, GENERAL PURPOSE.

2.14.5 Insulation

The requirements for shop and field applied insulation are specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS.

2.14.6 Controls

The requirements for controls are specified in Section 23 05 93 TESTING, ADJUSTING, AND BALANCING OF HVAC SYSTEMS and 23 09 23.13 22 BACnet DIRECT DIGITAL CONTROL SYSTEMS FOR HVAC.

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Contracting Officer of any discrepancy before performing the work.

3.2 INSTALLATION

a. Install materials and equipment in accordance with the requirements of the contract drawings and approved manufacturer's installation instructions. Accomplish installation by workers skilled in this type of work. Perform installation so that there is no degradation of the designed fire ratings of walls, partitions, ceilings, and floors.

b. No installation is permitted to block or otherwise impede access to any existing machine or system. Install all hinged doors to swing open a minimum of 120 degrees. Provide an area in front of all access doors that clears a minimum of 3 feet. In front of all access doors to

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electrical circuits, clear the area the minimum distance to energized circuits as specified in OSHA Standards, part 1910.333 (Electrical-Safety Related work practices)and an additional 3 feet.

c. Except as otherwise indicated, install emergency switches and alarms in conspicuous locations. Mount all indicators, to include gauges, meters, and alarms in order to be easily visible by people in the area.

3.2.1 Condensate Drain Lines

Provide water seals in the condensate drain from all units. Provide a depth of each seal of 2 inches plus the number of inches, measured in water gauge, of the total static pressure rating of the unit to which the drain is connected. Provide water seals that are constructed of 2 tees and an appropriate U-bend with the open end of each tee plugged. Provide pipe cap or plug cleanouts where indicated. Connect drains indicated to connect to the sanitary waste system using an indirect waste fitting. Insulate air conditioner drain lines as specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS.

3.2.2 Equipment and Installation

Provide frames and supports for tanks, compressors, pumps, valves, air handling units, fans, coils, dampers, and other similar items requiring supports. Floor mount or ceiling hang air handling units as indicated. Anchor and fasten as detailed. Set floor-mounted equipment on not less than 6 inch concrete pads or curbs doweled in place unless otherwise indicated. Make concrete foundations heavy enough to minimize the intensity of the vibrations transmitted to the piping, duct work and the surrounding structure, as recommended in writing by the equipment manufacturer. In lieu of a concrete pad foundation, build a concrete pedestal block with isolators placed between the pedestal block and the floor. Make the concrete foundation or concrete pedestal block a mass not less than three times the weight of the components to be supported. Provide the lines connected to the pump mounted on pedestal blocks with flexible connectors. Submit foundation drawings as specified in paragraph DETAIL DRAWINGS. Provide concrete for foundations as specified in Section 03 30 00 CAST-IN-PLACE CONCRETE.

3.2.3 Access Panels

Install access panels for concealed valves, vents, controls, dampers, and items requiring inspection or maintenance of sufficient size, and locate them so that the concealed items are easily serviced and maintained or completely removed and replaced. Provide access panels as specified in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.

3.2.4 Flexible Duct

Install pre-insulated flexible duct in accordance with the latest printed instructions of the manufacturer to ensure a vapor tight joint. Provide hangers, when required to suspend the duct, of the type recommended by the duct manufacturer and set at the intervals recommended.

3.2.5 Metal Ductwork

Install according to SMACNA 1966 unless otherwise indicated. Install duct supports for sheet metal ductwork according to SMACNA 1966, unless otherwise specified. Do not use friction beam clamps indicated in

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SMACNA 1966. Anchor risers on high velocity ducts in the center of the vertical run to allow ends of riser to move due to thermal expansion. Erect supports on the risers that allow free vertical movement of the duct. Attach supports only to structural framing members and concrete slabs. Do not anchor supports to metal decking unless a means is provided and approved for preventing the anchor from puncturing the metal decking. Where supports are required between structural framing members, provide suitable intermediate metal framing. Where C-clamps are used, provide retainer clips.

3.2.6 Dust Control

To prevent the accumulation of dust, debris and foreign material during construction, perform temporary dust control protection. Protect the distribution system (supply and return) with temporary seal-offs at all inlets and outlets at the end of each day's work. Keep temporary protection in place until system is ready for startup.

3.2.7 Insulation

Provide thickness and application of insulation materials for ductwork, piping, and equipment according to Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. Externally insulate outdoor air intake ducts and plenums up to the point where the outdoor air reaches the conditioning unit.

3.2.8 Duct Test Holes

Provide holes with closures or threaded holes with plugs in ducts and plenums as indicated or where necessary for the use of pitot tube in balancing the air system. Plug insulated duct at the duct surface, patched over with insulation and then marked to indicate location of test hole if needed for future use.

3.2.9 Power Transmission Components Adjustment

Test V-belts and sheaves for proper alignment and tension prior to operation and after 72 hours of operation at final speed. Uniformly load belts on drive side to prevent bouncing. Make alignment of direct driven couplings to within 50 percent of manufacturer's maximum allowable range of misalignment.

3.3 EQUIPMENT PADS

Provide equipment pads to the dimensions shown or, if not shown, to conform to the shape of each piece of equipment served with a minimum 3-inch margin around the equipment and supports. Allow equipment bases and foundations, when constructed of concrete or grout, to cure a minimum of 14 calendar days before being loaded.

3.4 CUTTING AND PATCHING

Install work in such a manner and at such time that a minimum of cutting and patching of the building structure is required. Make holes in exposed locations, in or through existing floors, by drilling and smooth by sanding. Use of a jackhammer is permitted only where specifically approved. Make holes through masonry walls to accommodate sleeves with an iron pipe masonry core saw.

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3.5 CLEANING

Thoroughly clean surfaces of piping and equipment that have become covered with dirt, plaster, or other material during handling and construction before such surfaces are prepared for final finish painting or are enclosed within the building structure. Before final acceptance, clean mechanical equipment, including piping, ducting, and fixtures, and free from dirt, grease, and finger marks. Incorporate housekeeping for field construction work which leaves all furniture and equipment in the affected area free of construction generated dust and debris; and, all floor surfaces vacuum-swept clean.

3.6 PENETRATIONS

Provide sleeves and prepared openings for duct mains, branches, and other penetrating items, and install during the construction of the surface to be penetrated. Cut sleeves flush with each surface. Place sleeves for round duct 15 inches and smaller. Build framed, prepared openings for round duct larger than 15 inches and square, rectangular or oval ducts. Sleeves and framed openings are also required where grilles, registers, and diffusers are installed at the openings. Provide one inch clearance between penetrating and penetrated surfaces except at grilles, registers, and diffusers. Pack spaces between sleeve or opening and duct or duct insulation with mineral fiber conforming with ASTM C553, Type 1, Class B-2.

a. Sleeves: Fabricate sleeves, except as otherwise specified or indicated, from 20 gauge thick mill galvanized sheet metal. Where sleeves are installed in bearing walls or partitions, provide black steel pipe conforming with ASTM A53/A53M, Schedule 20.

b. Framed Prepared Openings: Fabricate framed prepared openings from 20 gauge galvanized steel, unless otherwise indicated.

c. Insulation: Provide duct insulation in accordance with Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS continuous through sleeves and prepared openings except firewall penetrations. Terminate duct insulation at fire dampers and flexible connections. For duct handling air at or below 60 degrees F, provide insulation continuous over the damper collar and retaining angle of fire dampers, which are exposed to unconditioned air.

d. Closure Collars: Provide closure collars of a minimum 4 inches wide, unless otherwise indicated, for exposed ducts and items on each side of penetrated surface, except where equipment is installed. Install collar tight against the surface and fit snugly around the duct or insulation. Grind sharp edges smooth to prevent damage to penetrating surface. Fabricate collars for round ducts 15 inches in diameter or less from 20 gauge galvanized steel. Fabricate collars for square and rectangular ducts, or round ducts with minimum dimension over 15 inches from 18 gauge galvanized steel. Fabricate collars for square and rectangular ducts with a maximum side of 15 inches or less from 20 gauge galvanized steel. Install collars with fasteners a maximum of 6 inches on center. Attach to collars a minimum of 4 fasteners where the opening is 12 inches in diameter or less, and a minimum of 8 fasteners where the opening is 20 inches in diameter or less.

e. Firestopping: Where ducts pass through fire-rated walls, fire partitions, and fire rated chase walls, seal the penetration with fire stopping materials as specified in Section 07 84 00 FIRESTOPPING.

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3.7 FIELD PAINTING OF MECHANICAL EQUIPMENT

Clean, pretreat, prime and paint metal surfaces; except aluminum surfaces need not be painted. Apply coatings to clean dry surfaces. Clean the surfaces to remove dust, dirt, rust, oil and grease by wire brushing and solvent degreasing prior to application of paint, except clean to bare metal on metal surfaces subject to temperatures in excess of 120 degrees F. Where more than one coat of paint is specified, apply the second coat after the preceding coat is thoroughly dry. Lightly sand damaged painting and retouch before applying the succeeding coat. Provide aluminum or light gray finish coat.

a. Temperatures less than 120 degrees F: Immediately after cleaning, apply one coat of pretreatment primer applied to a minimum dry film thickness of 0.3 mil, one coat of primer applied to a minimum dry film thickness of one mil; and two coats of enamel applied to a minimum dry film thickness of one mil per coat to metal surfaces subject to temperatures less than 120 degrees F.

b. Temperatures between 120 and 400 degrees F: Apply two coats of 400 degrees F heat-resisting enamel applied to a total minimum thickness of two mils to metal surfaces subject to temperatures between 120 and 400 degrees F.

c. Temperatures greater than 400 degrees F: Apply two coats of 315 degrees C 600 degrees F heat-resisting paint applied to a total minimum dry film thickness of two mils to metal surfaces subject to temperatures greater than 400 degrees F.

3.8 IDENTIFICATION SYSTEMS

Provide identification tags made of brass, engraved laminated plastic, or engraved anodized aluminum, indicating service and item number on all valves and dampers. Provide tags that are 1-3/8 inch minimum diameter with stamped or engraved markings. Make indentations black for reading clarity. Attach tags to valves with No. 12 AWG 0.0808-inch diameter corrosion-resistant steel wire, copper wire, chrome-plated beaded chain or plastic straps designed for that purpose.

3.9 DUCTWORK LEAK TESTS

The requirements for ductwork leak tests are specified in Section 23 05 93 TESTING, ADJUSTING AND BALANCING FOR HVAC.

3.10 DAMPER ACCEPTANCE TEST

Submit the proposed schedule, at least 2 weeks prior to the start of test. Operate all fire dampers and smoke dampers under normal operating conditions, prior to the occupancy of a building to determine that they function properly. Test each fire damper equipped with fusible link by having the fusible link cut in place. Test dynamic fire dampers with the air handling and distribution system running. Reset all fire dampers with the fusible links replaced after acceptance testing. To ensure optimum operation and performance, install the damper so it is square and free from racking.

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3.11 TESTING, ADJUSTING, AND BALANCING

The requirements for testing, adjusting, and balancing are specified in Section 23 05 93 TESTING, ADJUSTING AND BALANCING FOR HVAC. Begin testing, adjusting, and balancing only when the air supply and distribution, including controls, has been completed, with the exception of performance tests.

3.12 PERFORMANCE TESTS

After testing, adjusting, and balancing is complete as specified, test each system as a whole to see that all items perform as integral parts of the system and temperatures and conditions are evenly controlled throughout the building. Record the testing during the applicable season. Make corrections and adjustments as necessary to produce the conditions indicated or specified. Conduct capacity tests and general operating tests by an experienced engineer. Provide tests that cover a period of not less than 7 days for each system and demonstrate that the entire system is functioning according to the specifications. Make coincidental chart recordings at points indicated on the drawings for the duration of the time period and record the temperature at space thermostats or space sensors, the humidity at space humidistats or space sensors and the ambient temperature and humidity in a shaded and weather protected area.

Submit test reports for the ductwork leak test, and performance tests in booklet form, upon completion of testing. Document phases of tests performed including initial test summary, repairs/adjustments made, and final test results in the reports.

3.13 CLEANING AND ADJUSTING

Provide a temporary bypass for water coils to prevent flushing water from passing through coils. Thoroughly clean ducts, plenums, and casing of debris and blow free of small particles of rubbish and dust and then vacuum clean before installing outlet faces. Wipe equipment clean, with no traces of oil, dust, dirt, or paint spots. Provide temporary filters prior to startup of all fans that are operated during construction, and install new filters after all construction dirt has been removed from the building, and the ducts, plenums, casings, and other items specified have been vacuum cleaned. Maintain system in this clean condition until final acceptance. Properly lubricate bearings with oil or grease as recommended by the manufacturer. Tighten belts to proper tension. Adjust control valves and other miscellaneous equipment requiring adjustment to setting indicated or directed. Adjust fans to the speed indicated by the manufacturer to meet specified conditions. Maintain all equipment installed under the contract until close out documentation is received, the project is completed and the building has been documented as beneficially occupied.

3.14 OPERATION AND MAINTENANCE

3.14.1 Operation and Maintenance Manuals

Submit six manuals at least 2 weeks prior to field training. Submit data complying with the requirements specified in Section 01 78 23 OPERATION AND MAINTENANCE DATA. Submit Data Package 3 for the items/units listed under SD-10 Operation and Maintenance Data

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3.14.2 Operation And Maintenance Training

Conduct a training course for the members of the operating staff as designated by the Contracting Officer. Make the training period consist of a total of 8 hours of normal working time and start it after all work specified herein is functionally completed and the Performance Tests have been approved. Conduct field instruction that covers all of the items contained in the Operation and Maintenance Manuals as well as demonstrations of routine maintenance operations. Submit the proposed On-site Training schedule concurrently with the Operation and Maintenance Manuals and at least 14 days prior to conducting the training course.

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SECTION 23 03 00.00 20

BASIC MECHANICAL MATERIALS AND METHODS08/10

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus

1.2 RELATED REQUIREMENTS

This section applies to all sections of Divisions: 21, FIRE SUPPRESSION; 22, PLUMBING; and 23, HEATING, VENTILATING, AND AIR CONDITIONING of this project specification, unless specified otherwise in the individual section.

1.3 QUALITY ASSURANCE

1.3.1 Material and Equipment Qualifications

Provide materials and equipment that are standard products of manufacturers regularly engaged in the manufacture of such products, which are of a similar material, design and workmanship. Standard products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year use shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2 year period.

1.3.2 Alternative Qualifications

Products having less than a two-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturer's factory or laboratory tests, can be shown.

1.3.3 Service Support

The equipment items shall be supported by service organizations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. These service organizations shall be reasonably convenient to the equipment installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.

1.3.4 Manufacturer's Nameplate

Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be

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acceptable.

1.3.5 Modification of References

In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction", or words of similar meaning, to mean the Contracting Officer.

1.3.5.1 Definitions

For the International Code Council (ICC) Codes referenced in the contract documents, advisory provisions shall be considered mandatory, the word "should" shall be interpreted as "shall." Reference to the "code official" shall be interpreted to mean the "Contracting Officer." For Navy owned property, references to the "owner" shall be interpreted to mean the "Contracting Officer." For leased facilities, references to the "owner" shall be interpreted to mean the "lessor." References to the "permit holder" shall be interpreted to mean the "Contractor."

1.3.5.2 Administrative Interpretations

For ICC Codes referenced in the contract documents, the provisions of Chapter 1, "Administrator," do not apply. These administrative requirements are covered by the applicable Federal Acquisition Regulations (FAR) included in this contract and by the authority granted to the Officer in Charge of Construction to administer the construction of this project. References in the ICC Codes to sections of Chapter 1, shall be applied appropriately by the Contracting Officer as authorized by his administrative cognizance and the FAR.

1.4 DELIVERY, STORAGE, AND HANDLING

Handle, store, and protect equipment and materials to prevent damage before and during installation in accordance with the manufacturer's recommendations, and as approved by the Contracting Officer. Replace damaged or defective items.

1.5 ELECTRICAL REQUIREMENTS

Furnish motors, controllers, disconnects and contactors with their respective pieces of equipment. Motors, controllers, disconnects and contactors shall conform to and have electrical connections provided under Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Furnish internal wiring for components of packaged equipment as an integral part of the equipment. Extended voltage range motors will not be permitted. Controllers and contactors shall have a maximum of 120 volt control circuits, and shall have auxiliary contacts for use with the controls furnished. When motors and equipment furnished are larger than sizes indicated, the cost of additional electrical service and related work shall be included under the section that specified that motor or equipment. Power wiring and conduit for field installed equipment shall be provided under and conform to the requirements of Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.

1.6 INSTRUCTION TO GOVERNMENT PERSONNEL

When specified in other sections, furnish the services of competent instructors to give full instruction to the designated Government personnel

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in the adjustment, operation, and maintenance, including pertinent safety requirements, of the specified equipment or system. Instructors shall be thoroughly familiar with all parts of the installation and shall be trained in operating theory as well as practical operation and maintenance work.

Instruction shall be given during the first regular work week after the equipment or system has been accepted and turned over to the Government for regular operation. The number of man-days (8 hours per day) of instruction furnished shall be as specified in the individual section. When more than 4 man-days of instruction are specified, use approximately half of the time for classroom instruction. Use other time for instruction with the equipment or system.

When significant changes or modifications in the equipment or system are made under the terms of the contract, provide additional instruction to acquaint the operating personnel with the changes or modifications.

1.7 ACCESSIBILITY

Install all work so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install concealed valves, expansion joints, controls, dampers, and equipment requiring access, in locations freely accessible through access doors.

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

3.1 PAINTING OF NEW EQUIPMENT

New equipment painting shall be factory applied or shop applied, and shall be as specified herein, and provided under each individual section.

3.1.1 Factory Painting Systems

Manufacturer's standard factory painting systems may be provided subject to certification that the factory painting system applied will withstand 125 hours in a salt-spray fog test, except that equipment located outdoors shall withstand 3000 hours in a salt-spray fog test. Salt-spray fog test shall be in accordance with ASTM B117, and for that test the acceptance criteria shall be as follows: immediately after completion of the test, the paint shall show no signs of blistering, wrinkling, or cracking, and no loss of adhesion; and the specimen shall show no signs of rust creepage beyond 0.125 inch on either side of the scratch mark.

The film thickness of the factory painting system applied on the equipment shall not be less than the film thickness used on the test specimen. If manufacturer's standard factory painting system is being proposed for use on surfaces subject to temperatures above 120 degrees F, the factory painting system shall be designed for the temperature service.

3.1.2 Shop Painting Systems for Metal Surfaces

Clean, pretreat, prime and paint metal surfaces; except aluminum surfaces need not be painted. Apply coatings to clean dry surfaces. Clean the surfaces to remove dust, dirt, rust, oil and grease by wire brushing and solvent degreasing prior to application of paint, except metal surfaces

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subject to temperatures in excess of 120 degrees F shall be cleaned to bare metal.

Where more than one coat of paint is specified, apply the second coat after the preceding coat is thoroughly dry. Lightly sand damaged painting and retouch before applying the succeeding coat. Color of finish coat shall be aluminum or light gray.

a. Temperatures Less Than 120 Degrees F: Immediately after cleaning, the metal surfaces subject to temperatures less than 120 degrees F shall receive one coat of pretreatment primer applied to a minimum dry film thickness of 0.3 mil, one coat of primer applied to a minimum dry film thickness of 1 mil; and two coats of enamel applied to a minimum dry film thickness of 1 mil per coat.

b. Temperatures Between 120 and 400 Degrees F: Metal surfaces subject to temperatures between 120 and 400 degrees F shall receive two coats of 400 degrees F heat-resisting enamel applied to a total minimum thickness of 2 mils.

c. Temperatures Greater Than 400 Degrees F: Metal surfaces subject to temperatures greater than 400 degrees F shall receive two coats of 600 degrees F heat-resisting paint applied to a total minimum dry film thickness of 2 mils.

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SECTION 23 05 15

COMMON PIPING FOR HVAC02/09

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2005) Steel Construction Manual

AMERICAN WELDING SOCIETY (AWS)

AWS WHB-2.9 (2004) Welding Handbook; Volume 2, Welding Processes, Part 1

ASME INTERNATIONAL (ASME)

ASME B16.1 (2010) Gray Iron Pipe Flanges and Flanged Fittings Classes 25, 125, and 250

ASME B16.22 (2012) Standard for Wrought Copper and Copper Alloy Solder Joint Pressure Fittings

ASME B16.3 (2011) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.39 (2009) Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300

ASME B16.5 (2013) Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B16.9 (2012) Standard for Factory-Made Wrought Steel Buttwelding Fittings

ASME B31.3 (2012) Process Piping

ASME B40.100 (2005; R 2010) Pressure Gauges and Gauge Attachments

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASME BPVC SEC VIII D1 (2010) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ASTM INTERNATIONAL (ASTM)

ASTM A126 (2004; R 2009) Standard Specification for Gray Iron Castings for Valves, Flanges,

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and Pipe Fittings

ASTM A197/A197M (2000; R 2011) Standard Specification for Cupola Malleable Iron

ASTM A234/A234M (2011a) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM A276 (2010) Standard Specification for Stainless Steel Bars and Shapes

ASTM A278/A278M (2001; R 2011) Standard Specification for Gray Iron Castings for Pressure-Containing Parts for Temperatures Up to 650 degrees F (350 degrees C)

ASTM A307 (2012) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A563 (2007a) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A6/A6M (2012) Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling

ASTM B32 (2008) Standard Specification for Solder Metal

ASTM B62 (2009) Standard Specification for Composition Bronze or Ounce Metal Castings

ASTM B88 (2009) Standard Specification for Seamless Copper Water Tube

ASTM C109/C109M (2012) Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2-in. or (50-mm) Cube Specimens)

ASTM C404 (2011) Standard Specification for Aggregates for Masonry Grout

ASTM C476 (2010) Standard Specification for Grout for Masonry

ASTM C553 (2011) Standard Specification for Mineral Fiber Blanket Thermal Insulation for Commercial and Industrial Applications

ASTM C67 (2012) Standard Test Methods for Sampling and Testing Brick and Structural Clay Tile

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ASTM C920 (2011) Standard Specification for Elastomeric Joint Sealants

ASTM E1 (2007) Standard Specification for ASTM Liquid-in-Glass Thermometers

ASTM E814 (2011a) Standard Test Method for Fire Tests of Through-Penetration Fire Stops

ASTM F104 (2011) Standard Classification System for Nonmetallic Gasket Materials

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)

MSS SP-125 (2010) Gray Iron and Ductile Iron In-Line, Spring-Loaded, Center-Guided Check Valves

MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-67 (2011) Butterfly Valves

MSS SP-69 (2003; Notice 2012) Pipe Hangers and Supports - Selection and Application (ANSI Approved American National Standard)

MSS SP-72 (2010a) Ball Valves with Flanged or Butt-Welding Ends for General Service

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

CID A-A-1922 (Rev A; Notice 2) Shield, Expansion (Caulking Anchors, Single Lead)

CID A-A-1923 (Rev A; Notice 2) Shield, Expansion (Lag, Machine and Externally Threaded Wedge Bolt Anchors)

CID A-A-1924 (Rev A; Notice 2) Shield, Expansion (Self Drilling Tubular Expansion Shell Bolt Anchors

CID A-A-1925 (Rev A; Notice 2) Shield Expansion (Nail Anchors)

CID A-A-55614 (Basic; Notice 2) Shield, Expansion (Non-Drilling Expansion Anchors)

CID A-A-55615 (Basic; Notice 2) Shield, Expansion (Wood Screw and Lag Bolt Self-Threading Anchors

UNDERWRITERS LABORATORIES (UL)

UL 1479 (2003; Reprint Oct 2012) Fire Tests of Through-Penetration Firestops

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1.2 GENERAL REQUIREMENTS

Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS applies to work specified in this section.

Section 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT applies to work specified in this section.

Submit Record Drawings for pipes, valves and accessories providing current factual information including deviations and amendments to the drawings, and concealed and visible changes in the work.

Submit Coordination Drawings for pipes, valves and specialties showing coordination of work between different trades and with the structural and architectural elements of work. Detail all drawings sufficiently to show overall dimensions of related items, clearances, and relative locations of work in allotted spaces. Indicate on drawings where conflicts or clearance problems exist between various trades.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Submit the following for pipes, valves and specialties showing conformance with the referenced standards contained within this section.

Record DrawingsCoordination Drawings

SD-03 Product Data

Submit equipment and performance data for the following items consisting of corrosion resistance, life expectancy, gage tolerances, and grade line analysis.

Submit Manufacturer's catalog data for the following items:

Pipe and FittingsPiping SpecialtiesValvesMiscellaneous MaterialsSupporting Elements

SD-06 Test Reports

Submit test reports on the following tests in accordance with paragraph entitled, "Piping Installation," of this section.

Hydrostatic TestsAir TestsValve-Operating TestsDrainage Tests

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Pneumatic TestsNon-Destructive Electric TestsSystem Operation Tests

SD-07 Certificates

Submit Certificates for the following in accordance with paragraph entitled, "Pipe Installation," of this section.

Surface ResistanceShear and Tensile StrengthsTemperature RatingsBending TestsFlattening TestsTransverse Guided Weld Bend Tests

SD-10 Operation and Maintenance Data

Submit Operation and Maintenance Manuals in accordance with paragraph entitled, "Operation and Maintenance," of this section.

1.4 QUALITY ASSURANCE

1.4.1 Material and Equipment Qualifications

Provide materials and equipment that are standard products of manufacturers regularly engaged in the manufacture of such products, which are of a similar material, design and workmanship. Standard products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year use shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2 year period.

1.4.2 Alternative Qualifications

Products having less than a two-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturer's factory or laboratory tests, can be shown.

1.4.3 Service Support

The equipment items shall be supported by service organizations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. These service organizations shall be reasonably convenient to the equipment installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.

1.4.4 Manufacturer's Nameplate

Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.

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1.4.5 Modification of References

In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction", or words of similar meaning, to mean the Contracting Officer.

1.4.5.1 Definitions

For the International Code Council (ICC) Codes referenced in the contract documents, advisory provisions shall be considered mandatory, the word "should" shall be interpreted as "shall." Reference to the "code official" shall be interpreted to mean the "Contracting Officer." For Navy owned property, references to the "owner" shall be interpreted to mean the "Contracting Officer." For leased facilities, references to the "owner" shall be interpreted to mean the "lessor." References to the "permit holder" shall be interpreted to mean the "Contractor."

1.4.5.2 Administrative Interpretations

For ICC Codes referenced in the contract documents, the provisions of Chapter 1, "Administrator," do not apply. These administrative requirements are covered by the applicable Federal Acquisition Regulations (FAR) included in this contract and by the authority granted to the Officer in Charge of Construction to administer the construction of this project. References in the ICC Codes to sections of Chapter 1, shall be applied appropriately by the Contracting Officer as authorized by his administrative cognizance and the FAR.

1.5 DELIVERY, STORAGE, AND HANDLING

Handle, store, and protect equipment and materials to prevent damage before and during installation in accordance with the manufacturer's recommendations, and as approved by the Contracting Officer. Replace damaged or defective items.

1.6 ELECTRICAL REQUIREMENTS

Furnish motors, controllers, disconnects and contactors with their respective pieces of equipment. Motors, controllers, disconnects and contactors shall conform to and have electrical connections provided under Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Furnish internal wiring for components of packaged equipment as an integral part of the equipment. Extended voltage range motors will not be permitted. Controllers and contactors shall have a maximum of 120 volt control circuits, and shall have auxiliary contacts for use with the controls furnished. When motors and equipment furnished are larger than sizes indicated, the cost of additional electrical service and related work shall be included under the section that specified that motor or equipment. Power wiring and conduit for field installed equipment shall be provided under and conform to the requirements of Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.

1.7 INSTRUCTION TO GOVERNMENT PERSONNEL

When specified in other sections, furnish the services of competent instructors to give full instruction to the designated Government personnel in the adjustment, operation, and maintenance, including pertinent safety requirements, of the specified equipment or system. Instructors shall be

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thoroughly familiar with all parts of the installation and trained in operating theory as well as practical operation and maintenance work.

Give instruction during the first regular work week after the equipment or system has been accepted and turned over to the Government for regular operation. The number of man-days (8 hours per day) of instruction furnished shall be as specified in the individual section. When more than 4 man-days of instruction are specified, use approximately half of the time for classroom instruction. Use other time for instruction with the equipment or system.

When significant changes or modifications in the equipment or system are made under the terms of the contract, provide additional instruction to acquaint the operating personnel with the changes or modifications.

1.8 ACCESSIBILITY

Install all work so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install concealed valves, expansion joints, controls, dampers, and equipment requiring access, in locations freely accessible through access doors.

PART 2 PRODUCTS

2.1 PIPE AND FITTINGS

2.1.1 Type BCS, Black Carbon Steel

Pipe 1/8 through 10 inches shall be Schedule 40 seamless or electric-resistance welded black carbon steel, conforming to ASTM A53/A53M, Type E, Grade B (electric-resistance welded) Type S (seamless).

Fittings 2 inches and under shall be 150-pounds per square inch, gage (psig) working steam pressure (wsp) banded black malleable iron screwed, conforming to ASTM A197/A197M and ASME B16.3.

Unions 2 inches and under shall be 250 pounds per square inch, wsp female, screwed, black malleable iron with brass-to-iron seat, and ground joint, conforming to ASME B16.39.

Fittings 2-1/2 inches and over shall be Steel butt weld, conforming to ASTM A234/A234M and ASME B16.9 to match pipe wall thickness.

Flanges 2-1/2 inches and over shall be 150-pound forged-steel conforming to ASME B16.5, welding neck to match pipe wall thickness.

2.1.2 Type CPR, Copper

2.1.2.1 Type CPR-A, Copper Above Ground

Tubing 2 inches and under shall be seamless copper tubing, conforming to ASTM B88, Type L (hard-drawn for all horizontal and all exposed vertical lines, annealed for concealed vertical lines).

Fittings 2 inches and under shall be 150-psigwsp wrought-copper solder joint fittings conforming to ASME B16.22.

Unions 2 inches and under shall be 150-psig wsp wrought-copper solder joint, conforming to ASME B16.22.

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Solder must be 60-40 tin-antimony, alloy Sb-5, conforming to ASTM B32.

2.2 PIPING SPECIALTIES

2.2.1 Air Separator

Air separated from converter discharge water shall be ejected by a reduced-velocity device vented to the compression tank.

Air separator shall be carbon steel, designed, fabricated, tested, and stamped in conformance with ASME BPVC SEC VIII D1 for service pressures not less than 125 psi.

2.2.2 Air Vents

Manual air vents shall be 3/8-inch globe valves.

Automatic air vents on pumps, mains, and where indicated shall be of ball-float construction. Vent inlet shall be not less than 3/4-inch ips and the outlet not less than 1/4-inch ips. Orifice shall be 1/8 inch. Provide corrosion-resistant steel trim conforming to ASTM A276. Vent shall be fitted with try-cock. Vent shall discharge air at any pressure up to 150 psi. Outlet shall be copper tube routed.

2.2.3 Compression Tank

Provide compression tank designed, fabricated, tested, and stamped for a working pressure of not less than 125 psi in accordance with ASME BPVC SEC VIII D1. Tank shall be hot-dip galvanized after fabrication to produce not less than 1.5 ounces of zinc coating per square foot of single-side surface.

Tank accessories shall include red-lined gage-glass complete with glass protectors and shutoff valves, air charger and drainer, and manual vent.

2.2.4 Dielectric Connections

Dissimilar pipe metals shall be electrically insulated from each other by couplings, unions, or flanges commercially manufactured for that purpose and rated for the service pressure and temperature.

2.2.5 Flexible Metallic Pipe

Flexible pipe shall be the bellows-type with wire braid cover and designed, constructed, and rated in accordance with the applicable requirements of ASME B31.3.

Working pressure minimum rating shall be 100 psi at 300 degrees F.

Minimum burst pressure shall be four times working pressure at 300 degrees F. Bellows material shall be AISI Type 316L corrosion-resistant steel. Braid shall be AISI 300 series corrosion-resistant steel wire.

Flanged end connection rating and materials shall conform to specifications for system primary-pressure rating.

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2.2.6 Pressure Gages

Pressure gages shall conform to ASME B40.100 and to requirements specified herein. Pressure-gage size shall be 3-1/2 inches nominal diameter. Case shall be corrosion-resistant steel, conforming to any of the AISI 300 series of ASTM A6/A6M, with an ASM No. 4 standard commercial polish or better. Equip gages with adjustable red marking pointer and damper-screw adjustment in inlet connection. Service-pressure reading shall be at midpoint of gage range. All gages shall be Grade B or better and be equipped with gage isolators.

2.2.7 Sleeve Couplings

Sleeve couplings for plain-end pipe shall consist of one steel middle ring, two steel followers, two chloroprene or Buna-N elastomer gaskets, and the necessary steel bolts and nuts.

2.2.8 Thermometers

Thermometers shall conform to ASTM E1, except for being filled with a red organic liquid. Thermometers shall be an industrial pattern armored glass model, (well-threaded and seal-welded). Thermometers installed 6 feet or higher above the floor shall have an adjustable angle body. Scale shall be not less than 7 inches long. Case face shall be manufactured from manufacturer's standard polished aluminum or AISI 300 series polished corrosion-resistant steel. Thermometer range shall be 0 deg F to 150 deg F. Provide thermometers with nonferrous separable wells. Provide lagging extension to accommodate insulation thickness.

2.2.9 Line Strainers, Water Service

Strainers shall be Y-type with removable basket. Strainers in sizes 2-inch ips and smaller shall have screwed ends. In sizes 2-1/2-inch ips and larger, strainers shall have flanged ends. Body working-pressure rating shall exceed maximum service pressure of system in which installed by at least 50 percent. Body shall have cast-in arrows to indicate direction of flow. All strainer bodies fitted with screwed screen retainers shall have straight threads and gasketed with nonferrous metal. Strainer bodies 2-1/2-inches and larger, fitted with bolted-on screen retainers, shall have offset blowdown holes. All strainers larger than2-1/2-inches shall be fitted with manufacturer's standard ball-type blowdown valve. Body material shall be cast iron conforming to Class 30 ASTM A278/A278M. Where system material is nonferrous, metal strainer body material shall be nonferrous metal.

Minimum free-hole area of strainer element shall be equal to not less than 3.4 times the internal area of connecting piping. Strainer screens shall have perforations not to exceed 0.045-inch. Strainer screens shall have finished ends fitted to machined screen chamber surfaces to preclude bypass flow. Strainer element material shall be AISI Type 304 corrosion-resistant steel.

2.3 VALVES

2.3.1 Ball and Butterfly Valves

Ball valves shall conform to MSS SP-72 for Figure 1A, 1 piece body and shall be rated for service at not less than 175 psig at 200 degrees F. Valve bodies in sizes 2 inches and smaller shall be screwed-end

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connection-type constructed of Class A copper alloy. Valve bodies in sizes 2-1/2 inches and larger shall be flanged-end connection type, constructed of Class D material. Balls and stems of valves 2 inches and smaller shall be manufacturer's standard with hard chrome plating finish. Balls and stems of valves 2-1/2 inches and larger shall be manufacturer's standard Class C corrosion-resistant steel alloy with hard chrome plating. Balls of valves 6 inches and larger may be Class D with 900 Brinell hard chrome plating. Valves shall be suitable for flow from either direction and shall seal equally tight in either direction. Valves with ball seals held in place by spring washers are not acceptable. All valves shall have adjustable packing glands. Seats and seals shall be tetrafluoroethylene.

Butterfly valves shall conform to MSS SP-67. Valves shall be wafer type for mounting between specified flanges and shall be rated for 150-psig shutoff and nonshock working pressure. Bodies shall be cast ferrous metal conforming to ASTM A126, Class B, and to ASME B16.1 for body wall thickness. Seats and seals shall be of the resilient elastomer type designed for field removal and replacement.

2.3.2 Drain, Vent, and Gage Cocks

Drain, vent, and gage cocks shall be lever handle, ground key type, with washer and screw, constructed of polished ASTM B62 bronze, and rated 125-psi wsp. End connections shall be rated for specified service pressure.

Pump vent cocks, and where spray control is required, shall be UL umbrella-hood type, constructed of manufacturer's standard polished brass. Cocks shall be 1/2-inch ips male, end threaded, and rated at not less than 125 psi at 225 degrees F.

2.3.3 Nonslam Check Valves (NSV)

Check valves at pump discharges in sizes 2 inches and larger shall be nonslam or silent-check type conforming to MSS SP-125. Valve disc or plate shall close before line flow can reverse to eliminate slam and water-hammer due to check-valve closure. Valve shall be Class 125 rated for 200-psi maximum, nonshock pressure at 150 degrees F in sizes to 12 inches. Valves shall be fitted with flanges conforming to ASME B16.1. Valve body may be cast iron, conforming to ASTM A278/A278M, Class 40 or equivalent strength ductile iron. Disks shall be manufacturer's standard bronze, aluminum bronze, or corrosion-resistant steel. Pins, springs, and miscellaneous trim shall be manufacturer's standard corrosion-resistant steel. Disk and shaft seals shall be Buna-N elastomer tetrafluoroethylene.

2.4 MISCELLANEOUS MATERIALS

2.4.1 Bolting

Flange and general purpose bolting shall be hex-head and must conform to ASTM A307, Grade B (bolts, for flanged joints in piping systems where one or both flanges are cast iron). Heavy hex-nuts shall conform to ASTM A563. Square-head bolts and nuts are not acceptable. Threads shall be coarse-thread series.

2.4.2 Elastomer Caulk

Polysulfide- or polyurethane-base elastomer caulking material shall be two-component type, conforming to ASTM C920.

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2.4.3 Flange Gaskets

Compressed non-asbestos sheet, conforming to ASTM F104, coated on both sides with graphite or similar lubricant, with nitrile composition, binder rated to 750 degrees F.

2.4.4 Grout

Shrink-resistant grout shall be a premixed and packaged metallic-aggregate, mortar-grouting compound conforming to ASTM C404 and ASTM C476.

Shrink-resistant grout shall be a combination of premeasured and packaged epoxy polyamide or amine resins and selected aggregate mortar grouting compound conforming to the following requirements:

Tensile strength 1,900 psi, minimum

Compressive strength ASTM C109/C109M 14,000 psi, minimum

Shrinkage, linear 0.00012 inch per inch, maximum

Water absorption ASTM C67 0.1 percent, maximum

Bond strength to 1,000 psi, minimum steel in shear minimum

2.4.5 Pipe Thread Compounds

Use tetrafluoroethylene tape not less than 2 to 3 mils thick in potable and process water and in chemical systems for pipe sizes to and including 1-inch ips. Tetrafluoroethylene dispersions and other suitable compounds shall be used for all other applications upon approval by the Contracting Officer; however, no lead-containing compounds shall be used in potable water systems.

2.5 SUPPORTING ELEMENTS

Provide all necessary piping systems and equipment supporting elements, including but not limited to: building structure attachments; supplementary steel; hanger rods, stanchions, and fixtures; vertical pipe attachments; horizontal pipe attachments; anchors; guides; and spring-cushion, variable, or constant supports. All supporting elements shall be suitable for stresses imposed by systems pressures and temperatures and natural and other external forces normal to this facility without damage to supporting element system or to work being supported.

Supporting elements shall conform to requirements of ASME B31.3, MSS SP-58, and MSS SP-69 except as noted.

Attachments welded to pipe shall be made of materials identical to that of pipe or materials accepted as permissible raw materials by referenced code or standard specification.

Supporting elements exposed to weather shall be hot-dip galvanized or stainless steel. Materials shall be of such a nature that their apparent and latent-strength characteristics are not reduced due to galvanizing process. Supporting elements in contact with copper tubing shall be electroplated with copper.

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Type designations specified herein are based on MSS SP-58 and MSS SP-69. Masonry anchor group-, type-, and style-combination designations shall be in accordance with CID A-A-1922, CID A-A-1923, CID A-A-1924, CID A-A-1925 , CID A-A-55614, and CID A-A-55615. Support elements, except for supplementary steel, shall be cataloged, load rated, commercially manufactured products.

2.5.1 Building Structure Attachments

2.5.1.1 Beam Clamps

Beam clamps shall be center-loading MSS SP-58 Type 20.

When it is not possible to use center-loading beam clamps, eccentric-loading beam clamps, MSS SP-58 Type 19 may be used for piping sizes 2 inches and less and for piping sizes 2 through 10 inches provided two counterbalancing clamps are used per point of pipe support. Where more than one rod is used per point of pipe support, rod diameter shall be determined in accordance with referenced standards.

2.5.1.2 C-Clamps

Do not use C-clamps.

2.5.2 Horizontal Pipe Attachments

2.5.2.1 Single Pipes

Support piping in sizes to and including 2-inch ips by MSS SP-58 Type 6 solid malleable iron pipe rings, except that split-band-type rings shall be used in sizes up to 1-inch ips.

Support piping in sizes through 8-inch ips inclusive by MSS SP-58 Type 1 attachments.

MSS SP-58 Type 1 and Type 6 assemblies shall be used on vapor-sealed insulated piping and shall have an inside diameter larger than pipe being supported to provide adequate clearance during pipe movement.

MSS SP-58 Type 40 shields shall be used on all insulated piping. Area of the supporting surface shall be such that compression deformation of insulated surfaces does not occur. Longitudinal and transverse shield edges shall be rolled away from the insulation.

Provide insulated piping without vapor barrier on roll supports with MSS SP-58 Type 39 saddles.

Spring supports shall be as indicated.

2.5.2.2 Parallel Pipes

Trapeze hangers fabricated from structural steel shapes, with U-bolts, shall be used in congested areas and where multiple pipe runs occur. Structural steel shapes shall be of commercially available, proprietary design, rolled steel.

2.5.3 Vertical Pipe Attachments

Vertical pipe attachments shall be MSS SP-58 Type 8.

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Shop drawing data shall include complete fabrication and attachment details of any spring supports.

2.5.4 Hanger Rods and Fixtures

Only circular cross section rod hangers shall be used to connect building structure attachments to pipe support devices. Pipe, straps, or bars of equivalent strength shall be used for hangers only where approved by the Contracting Officer.

Turnbuckles, swing eyes, and clevises shall be provided as required by support system to accommodate temperature change, pipe accessibility, and adjustment for load and pitch. Rod couplings are not acceptable.

2.5.5 Supplementary Steel

Where it is necessary to frame structural members between existing members or where structural members are used in lieu of commercially rated supports, design and fabricate such supplementary steel in accordance with AISC 325.

PART 3 EXECUTION

3.1 PIPE INSTALLATION

Submit certificates for pipes, valves and specialties showing conformance with test requirements as contained in the reference standards contained in this section. Certificates shall verify Surface Resistance, Shear and Tensile Strengths, Temperature Ratings, Bending Tests, Flattening Tests and Transverse Guided Weld Bend Tests.

Test reports for Hydrostatic Tests, Air Tests, Valve-Operating Tests, Drainage Tests, Pneumatic Tests, Non-Destructive Electric Tests and System Operation Tests shall be provided by the Contractor, in compliance with referenced standards contained within this section.

Fabricate and install piping systems in accordance with ASME B31.3, MSS SP-69, and AWS WHB-2.9.

Connections between steel piping and copper piping shall be electrically isolated from each other with dielectric couplings (or unions) or flanged with gaskets rated for the service.

Make final connections to equipment with unions or flanges provided every 100 feet of straight run. Provide unions in the line downstream of screwed- and welded-end valves.

Ream all pipe ends before joint connections are made.

Screwed joints shall be made up with specified joint compound and not more than three threads shall show after joint is made up.

Apply joint compounds to the male thread only and exercise care to prevent compound from reaching the unthreaded interior of the pipe.

Provide screwed unions, welded unions, or bolted flanges wherever required to permit convenient removal of equipment, valves, and piping accessories from the piping system for maintenance.

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Securely support piping systems with due allowance for thrust forces, thermal expansion and contraction, and shall not be subjected to mechanical, chemical, vibrational or other damage as specified in ASME B31.3.

Field welded joints shall conform to the requirements of the AWS WHB-2.9, ASME B31.3, and ASME BPVC SEC IX.

3.2 VALVES

Provide valves in piping mains and all branches and at equipment where indicated and as specified.

Provide valves to permit isolation of branch piping and each equipment item from the balance of the system.

Valves unavoidably located in furred or other normally inaccessible places shall be provided with access panels adequately sized for the location and located so that concealed items may be serviced, maintained, or replaced.

3.3 SUPPORTING ELEMENTS INSTALLATION

Provide supporting elements in accordance with the referenced codes and standards.

Support piping from building structure. No piping shall be supported from roof deck or from other pipe.

Piping shall run parallel with the lines of the building. Space and install piping and components so that a threaded pipe fitting may be removed between adjacent pipes and so that there shall be no less than 1/2 inch of clear space between the finished surface and other work and between the finished surface of parallel adjacent piping. Hangers on different adjacent service lines running parallel with each other shall be arranged to be in line with each other and parallel to the lines of the building.

Install piping support elements at intervals specified hereinafter, at locations not more than 3 feet from the ends of each runout, and not over 1 foot from each change in direction of piping.

Load rating for all pipe-hanger supports shall be based on insulated weight of lines filled with water and forces imposed. Deflection per span shall not exceed slope gradient of pipe. Supports shall be in accordance with the following minimum rod size and maximum allowable hanger spacing for specified pipe. For concentrated loads such as valves, the allowable span must be reduced proportionately:

PIPE SIZE ROD SIZE STEEL PIPE COPPER PIPE INCHES INCHES FEET FEET

1 and smaller 3/8 8 6

1-1/4 to 1-1/2 3/8 10 8

2 3/8 10 8

2-1/2 to 3-1/2 1/2 12 12

4 to 5 5/8 16 14

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PIPE SIZE ROD SIZE STEEL PIPE COPPER PIPE INCHES INCHES FEET FEET

6 3/4 16 16

8 to 12 7/8 20 20

14 to 18 1 20 20

20 and over 1-1/4 20 20

Provide vibration isolation supports where needed. Refer to Section 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT where A/C equipment and piping is installed.

3.4 PENETRATIONS

Effective sound stopping and adequate operating clearance shall be provided to prevent structure contact where piping penetrates walls, floors, or ceilings into occupied spaces adjacent to equipment rooms; where similar penetrations occur between occupied spaces; and where penetrations occur from pipe chases into occupied spaces. Occupied spaces shall include space above ceilings where no special acoustic treatment of ceiling is provided. Penetrations shall be finished to be compatible with surface being penetrated.

3.5 SLEEVES

Provide sleeves where piping passes through roofs, masonry, concrete walls and floors.

Sleeves passing through steel decks shall be continuously welded to the deck.

Sleeves that extend through floors, roofs, load bearing walls, and fire barriers shall be continuous and fabricated from Schedule 40 steel pipe, with welded anchor lugs. All other sleeves shall be formed by molded linear polyethylene liners or similar materials that are removable. Diameter of sleeves shall be large enough to accommodate pipe, insulation, and jacketing without touching the sleeve and shall provide a minimum 3/8-inch clearance. Sleeve size must accommodate mechanical and thermal motion of pipe to preclude transmission of vibration to walls and the generation of noise.

Space between a pipe, bare or insulated, and the inside of a pipe sleeve or a construction surface penetration shall be packed solid with a mineral fiber conforming to ASTM C553 Type V (flexible blanket), (to 1,000 degrees F). Provide this packing wherever the piping passes through firewalls, equipment room walls, floors, and ceilings connected to occupied spaces, and other locations where sleeves or construction-surface penetrations occur between occupied spaces. Where sleeves or construction surface penetrations occur between conditioned and unconditioned spaces, the space between a pipe, bare or insulated, and the inside of a pipe sleeve or construction surface penetration shall be filled with an elastomer caulk to a depth of 1/2 inch. All surfaces to be caulked shall be oil- and grease-free.

Through-Penetration fire stop materials and methods shall be in accordance

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with ASTM E814 and UL 1479.

Exterior wall sleeves shall be caulked watertight with lead and oakum or mechanically expandable chloroprene inserts with mastic-sealed metal components.

Sleeve height above roof surface shall be a minimum of 12 and a maximum of 18 inches.

3.6 FLASHINGS

Provide flashings at penetrations of building boundaries by mechanical systems and related work.

3.7 DISINFECTION

Flush piping with potable water until visible grease, dirt and other contaminants are removed (visual inspection).

3.8 OPERATION AND MAINTENANCE

Operation and Maintenance Manuals shall be consistent with manufacturer's standard brochures, schematics, printed instructions, general operating procedures and safety precautions. Test data shall be clear and readily legible.

-- End of Section --

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SECTION 23 05 48.00 40

VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT02/11

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ACOUSTICAL SOCIETY OF AMERICA (ASA)

ASA S2.71 (1983; R 2006) Guide to the Evaluation of Human Exposure to Vibration in Buildings

NATIONAL ENVIRONMENTAL BALANCING BUREAU (NEBB)

NEBB PROCEDURAL STANDARDS (2005) Procedural Standards for TAB (Testing, Adjusting and Balancing) Environmental Systems

1.2 ADMINISTRATIVE REQUIREMENTS

Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS applies to work specified in this section to the extent applicable.

Ensure all vibration-control apparatus is the product of a single manufacturing source, where possible. Human exposure levels should be considered using ASA S2.71 and NEBB PROCEDURAL STANDARDS.

Scheduled isolation mounting is in inches and is a minimum static deflection.

Spans referred to in Part 2, "Vibration-Isolation Systems Application," means longest bay dimension.

Determine exact mounting sizes and number of isolators by the isolator manufacturer based on equipment that will be installed. Check equipment revolutions per minute (rpm) and spring deflections to verify that resonance cannot occur.

Five working days prior to commencement of installation, submit installation drawings for vibration isolator systems including equipment and performance requirements.

Indicate within outline drawings for vibration isolator systems, overall physical features, dimensions, ratings, service requirements, and weights of equipment.

Within ten working days of Contract Award, submit equipment and performance data for vibration isolator systems including equipment base design; inertia-block mass relative to support equipment weight; spring loads and free, operating, and solid heights of spring; spring diameters; nonmetallic isolator loading and deflection; disturbing frequency; natural frequency of mounts; deflection of working member; and anticipated amount of physical

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movement at the reference points.

Ensure data includes the following:

a. Mountings

b. Bases

c. Isolators

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Installation Drawings; G

Outline Drawings; G

SD-03 Product Data

Equipment and Performance Data; G

Isolators; G

SD-06 Test Reports

Type of Isolator; G

Type of Base; G

Allowable Deflection; G

Measured Deflection; G

PART 2 PRODUCTS

2.1 TYPE OF VIBRATION-ISOLATION PROVISIONS

Design for vibration isolation using NEBB PROCEDURAL STANDARDS as applicable to the following sections.

Submit test reports for testing vibration isolation for each type of isolator and each type of base, and meet referenced standards contained within this section. Include in test reports allowable deflection and measured deflection also meeting referenced standards within this section.

2.1.1 Materials

Ensure rubber is natural rubber and elastomer is chloroprene. Shore A durometer measurement of both materials and range between 40 and 60.

Inorganic materials such as precompressed, high-density, fibrous glass encased in a resilient moisture-impervious membrane may be used in lieu of specified natural rubber and elastomers. Where this substitution is made,

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ensure specified deflections are modified by the manufacturing source to accommodate physical characteristics of inorganic materials and to provide equal or better vibration isolation.

Ensure weather-exposed metal vibration-isolator parts are corrosion protected. Chloroprene coat springs.

2.1.2 Mountings

Provide the following mountings:

Type B: Double rubber-in-shear with molded-in steel reinforcement in top and bottom. Maximum deflections up to 0.50 inch are allowed.

Type C: Free-standing laterally stable open-spring type for deflections over 0.50 inch, with built-in bearing and leveling provisions, 0.25-inch thick Type A base elastomer pads, and accessories. Ensure outside diameter of each spring is equal to or greater than 0.9 times the operating height of the spring under rated load.

Type D: Partially housed type, containing one or more vertically restrained springs with at least 0.50 inch clearance maintained around springs, with adjustable limit stops, 0.25-inch thick Type A base elastomer pads, and accessories.

Type F: Combination spring and rubber-in-shear steel framed for hanger-rod mounting, with minimum total static deflection of 1 inch.

2.1.3 Bases

Provide the following bases:

Type U: Unit isolators without rails, structural-steel bases, or inertia blocks.

Type R: Rails, connected mill-rolled structural steel, of sufficient dimension to preclude deflection at midpoint of unsupported span in excess of 1/1,440th of the span between isolators, power transmission, component misalignment, and any overhung weight. Where Type R bases are specified and the equipment proposed requires additional base support, use a Type S base.

Type S: Structural-steel bases common to a supported assembly, made from welded-joint mill-rolled structural steel with closed-perimeter configuration, isolators attached to outrigger supports.

Ensure height of steel members is sufficient to provide stiffness required to maintain equipment manufacturer's recommended alignment and duty efficiency of power-transmission components. Ensure height of steel member does not result in member deflection at midpoint of unsupported span of more than 1/1,440th of the span between isolators. Minimum height is 5 inches.

Type CIB: Provide concrete inertia blocks common to the entire assembly, with welded-joint construction, mill-rolled structural-steel perimeters, welded-in No. 4 reinforcing bars 8 inches on center each way near the bottom of the block, outrigger-isolator mounting provisions, anchor bolts, and be filled with 3,000 psi cured-strength

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concrete.

2.2 VIBRATION-ISOLATION SYSTEMS APPLICATION

Vibration isolation design per NEBB PROCEDURAL STANDARDS.

2.2.1 Centrifugal Pump Locations

ON\ABOVE ON\ABOVE ON\ABOVE GRADE GRADE GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS*

Close- couple through 5 hp None -R-0.35 C-S-1.0 C-S-1.0

Bedplate- mounted through 5 hp None C-CIB-1.0 C-CIB-1.5 C-CIB-1.75

7-1/2 hp None C-CIB-1.0 C-CIB-1.75 C-CIB-2.5

*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES

2.2.2 Air-Cooled Condensing Unit Locations

20-FOOT 30-FOOT 40-FOOT ROOF-SPAN ROOF-SPAN ROOF-SPAN TYPE EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS*

Through 5 hp over 900 rpm B-U-0.5 D-U-1.0 D-U-1.75

Over 5 hp to 500 rpm B-U-0.5 D-U-1.75 D-U-2.5

500 rpm and over B-U-0.5 D-U-1.0 D-U-1.75

*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES

2.2.3 Low-Pressure Suspended Air-Handling Unit (AHU) Locations

Vibration-isolation provisions apply to ceiling-suspended Air Moving and Conditioning Association Class A packaged central-station units.

20-FOOT 30-FOOT 40-FOOT ROOF-SPAN ROOF-SPAN ROOF-SPAN TYPE EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS*

Through 5 hp F-U-1.0 F-U-1.0 F-U-1.0

7-1/2 hp and over 250 to 500 rpm F-U-1.75 F-U-1.75 F-U-1.75

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20-FOOT 30-FOOT 40-FOOT ROOF-SPAN ROOF-SPAN ROOF-SPAN TYPE EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* 500 rpm and over F-U-1.0 F-U-1.25 F-U-1.55

*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES

2.2.4 Low-Pressure AHU Locations

Vibration-isolation provisions apply to floor-mounted Air Moving and Conditioning Association Class A packaged central-station units.

ON\ABOVE ON\ABOVE ON\ABOVE GRADE GRADE GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS*

Through 5 hp B-U-0.35 C-U-1.0 C-U-1.0 C-U-1.0

7-1/2 hp and over 250 to 500 rpm B-U-0.35 C-U-1.75 C-U-1.75 C-U-1.75

500 rpm B-U-0.35 C-U-1.0 C-U-1.5

*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES

2.2.5 Centrifugal Pump Locations

ON\ABOVE ON\ABOVE ON\ABOVE GRADE GRADE GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS*

Close- couple through 5 hp None -R-0.35 C-S-1.0 C-S-1.0

Bedplate- mounted through 5 hp None C-CIB-1.0 C-CIB-1.5 C-CIB-1.75

7-1/2 hp None C-CIB-1.0 C-CIB-1.75 C-CIB-2.5

*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES

2.3 PIPE AND DUCT VIBRATION ISOLATION

Type G: Provide isolators with in-series contained steel springs and preformed fibrous-glass or chloroprene-elastomer elements for connecting to building-structure attachments. Load devices by supported system during operating conditions to produce a minimum

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spring and elastomer static deflection of 1 inch and 3/8 inch, respectively.

2.3.1 Vertical Piping

Type L: Provide isolators which are pipe base-support devices with one or more contained steel springs. Load devices by supported system during operating conditions to produce a minimum static deflection of 1 inch. Equip devices with precompression and vertical-limit features, as well as a minimum 1/4-inch thick elastomer sound pad and isolation washers, for mounting to floor.

Type M: Provide isolators which are elastomer mounted baseplate and riser pipe-guide devices, with contained double acting elastomer elements which under rated load have a minimum static deflection of 3/8 inch. Size isolator to accommodate thermal insulation within the stationary guide ring.

PART 3 EXECUTION

3.1 INSTALLATION

Install equipment in accordance with manufacturer's recommendations.

Ensure rails and structural steel bases are raised not less than 1 inch above the floor and are level when equipment supported is under operating load.

Ensure vibration-isolation installation and deflection testing after equipment start-up is directed by a competent representative of the manufacturer.

3.2 TESTS AND REPORTS

Ensure vibration-isolation devices are deflection tested. Submit test reports in accordance with paragraph entitled, "Submittals," substantiating that all equipment has been isolated as specified and that minimum specified deflections have been met. Make all measurements in the presence of the Contracting Officer.

-- End of Section --

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TESTING, ADJUSTING, AND BALANCING FOR HVAC08/09

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ACOUSTICAL SOCIETY OF AMERICA (ASA)

ASA S1.11 (2004; Errata 2005; R 2009) Specification for Octave- Band and Fractional-Octave-Band Analog and Digital Filters (ASA 65)

ASA S1.4 (1983; Amendment 1985; R 2006) Specification for Sound Level Meters (ASA 47)

AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA)

AMCA 203 (1990; R 2011) Field Performance Measurements of Fan Systems

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)

ASHRAE HVAC APP IP HDBK (2011) HVAC Applications Handbook, I-P Edition

ASSOCIATED AIR BALANCE COUNCIL (AABC)

AABC MN-1 (2002; 6th ed) National Standards for Total System Balance

AABC MN-4 (1996) Test and Balance Procedures

NATIONAL ENVIRONMENTAL BALANCING BUREAU (NEBB)

NEBB MASV (2006) Procedural Standards for Measurements and Assessment of Sound and Vibration

NEBB PROCEDURAL STANDARDS (2005) Procedural Standards for TAB (Testing, Adjusting and Balancing) Environmental Systems

SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)

SMACNA 1780 (2002) HVAC Systems - Testing, Adjusting and Balancing, 3rd Edition

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SMACNA 1858 (2004) HVAC Sound And Vibration Manual - First Edition

SMACNA 1972 CD (2012) HVAC Air Duct Leakage Test Manual - 2nd Edition

1.2 DEFINITIONS

a. AABC: Associated Air Balance Council.

b. COTR: Contracting Officer's Technical Representative.

c. DALT: Duct air leakage test

d. DALT'd: Duct air leakage tested

e. HVAC: Heating, ventilating, and air conditioning; or heating, ventilating, and cooling.

f. NEBB: National Environmental Balancing Bureau

g. Out-of-tolerance data: Pertains only to field acceptance testing of Final DALT or TAB report. When applied to DALT work, this phase means "a leakage rate measured during DALT field acceptance testing which exceeds the leakage rate allowed by Appendix D REQUIREMENTS FOR DUCT AIR LEAK TESTING." When applied to TAB work this phase means "a measurement taken during TAB field acceptance testing which does not fall within the range of plus 5 to minus 5 percent of the original measurement reported on the TAB Report for a specific parameter."

h. Season of maximum heating load: The time of year when the outdoor temperature at the project site remains within plus or minus 30 degrees Fahrenheit of the project site's winter outdoor design temperature, throughout the period of TAB data recording.

i. Season of maximum cooling load: The time of year when the outdoor temperature at the project site remains within plus or minus 5 degrees Fahrenheit of the project site's summer outdoor design temperature, throughout the period of TAB data recording.

j. Season 1, Season 2: Depending upon when the project HVAC is completed and ready for TAB, Season 1 is defined, thereby defining Season 2. Season 1 could be the season of maximum heating load, or the season of maximum cooling load.

k. Sound measurements terminology: Defined in AABC MN-1, NEBB MASV, or SMACNA 1858 (TABB).

l. TAB: Testing, adjusting, and balancing (of HVAC systems).

m. TAB'd: HVAC Testing/Adjusting/Balancing procedures performed.

n. TAB Agency: TAB Firm

o. TAB team field leader: TAB team field leader

p. TAB team supervisor: TAB team engineer.

q. TAB team technicians: TAB team assistants.

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r. TABB: Testing Adjusting and Balancing Bureau.

1.2.1 Similar Terms

In some instances, terminology differs between the Contract and the TAB Standard primarily because the intent of this Section is to use the industry standards specified, along with additional requirements listed herein to produce optimal results.

The following table of similar terms is provided for clarification only. Contract requirements take precedent over the corresponding AABC, NEBB, or TABB requirements where differences exist.

SIMILAR TERMS

Contract Term AABC Term NEBB Term TABB Term

TAB Standard National Standards for Testing and Balancing Heating, Ventilating, and Air Conditioning Systems

Procedural Standards for Testing, Adjusting and Balancing of Environmental Systems

International Standards for Environmental Systems Balance

TAB Specialist TAB Engineer TAB Supervisor TAB Supervisor

Systems Readiness Check

Construction Phase Inspection

Field Readiness Check & Preliminary Field Procedures

Field Readiness Check & Prelim. Field Procedures

1.3 WORK DESCRIPTION

The work includes duct air leakage testing (DALT) and testing, adjusting, and balancing (TAB) of newheating, ventilating, and cooling (HVAC) air distribution systems including ducts, and piping which are located within, on, under, between, and adjacent to buildings.

Perform TAB in accordance with the requirements of the TAB procedural standard recommended by the TAB trade association that approved the TAB Firm's qualifications. Comply with requirements of AABC MN-1, NEBB PROCEDURAL STANDARDS, or SMACNA 1780 (TABB) as supplemented and modified by this specification section. All recommendations and suggested practices contained in the TAB procedural standards are considered mandatory.

Conduct DALT and TAB of the indicated existing systems and equipment and submit the specified DALT and TAB reports for approval. Conduct DALT testing in compliance with the requirements specified in SMACNA 1972 CD, except as supplemented and modified by this section. Conduct DALT and TAB work in accordance with the requirements of this section.

1.3.1 Air Distribution Systems

Test, adjust, and balance systems (TAB) in compliance with this section.

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Obtain Contracting Officer's written approval before applying insulation to exterior of air distribution systems as specified under Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS.

1.3.2 Water Distribution Systems

TAB systems in compliance with this section. Obtain Contracting Officer's written approval before applying insulation to water distribution systems as specified under Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. At Contractor's option and with Contracting Officer's written approval, the piping systems may be insulated before systems are TAB'd.

Terminate piping insulation immediately adjacent to each flow control valve, automatic control valve, or device. Seal the ends of pipe insulation and the space between ends of pipe insulation and piping, with waterproof vapor barrier coating.

After completion of work under this section, insulate the flow control valves and devices as specified under Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS.

1.3.3 TAB SCHEMATIC DRAWINGS

Show the following information on TAB Schematic Drawings:

1. A unique number or mark for each piece of equipment or terminal.

2. Air quantities at air terminals.

3. Air quantities and temperatures in air handling unit schedules.

4. Water quantities and temperatures in thermal energy transfer equipment schedules.

5. Water quantities and heads in pump schedules.

6. Water flow measurement fittings and balancing fittings.

7. Ductwork Construction and Leakage Testing Table that defines the DALT test requirements, including each applicable HVAC duct system ID or mark, duct pressure class, duct seal class, and duct leakage test pressure. This table is included in the file for Graphics for Unified Facilities Guide Specifications:http://www.wbdg.org/ccb/NAVGRAPH/graphtoc.pdf

The Testing, Adjusting, and Balancing (TAB) Specialist must review the Contract Plans and Specifications and advise the Contracting Officer of any deficiencies that would prevent the effective and accurate TAB of the system. The TAB Specialist must provide a Design Review Report individually listing each deficiency and the corresponding proposed corrective action necessary for proper system operation.

1.3.4 Related Requirements

Requirements for price breakdown of HVAC TAB work are specified in Section 01 20 00.00 20 PRICE AND PAYMENT PROCEDURES.

Requirements for construction scheduling related to HVAC TAB work are specified in Section 01 32 17.00 20 NETWORK ANALYSIS SCHEDULES (NAS).

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1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Tab Firm; G

Designation of TAB team assistants; G

Designation of TAB team engineer; G

Designation of TAB team field leader; G

SD-02 Shop Drawings

Report Forms; G

SD-06 Test Reports

DALT and TAB Work Execution Schedule; G

DALT and TAB Procedures Summary; G

Design review report; G

Pre-Final DALT report; G

Final DALT report; G

TAB report for Season 1; G

TAB report for Season 2; G

SD-07 Certificates

Independent TAB agency and personnel qualifications; G

Advance notice of Pre-Final DALT field work; G

Completed Pre-Final DALT Work Checklist; G

Advance Notice of Season 1 TAB Field Work; G

Completed Season 1 Pre-TAB Work Checklist

Advance Notice of Season 2 TAB Field Work; G

Completed Season 2 Pre-TAB Work Checklist

TAB Firm; G

Independent TAB Agency and Personnel Qualifications; G

DALT and TAB Submittal and Work Schedule; G

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Design review report; G

1.5 QUALITY ASSURANCE

1.5.1 Independent TAB Agency and Personnel Qualifications

To secure approval for the proposed agency, submit information certifying that the TAB agency is a first tier subcontractor who is not affiliated with any other company participating in work on this contract, including design, furnishing equipment, or construction. Further, submit the following, for the agency, to Contracting Officer for approval:

a. Independent AABC or NEBB or TABB TAB agency:

TAB agency: AABC registration number and expiration date of current certification; or NEBB certification number and expiration date of current certification; or TABB certification number and expiration date of current certification.

TAB team supervisor: Name and copy of AABC or NEBB or TABB TAB supervisor certificate and expiration date of current certification.

TAB team field leader: Name and documented evidence that the team field leader has satisfactorily performed full-time supervision of TAB work in the field for not less than 3 years immediately preceding this contract's bid opening date.

TAB team field technicians: Names and documented evidence that each field technician has satisfactorily assisted a TAB team field leader in performance of TAB work in the field for not less than one year immediately preceding this contract's bid opening date.

Current certificates: Registrations and certifications are current, and valid for the duration of this contract. Renew Certifications which expire prior to completion of the TAB work, in a timely manner so that there is no lapse in registration or certification. TAB agency or TAB team personnel without a current registration or current certification are not to perform TAB work on this contract.

b. TAB Team Members: TAB team approved to accomplish work on this contract are full-time employees of the TAB agency. No other personnel is allowed to do TAB work on this contract.

c. Replacement of TAB team members: Replacement of members may occur if each new member complies with the applicable personnel qualifications and each is approved by the Contracting Officer.

1.6 SEQUENCING AND SCHEDULING

1.6.1 DALT and TAB Submittal and Work Schedule

Comply with additional requirements specified in Appendix C: DALT AND TAB SUBMITTAL AND WORK SCHEDULE included at the end of this section

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1.6.2 Projects with Phased Construction

This specification section is structured as though the HVAC construction, and thereby the TAB work, will be completed in a single phase. When the construction is completed in phases, the DALT work and TAB work must be planned, completed, and accepted for each construction phase.

1.6.2.1 Phasing of Work

This specification section is structured as though the HVAC construction, and thereby the TAB work, is going to be completed in a single phase in spite of the fact that there will be two seasons. All elements of the TAB work are addressed on this premise. When a contract is to be completed in construction phases, including the TAB work, and the DALT work, the TAB work and DALT work must be planned for, completed and approved by the Contracting Officer with each phase. An example of this case would be one contract that requires the rehabilitation of the HVAC in each of several separated buildings. At the completion of the final phase, compile all approved reports and submit as one document.

1.7 SUBCONTRACTOR SPECIAL REQUIREMENTS

Perform all work in this section in accordance with the paragraph entitled "Subcontractor Special Requirements" in Section 01 30 00 ADMINISTRATIVE REQUIREMENTS, stating that all contract requirements of this section must be accomplished directly by a first tier subcontractor. No work may be performed by a second tier subcontractor.

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

3.1 WORK DESCRIPTIONS OF PARTICIPANTS

Comply with requirements of this section as specified in Appendix A WORK DESCRIPTIONS OF PARTICIPANTS.

3.2 PRE-DALT/TAB MEETING

Meet with the Contracting Officer's technical representative (COTR)to develop a mutual understanding relative to the details of the DALT work and TAB work requirements. Ensure that the TAB supervisor is present at this meeting. Requirements to be discussed include required submittals, work schedule, and field quality control.

3.3 DALT PROCEDURES

3.3.1 Instruments, Consumables and Personnel

Provide instruments, consumables and personnel required to accomplish the DALT field work. Follow the same basic procedure specified below for TAB Field Work, including maintenance and calibration of instruments, accuracy of measurements, preliminary procedures, field work, workmanship and treatment of deficiencies. Calibrate and maintain instruments in accordance with manufacturer's written procedures.

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3.3.2 Advance Notice of Pre-Final DALT Field Work

On completion of the installation of each duct system indicated to be DALT'd, notify the Contracting Officer in writing prior to the COTR's duct selection field visit.

3.3.3 Ductwork To Be DALT'd

From each duct system indicated as subject to DALT, the COTR will randomly select sections of each completed duct system for testing by the Contractor's TAB Firm. The sections selected will not exceed 20 percent of the total measured linear footage of duct systems indicated as subject to DALT. Sections of duct systems subject to DALT will include 20 percent of main ducts, branch main ducts, branch ducts and plenums for supply, return, exhaust, and plenum ductwork.

It is acceptable for an entire duct system to be DALT'd instead of disassembling that system in order to DALT only the 20 percent portion specified above.

3.3.4 DALT Testing

Perform DALT on the HVAC duct sections of each system as selected by the COTR. Use the duct class, seal class, leakage class and the leak test pressure data indicated on the drawings, to comply with the procedures specified in SMACNA 1972 CD.

In spite of specifications of SMACNA 1972 CD to the contrary, DALT ductwork of construction class of 3-inch water gauge static pressure and below if indicated to be DALT'd. Complete DALT work on the COTR selected ductwork within 48 hours after the particular ductwork was selected for DALT. Separately conduct DALT work for large duct systems to enable the DALT work to be completed in 48 hours.

3.3.5 Pre-final DALT Report

After completion of the DALT work, prepare a Pre-final DALT Report meeting the additional requirements specified in Appendix B REPORTS - DALT and TAB. Data required by those data report forms shall be furnished by the TAB team. Prepare the report neatly and legibly; the Pre-final DALT report shall provide the basis for the Final DALT Report.

TAB supervisor shall review, approve and sign the Pre-Final DALT Report and submit this report within one day of completion of DALT field work. Verbally notify the COTR that the field check of the Pre-Final DALT Report data can commence.

3.3.6 Quality Assurance - COTR DALT Field Acceptance Testing

In the presence of the COTR and TAB team field leader, verify for accuracy Pre-final DALT Report data selected by the COTR. For each duct system, this acceptance testing shall be conducted on a maximum of 50 percent of the duct sections DALT'd.

Further, if any data on the Pre-final DALT report form for a given duct section is out-of-tolerance, then field acceptance testing shall be conducted on data for one additional duct section, preferably in the same duct system, in the presence of the COTR.

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3.3.7 Additional COTR Field Acceptance Testing

If any of the duct sections checked for a given system are determined to have a leakage rate measured that exceeds the leakage rate allowed by SMACNA Leak Test Manual for an indicated duct construction class and sealant class, terminate data checking for that section. The associated Pre-final DALT Report data for the given duct system will be disapproved. Make the necessary corrections and prepare a revised Pre-final DALT Report. Reschedule a field check of the revised report data with the COTR.

3.3.8 Certified Final DALT Report

On successful completion of all field checks of the Pre-Final DALT Report data for all systems, the TAB Supervisor shall assemble, review, approve, sign and submit the Final DALT Report in compliance with Appendix B REPORTS - DALT and TAB to the Contracting Officer for approval.

3.3.9 Prerequisite for TAB Field Work

Do not commence TAB field work prior to the completion and approval, for all systems, of the Final DALT Report.

3.4 TAB PROCEDURES

3.4.1 TAB Field Work

Test, adjust, and balance the HVAC systems until measured flow rates (air and water flow) are within plus or minus 5 percent of the design flow rates as specified or indicated on the contract documents.

That is, comply with the the requirements of AABC MN-1 , or SMACNA 1780 (TABB) and SMACNA 1858 (TABB),except as supplemented and modified by this section.

Provide instruments and consumables required to accomplish the TAB work. Calibrate and maintain instruments in accordance with manufacturer's written procedures.

Test, adjust, and balance the HVAC systems until measured flow rates (air and water flow) are within plus or minus 5 percent of the design flow rates as specified or indicated on the contract documents. Conduct TAB work, including measurement accuracy, and sound measurement work in conformance with the AABC MN-1 and AABC MN-4, or NEBB TABES and NEBB MASV, or SMACNA 1780 (used by TABB) and SMACNA 1858 sound measurement procedures, except as supplemented and modified by this section. The only water flow and air flow reporting which can be deferred until the Season 2 is that data which would be affected in terms of accuracy due to outside ambient conditions.

3.4.2 Preliminary Procedures

Use the approved pre-field engineering report as instructions and procedures for accomplishing TAB field work. TAB engineer is to locate, in the field, test ports required for testing. It is the responsibility of the sheet metal contractor to provide and install test ports as required by the TAB engineer.

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3.4.3 TAB Air Distribution Systems

3.4.3.1 Units With Coils

Report heating and cooling performance capacity tests for gas fired heat exchangers and DX coils for the purpose of verifying that the coils meet the indicated design capacity. Submit the following data and calculations with the coil test reports:

a. For air handlers with capacities greater than 7.5 tons (90,000 Btu) cooling, such as factory manufactured units, central built-up units and rooftop units, conduct capacity tests in accordance with AABC MN-4, procedure 3.5, "Coil Capacity Testing."

Do not determine entering and leaving wet and dry bulb temperatures by single point measurement, but by the average of multiple readings in compliance with paragraph 3.5-5, "Procedures", (in subparagraph d.) of AABC MN-4, Procedure 3.5, "Coil Capacity Testing."

Submit part-load coil performance data from the coil manufacturer converting test conditions to design conditions; use the data for the purpose of verifying that the coils meet the indicated design capacity in compliance with AABC MN-4, Procedure 3.5, "Coil Capacity Testing," paragraph 3.5.7, "Actual Capacity Vs. Design Capacity" (in subparagraph c.).

b. For units with capacities of 7.5 tons (90,000 Btu) or less, such as fan coil units, duct mounted reheat coils associated with VAV terminal units, and unitary units, such as through-the-wall heat pumps:

Determine the apparent coil capacity by calculations using single point measurement of entering and leaving wet and dry bulb temperatures; submit the calculations with the coil reports.

3.4.3.2 Air Handling Units

Air handling unit systems including fans (air handling unit fans, exhaust fans and winter ventilation fans), coils, ducts, plenums, mixing boxes, terminal units, variable air volume boxes, and air distribution devices for supply air, return air, outside air, mixed air relief air, and makeup air.

3.4.3.3 Rooftop Air Conditioning

Rooftop air conditioning systems including fans, coils, ducts, plenums, and air distribution devices for supply air, return air, and outside air.

For refrigeration compressors/condensers/condensing units/evaporators, report data as required by NEBB, AABC, and TABB standard procedures, including refrigeration operational data.

3.4.3.4 Heating and Ventilating Units

Heating and ventilating unit systems including fans, coils, ducts, plenums, roof vents, registers, diffusers, grilles, and louvers for supply air, return air, outside air, and mixed air.

3.4.3.5 Makeup Air Units

Makeup air unit systems including fans, coils, ducts, plenums, registers,

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diffusers, grilles, and louvers for supply air, return air, outside air, and mixed air.

3.4.3.6 Fan Coils

Fan coil unit systems including fans, coils, ducts, plenums, and air distribution devices for supply air, return air, and outside air.

3.4.3.7 Exhaust Fans

Exhaust fan systems including fans, ducts, plenums, grilles, and hoods for exhaust air.

3.4.4 Sound Measurement Work

3.4.4.1 Areas To Be Sound Measured

In the following spaces, measure and record the sound power level for each octave band listed in ASHRAE HVAC APP IP HDBK Noise Criteria:

a. All HVAC mechanical rooms, including machinery spaces and other spaces containing HVAC power drivers and power driven equipment.

b. All spaces sharing a common barrier with each mechanical room, including rooms overhead, rooms on the other side of side walls, and rooms beneath the mechanical room floor.

c. RTU System: Rooms: Indoor Shooting Ranges

3.4.4.2 Procedure

Measure sound levels in each room, when unoccupied except for the TAB team, with all HVAC systems that would cause sound readings in the room operating in their noisiest mode. Record the sound level in each octave band. Attempt to mitigate the sound level and bring the level to within the specified ASHRAE HVAC APP IP HDBK noise criteria goals, if such mitigation is within the TAB team's control. State in the report the ASHRAE HVAC APP IP HDBK noise criteria goals. If sound level cannot be brought into compliance, provide written notice of the deficiency to the Contractor for resolution or correction.

3.4.4.3 Timing

Measure sound levels at times prescribed by AABC or NEBB or TABB.

3.4.4.4 Meters

Measure sound levels with a sound meter complying with ASA S1.4, Type 1 or 2, and an octave band filter set complying with ASA S1.11. Use measurement methods for overall sound levels and for octave band sound levels as prescribed by NEBB.

3.4.4.5 Calibration

Calibrate sound levels as prescribed by AABC or NEBB or TABB, except that calibrators emitting a sound pressure level tone of 94 dB at 1000 hertz (Hz) are also acceptable.

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3.4.4.6 Background Noise Correction

Determine background noise component of room sound (noise) levels for each (of eight) octave bands as prescribed by AABC or NEBB or TABB.

3.4.5 TAB Work on Performance Tests With Seasonal Limitations

3.4.5.1 Performance Tests

Accomplish proportionate balancing TAB work on the air distribution systems and water distribution systems, in other words, accomplish adjusting and balancing of the air flows and water flows, any time during the duration of this contract, subject to the limitations specified elsewhere in this section. However, accomplish, within the following seasonal limitations, TAB work on HVAC systems which directly transfer thermal energy.

3.4.5.2 Season Of Maximum Load

Visit the contract site for at least two TAB work sessions for TAB field measurements. Visit the contract site during the season of maximum heating load and visit the contract site during the season of maximum cooling load, the goal being to TAB the operational performance of the heating systems and cooling systems under their respective maximum outdoor environment-caused loading. During the seasonal limitations, TAB the operational performance of the heating systems and cooling systems.

3.4.5.3 Ambient Temperatures

On each tab report form used for recording data, record the outdoor and indoor ambient dry bulb temperature range and the outdoor and indoor ambient wet bulb temperature range within which the report form's data was recorded. Record these temperatures at beginning and at the end of data taking.

3.4.5.4 Sound Measurements

Comply with paragraph entitled "Sound Measurement Work," specifically, the requirement that a room must be operating in its noisiest mode at the time of sound measurements in the room. The maximum noise level measurements could depend on seasonally related heat or cooling transfer equipment.

3.4.6 Workmanship

Conduct TAB work on the HVAC systems until measured flow rates are within plus or minus 5 percent of the design flow rates as specified or indicated on the contract documents. This TAB work includes adjustment of balancing valves, balancing dampers, and sheaves. Further, this TAB work includes changing out fan sheaves and pump impellers if required to obtain air and water flow rates specified or indicated. If, with these adjustments and equipment changes, the specified or indicated design flow rates cannot be attained, contact the Contracting Officer for direction.

3.4.7 Deficiencies

Strive to meet the intent of this section to maximize the performance of the equipment as designed and installed. However, if deficiencies in equipment design or installation prevent TAB work from being accomplished within the range of design values specified in the paragraph entitled "Workmanship," provide written notice as soon as possible to the Contractor

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and the Contracting Officer describing the deficiency and recommended correction.

Responsibility for correction of installation deficiencies is the Contractor's. If a deficiency is in equipment design, call the TAB team supervisor for technical assistance. Responsibility for reporting design deficiencies to Contractor is the TAB team supervisor's.

3.4.8 TAB Reports

Additional requirements for TAB Reports are specified in Appendix B REPORTS - DALT and TAB

3.4.9 Quality Assurance - COTR TAB Field Acceptance Testing

3.4.9.1 TAB Field Acceptance Testing

During the field acceptance testing, verify, in the presence of the COTR, random selections of data (water, air quantities, air motion, sound level readings) recorded in the TAB Report. Points and areas for field acceptance testing are to be selected by the COTR. Measurement and test procedures are the same as approved for TAB work for the TAB Report.

Field acceptance testing includes verification of TAB Report data recorded for the following equipment groups:

Group 1: All air handling units (rooftop and single zone).

Group 2: 25 percent of the VRF fan coils and associated diffusers and registers.

Group 3: 25 percent of the supply diffusers, registers, grilles associated with constant volume air handling units.

Group 4: 25 percent of the return grilles, return registers, exhaust grilles and exhaust registers.

Group 5: 25 percent of the supply fans, exhaust fans, and pumps.

Further, if any data on the TAB Report for Groups 2 through 5 is found not to fall within the range of plus 5 to minus 5 percent of the TAB Report data, additional group data verification is required in the presence of the COTR. Verify TAB Report data for one additional piece of equipment in that group. Continue this additional group data verification until out-of-tolerance data ceases to be found.

3.4.9.2 Additional COTR TAB Field Acceptance Testing

If any of the acceptance testing measurements for a given equipment group is found not to fall within the range of plus 5 to minus 5 percent of the TAB Report data, terminate data verification for all affected data for that group. The affected data for the given group will be disapproved. Make the necessary corrections and prepare a revised TAB Report. Reschedule acceptance testing of the revised report data with the COTR.

3.4.9.3 Prerequisite for Approval

Compliance with the field acceptance testing requirements of this section is a prerequisite for the final Contracting Officer approval of the TAB

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Report submitted.

3.5 MARKING OF SETTINGS

Upon the final TAB work approval, permanently mark the settings of HVAC adjustment devices including valves, gauges, splitters, and dampers so that adjustment can be restored if disturbed at any time. Provide permanent markings clearly indicating the settings on the adjustment devices which result in the data reported on the submitted TAB report.

3.6 MARKING OF TEST PORTS

The TAB team is to permanently and legibly mark and identify the location points of the duct test ports. If the ducts have exterior insulation, make these markings on the exterior side of the duct insulation. Show the location of test ports on the as-built mechanical drawings with dimensions given where the test port is covered by exterior insulation.

3.7 APPENDICES

Appendix A WORK DESCRIPTIONS OF PARTICIPANTSAppendix B REPORTS - DALT and TABAppendix C DALT AND TAB SUBMITTAL AND WORK SCHEDULEAppendix D REQUIREMENTS FOR DUCT AIR LEAK TESTING

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Appendix A

WORK DESCRIPTIONS OF PARTICIPANTS

The Contractor is responsible for ensuring compliance with all requirements of this specification section. However, the following delineation of specific work items is provided to facilitate and co-ordinate execution of the various work efforts by personnel from separate organizations.

1. Contractor

a. HVAC documentation: Provide pertinent contract documentation to the TAB Firm, to include the following: the contract drawings and specifications; copies of the approved submittal data for all HVAC equipment, air distribution devices, and air/water measuring/balancing devices; the construction work schedule; and other applicable documents requested by the TAB Firm. Provide the TAB Firm copies of contract revisions and modifications as they occur.

b. Schedules: Ensure the requirements specified under the paragraph "DALT and TAB Schedule" are met.

c. Pre-DALT and TAB meeting: Arrange and conduct the Pre-DALT and TAB meeting. Ensure that a representative is present for the sheet metal contractor, the mechanical contractor, the electrical contractor, and the automatic temperature controls contractor.

d. Coordinate Support: Provide and coordinate support personnel required by the TAB Firm in order to accomplish the DALT and TAB field work. Support personnel may include factory representatives, HVAC controls installers, HVAC equipment mechanics, sheet metal workers, pipe fitters, and insulators. Ensure support personnel are present at the work site at the times required.

e. Correct Deficiencies: Ensure the notifications of Construction Deficiencies are provided as specified herein. Refer to the paragraph entitled "Construction Deficiencies." Correct each deficiency as soon as practical with the Contracting Officer, and submit revised schedules and other required documentation.

f. Pre-TAB Work Checklists: Complete check out and debugging of HVAC equipment, ducts, and controls prior to the TAB engineer arriving at the project site to begin the TAB work. Debugging includes searching for and eliminating malfunctioning elements in the HVAC system installations, and verifying all adjustable devices are functioning as designed. Include as pre-TAB work checklist items, the deficiencies pointed out by the TAB team supervisor in the design review report.

Prior to the TAB field team's arrival, ensure completion of the applicable inspections and work items listed in the TAB team supervisor's DALT and TAB Work Procedures Summary. Do not allow the TAB team to commence TAB field work until all of the following are completed.

g. Give Notice of Testing: Submit advance notice of TAB field work accompanied by completed prerequisite HVAC Work List

h. Insulation work: Ensure that no insulation is shall not be installed on ducts to be DALT'd until DALT work on the subject ducts is complete.

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Ensure the duct and piping systems are properly insulated and vapor sealed upon the successful completion and acceptance of the DALT and TAB work.

2. TAB Team Supervisor

a. Overall management: Supervise and manage the overall TAB team work effort, including preliminary and technical DALT and TAB procedures and TAB team field work.

b. Schedule: Ensure the requirements specified under the paragraph "DALT and TAB Schedule" are met.

c. Submittals: Provide the submittals specified herein.

d. Pre-DALT/TAB meeting: Attend meeting with Contractor. Ensure TAB personnel that will be involved in the TAB work under this contract attend the meeting.

e. Design Review Report: Submit typed report describing omissions and deficiencies in the HVAC system's design that would preclude the TAB team from accomplishing the duct leakage testing work and the TAB work requirements of this section. Provide a complete explanation including supporting documentation detailing the design deficiency. State that no deficiencies are evident if that is the case.

f. Support required: Specify the technical support personnel required from the Contractor other than the TAB agency; such as factory representatives for temperature controls or for complex equipment. Inform the Contractor in writing of the support personnel needed and when they are needed. Furnish the notice as soon as the need is anticipated, either with the design review report, or the DALT and TAB Procedures Summary, the during the DALT or TAB field work.

Ensure the Contractor is properly notified and aware of all support personnel needed to perform the TAB work. Maintain communication with the Contractor regarding support personnel throughout the duration of the TAB field work, including the TAB field acceptance testing checking.

Ensure all inspections and verifications for the Pre-Final DALT and Pre-TAB Checklists are completely and successfully conducted before DALT and TAB field work is performed.

g. Advance Notice: Monitor the completion of the duct system installations and provide the Advance Notice for Pre-Final DALT field work as specified herein.

h. Technical Assistance: Provide technical assistance to the DALT and TAB field work.

i. Deficiencies Notification: Ensure the notifications of Construction Deficiencies are provided as specified herein. Comply with requirements of the paragraph entitled "Construction Deficiencies." Resolve each deficiency as soon as practical and submit revised schedules and other required documentation.

j. Procedures: Develop the required TAB procedures for systems or system components not covered in the TAB Standard.

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3. TAB Team Field Leader

a. Field manager: Manage, in the field, the accomplishment of the work specified in Part 3, "Execution."

b. Full time: Be present at the contract site when DALT field work or TAB field work is being performed by the TAB team; ensure day-to-day TAB team work accomplishments are in compliance with this section.

c. Prerequisite HVAC work: Do not bring the TAB team to the contract site until a copy of the prerequisite HVAC work list, with all work items certified by the Contractor to be working as designed, reaches the office of the TAB Agency.

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Appendix B

REPORTS - DALT and TAB

All submitted documentation must be typed, neat, and organized. All reports must have a waterproof front and back cover, a title page, a certification page, sequentially numbered pages throughout, and a table of contents. Tables, lists, and diagrams must be titled. Generate and submit for approval the following documentation:

1. DALT and TAB Work Execution Schedule

Submit a detailed schedule indicating the anticipated calendar date for each submittal and each portion of work required under this section. For each work entry, indicate the support personnel (such as controls provider, HVAC mechanic, etc.) that are needed to accomplish the work. Arrange schedule entries chronologically.

2. DALT and TAB Procedures Summary

Submit a detailed narrative describing all aspects of the DALT and TAB field work to be performed. Clearly distinguish between DALT information and TAB information. Include the following:

a. A list of the intended procedural steps for the DALT and TAB field work from start to finish. Indicate how each type of data measurement will be obtained. Include what Contractor support personnel are required for each step, and the tasks they need to perform.

b. A list of the project's submittals that are needed by the TAB Firm in order to meet this Contract's requirements.

c. The schematic drawings to be used in the required reports, which may include building floor plans, mechanical room plans, duct system plans, and equipment elevations. Indicate intended TAB measurement locations, including where test ports need to be provided by the Contractor.

d. The data presentation forms to be used in the report, with the preliminary information and initial design values filled in.

e. A list of DALT and TAB instruments to be used, edited for this project, to include the instrument name and description, manufacturer, model number, scale range, published accuracy, most recent calibration date, and what the instrument will be used for on this project.

f. A thorough checklist of the work items and inspections that need to be accomplished before DALT field work can be performed. The Contractor must complete, submit, and receive approval of the Completed Pre-Final DALT Work Checklist before DALT field work can be accomplished.

g. A thorough checklist of the work items and inspections that need to be accomplished before the Season 1 TAB field work can be performed. The Contractor must complete, submit, and receive approval of the Completed Season 1 Pre-TAB Work Checklist before the Season 1 TAB field work can be accomplished.

h. A thorough checklist of the work items and inspections that need to be

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accomplished before the Season 2 TAB field work can be performed. The Contractor must complete, submit, and receive approval of the Completed Season 2 Pre-TAB Work Checklist before the Season 2 TAB field work can be accomplished.

i. The checklists specified above shall be individually developed and tailored specifically for the work under this contract. Refer to NEBB PROCEDURAL STANDARDS, Section III, "Preliminary TAB Procedures" under the paragraphs titled, "Air Distribution System Inspection" and "Hydronic Distribution System Inspection" for examples of items to include in the checklists.

3. Design Review Report

Submit report containing the following information:

a. Review the contract specifications and drawings to verify that the TAB work can be successfully accomplished in compliance with the requirements of this section. Verify the presence and location of permanently installed test ports and other devices needed, including gauge cocks, thermometer wells, flow control devices, circuit setters, balancing valves, and manual volume dampers.

b. Submit a typed report describing omissions and deficiencies in the HVAC system's design that would preclude the TAB team from accomplishing the DALT work and the TAB work requirements of this section. Provide a complete explanation including supporting documentation detailing the design deficiency. If no deficiencies are evident, state so in the report.

4. Pre-Final DALT Report for COTR DALT Field Checks

Report the data for the Pre-Final DALT Report meeting the following requirements:

a. Submit a copy of the approved DALT and TAB Procedures Summary: Provide notations describing how actual field procedures differed from the procedures listed.

b. Report format: Submit a comprehensive report for the DALT field work data using data presentation forms equivalent to the "Air Duct Leakage Test Summary Report Forms" located in the SMACNA 1972 CD. In addition, submit in the report, a marked duct shop drawing which identifies each section of duct tested with assigned node numbers for each section. Node numbers shall be included in the completed report forms to identify each duct section.

c. Calculations: Include a copy of all calculations prepared in determining the duct surface area of each duct test section. Include in the DALT reports copy(s) of the calibration curve for each of the DALT test orifices used for testing.

d. Instruments: List the types of instruments actually used to measure the data. Include in the listing each instrument's unique identification number, calibration date, and calibration expiration date. Instruments are to be calibrated within one year of the date of use in the field; instrument calibration is to be traceable to the measuring standards of the National Institute of Standards and Technology.

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e. TAB Supervisor Approval: Include on the submitted report the typed name of the TAB supervisor and the dated signature of the TAB supervisor.

5. Final DALT Report

On successful completion of all COTR field checks of the Pre-final DALT Report data for all systems, the TABS Supervisor shall assemble, review, sign and submit the Final DALT Report to the Contracting Officer for approval.

6. TAB Reports: Submit TAB Report for Season 1 and TAB Report for Season 2 in the following manner:

a. Procedure Summary: Submit a copy of the approved DALT and TAB Procedures Summary. When applicable, provide notations describing how actual field procedures differed from the procedures listed.

b. Report format: Submit the completed data forms approved in the pre-field TAB Engineering Report completed by TAB field team, reviewed, approved and signed by the TAB supervisor. Bind the report with a waterproof front and back cover. Include a table of contents identifying by page number the location of each report. Report forms and report data shall be typewritten. Handwritten report forms or report data are not acceptable.

c. Temperatures: On each TAB report form reporting TAB work accomplished on HVAC thermal energy transfer equipment, include the indoor and outdoor dry bulb temperature range and indoor and outdoor wet bulb temperature range within which the TAB data was recorded. Include in the TAB report continuous time versus temperature recording data of wet and dry bulb temperatures for the rooms, or zones, as designated in the following list:

Indoor Shooting Ranges

(1) Data shall be measured and compiled on a continuous basis for the period in which TAB work affecting those rooms is being done.

(2) Data shall be measured/recorded only after the HVAC systems installations are complete, the systems fully balanced and the HVAC systems controls operating in fully automatic mode. Provide a detailed explanation wherever a final measurement did not achieve the required value.

(3) Data may be compiled using direct digital controls trend logging where available. Otherwise, the Contractor shall temporarily install calibrated time versus temperature/humidity recorders for this purpose. The HVAC systems and controls shall have been fully operational a minimum of 24 hours in advance of commencing data compilation. The specified data shall be included in the Season I and Season 2 TAB Report.

d. Air System Diagrams: Provided updated diagrams with final installed locations of all terminals and devices, any numbering changes, and actual test locations.

e. Air Static Pressure Profiles: Report static pressure profiles for air

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duct systems including: Rooftop Units, Air Handling Units, Make Up Air Units and Indoor Range Exhaust Fans. Report static pressure data for all supply, return, relief, exhaust and outside air ducts for the systems listed. The static pressure report data shall include, in addition to AABC or NEBB or TABB required data, the following:

(1) Report supply fan, return fan, relief fan, and exhaust fan inlet and discharge static pressures.

(2) Report static pressure drop across chilled water coils, DX coils, hot water coils, steam coils, electric resistance heating coils and heat reclaim devices installed in unit cabinetry or the system ductwork.

(3) Report static pressure drop across outside air, return air, and supply air automatic control dampers, both proportional and two-position, installed in unit cabinetry.

(4) Report static pressure drop across air filters, acoustic silencers, moisture eliminators, air flow straighteners, air flow measuring stations or other pressure drop producing specialty items installed in unit cabinetry, or in the system ductwork. Examples of these specialty items are smoke detectors, white sound generators, RF shielding, wave guides, security bars, blast valves, small pipes passing through ductwork, and duct mounted humidifiers.

Do not report static pressure drop across duct fittings provided for the sole purpose of conveying air, such as elbows, transitions, offsets, plenums, manual dampers, and branch takes-offs.

(5) Report static pressure drop across outside air and relief/exhaust air louvers.

(6) Report static pressure readings of supply air, return air, exhaust/relief air, and outside air in duct at the point where these ducts connect to each air moving unit.

f. Duct Transverses: Report duct traverses for main and branch main supply, exhaust ducts. This shall include all ducts, including those which lack 7 1/2 duct diameters upstream and 2 1/2 duct diameters downstream of straight duct unobstructed by duct fittings/offsets/elbows. The TAB Agency shall evaluate and report findings on the duct traverses taken. Evaluate the suitability of the duct traverse measurement based on satisfying the qualifications for a pitot traverse plane as defined by AMCA 203, "Field Measurements", Section 8, paragraph 8.3, "Location of Traverse Plane".

g. Instruments: List the types of instruments actually used to measure the tab data. Include in the listing each instrument's unique identification number, calibration date, and calibration expiration date.

Instrumentation, used for taking wet bulb temperature readings shall provide accuracy of plus or minus 5 percent at the measured face velocities. Submit instrument manufacturer's literature to document instrument accuracy performance is in compliance with that specified.

h. Performance Curves: The TAB Supervisor shall include, in the TAB

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Reports, factory pump curves and fan curves for pumps and fans TAB'd on the job.

i. Calibration Curves: The TAB Supervisor shall include, in the TAB Reports, a factory calibration curve for installed flow control balancing valves, flow venturis and flow orifices TAB'd on the job.

j. Data From TAB Field Work: After completion of the TAB field work, prepare the TAB field data for TAB supervisor's review and approval signature, using the reporting forms approved in the pre-field engineering report. Data required by those approved data report forms shall be furnished by the TAB team. Except as approved otherwise in writing by the Contracting Officer, the TAB work and thereby the TAB report shall be considered incomplete until the TAB work is accomplished to within the accuracy range specified in the paragraph entitled "Workmanship."

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Appendix C

DALT AND TAB SUBMITTAL AND WORK SCHEDULE

Perform the following items of work in the order listed adhering to the dates schedule specified below. Include the major items listed in this schedule in the project network analysis schedule required by Section 01 32 17.00 20 NETWORK ANALYSIS SCHEDULES (NAS).

Submit TAB Agency and TAB Personnel Qualifications: Within 42 calendar days after date of contract award.

Submit the DALT and TAB Work Execution Schedule: within 14 days after receipt of the TAB agency and TAB personnel qualifications approval. Revise and re-submit this schedule 28 days prior to commencement of DALT work and 28 days prior to the commencement of TAB Season 1 work and TAB Season 2 work.

Submit the DALT and TAB Work Procedures Summary: within 14 days after receipt of the initial approved DALT and TAB Work Execution Schedule.

Meet with the COTR at the Pre-DALT/TAB Meeting: Within 28 calendar days after receipt of the approved initial DALT/TAB Execution Schedule.

Submit Design Review Report: Within 56 calendar days after the receipt of the approved initial DALT and TAB Work Execution Schedule.

Advance Notice of Pre-Final DALT Field Work: After the completed installation of the HVAC duct system to be DALT'd, submit to the Contracting Officer an Advance Notice of Pre-Final DALT Field Work accompanied by the completed Pre-Final DALT Work Checklistchecklist for the subject duct system.

Ductwork Selected for DALT: Within 14 calendar days after receiving an acceptable completed Pre-Final DALT Work Checklist, the Contracting Officer's technical representative (COTR) will select the project ductwork sections to be DALT'd.

DALT Field Work: Within 48 hours of COTR's selection, complete DALT field work on selected project ductwork.

Submit Pre-Final DALT Report: Within two working days after completion of DALT field work, submit Pre-final DALT Report. Separate Pre-final DALT reports may be submitted to allow phased testing from system to system.

Quality Assurance - COTR DALT Field Checks: Upon approval of the Pre-final DALT Report, the COTR's DALT field check work shall be scheduled with the Contracting Officer.

Submit Final DALT Report: Within 14 calendar days after completion of successful DALT Work Field Check, submit Season 1 TAB report.

Advance Notice of Season 1 TAB Field Work: At a minimum of 14 calendar days prior to Season 1 TAB Field Work, submit advance notice of TAB field work accompanied by completed Season 1 Pre-TAB Work Checklist.

Season 1 TAB Field Work: At a minimum of 84 calendar days prior to CCD,

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and when the ambient temperature is within Season 1 limits, accomplish Season 1 TAB field work.

Submit Season 1 TAB Report: Within 14 calendar days after completion of Season 1 TAB field work, submit initial Season 1 TAB report.

Season 1 Quality Assurance - COTR TAB Field Check: 30 calendar days after initial Season 1 TAB report is approved by the Contracting Officer, conduct Season 1 field check.

Complete Season 1 TAB Work: Prior to CCD, complete all TAB work except Season 2 TAB work and submit final.

Receive the approved TAB report: Within 21 calendar days, receive the report from Contracting Officer approved TAB report.

Advance Notice of Season 2 TAB Field Work: At a minimum of 126 calendar days after CCD, submit advance notice of Season 2 TAB field work accompanied by completed Season 2 Pre-TAB Work Checklist.

Season 2 TAB Field Work: Within 14 calendar days after date of advance notice of Season 2 TAB field work and when the ambient temperature is within Season 2 limits, accomplish Season 2 TAB field work.

Submit Season 2 TAB Report: Within 14 calendar days after completion of Season 2 TAB field work, submit Season 2 TAB report.

Season 2 Quality Assurance - COTR TAB Field Checks: 28 calendar days after the Season 2 TAB report is approved by the Contracting Officer, conduct Season 2 field check.

Complete Season 2 TAB Work: Within 14 calendar days after the completion of Season 2 TAB field data check, complete all TAB work.

Receive the approved TAB report: Within calendar 21 days, receive the report from Contracting Officer.

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Appendix D

REQUIREMENTS FOR DUCT AIR LEAK TESTING

SYSTEMS

PackageRooftopw/CV

Unit No.1-8

Duct System Static Pressure, in inches W.C.

for Supply 2

for Return 1

for Exhaust 1

for Outside Air

1

System Oval/Round Duct and Rectangular Duct SMACNA Seal Class

for Supply A

for Return A

for Exhaust A

for Outside Air

A

System Oval/Round Duct SMACNA Leak Class

for Supply 6

for Return 12

for Exhaust 12

for Outside Air

12

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Appendix D

REQUIREMENTS FOR DUCT AIR LEAK TESTING

SYSTEMS

PackageRooftopw/CV

Unit No.1-8

System Rectangular Duct SMACNA Leak Class

for Supply 12

for Return 24

for Exhaust 12

for Outside Air

24

Duct Test Pressure, in inches W.C.

for Supply 50

for Return 1

for Exhaust 1

for Outside Air

1

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Appendix D

REQUIREMENTS FOR DUCT AIR LEAK TESTING

SYSTEMS

AHU &CV Unit

MAU & CVUnit

VRF FanCoil Units

IndoorShooting

Range ExhaustSystems Unit

No. 1-8

Duct System Static Pressure, in millimeters W.C.

for Supply

2 2 0.5 n/a

for Return

1 1 0.5 n/a

for Exhaust

0.5 0.5 n/a 1

for Outside Air

1 1 n/a n/a

System Oval/Round Duct and Rectangular Duct SMACNA Seal Class

for Supply

A A A A

for Return

A A A A

for Exhaust

A A A A

for Outside Air

A A A A

System Oval/Round Duct SMACNA Leak Class

for Supply

6 6 12 n/a

for Return

12 12 12 n/a

for Exhaust

12 12 n/a 12

for Outside Air

12 12 n/a n/a

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Appendix D

REQUIREMENTS FOR DUCT AIR LEAK TESTING

SYSTEMS

AHU &CV Unit

MAU & CVUnit

VRF FanCoil Units

IndoorShooting

Range ExhaustSystems Unit

No. 1-8

System Rectangular Duct SMACNA Leak Class

for Supply

12 12 24 n/a

for Return

24 24 24 n/a

for Exhaust

24 24 n/a 24

for Outside Air

24 24 n/a n/a

Duct Test Pressure, in inches W.C.

for Supply

2 2 0.5 n/a

for Return

1 1 0.5 n/a

for Exhaust

0.5 0.5 n/a 1

for Outside Air

1 1 n/a n/a

-- End of Section --

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SECTION 23 07 00

THERMAL INSULATION FOR MECHANICAL SYSTEMS02/13

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. At the discretion of the Government, the manufacturer of any material supplied will be required to furnish test reports pertaining to any of the tests necessary to assure compliance with the standard or standards referenced in this specification.

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)

ASHRAE 90.1 - IP (2010; Errata 1-3 2011; INT 1-12 2011; Addenda A, B, C, G, H, J, K, O, P, S, Y, Z, BZ, CG, CI and DS 2012; Errata 4-8 2012; INT 13-16 2012; Errata 9-12 2013; INT 17 2013) Energy Standard for Buildings Except Low-Rise Residential Buildings

ASTM INTERNATIONAL (ASTM)

ASTM A167 (1999; R 2009) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A240/A240M (2012a) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A580/A580M (2012a) Standard Specification for Stainless Steel Wire

ASTM B209 (2010) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

ASTM C1136 (2012) Standard Specification for Flexible, Low Permeance Vapor Retarders for Thermal Insulation

ASTM C1290 (2011) Standard Specification for Flexible Fibrous Glass Blanket Insulation Used to Externally Insulate HVAC Ducts

ASTM C1710 (2011) Standard Guide for Installation of Flexible Closed Cell Preformed Insulation in Tube and Sheet Form

ASTM C195 (2007) Standard Specification for Mineral

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Fiber Thermal Insulating Cement

ASTM C450 (2008) Standard Practice for Fabrication of Thermal Insulating Fitting Covers for NPS Piping, and Vessel Lagging

ASTM C534/C534M (2011) Standard Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in Sheet and Tubular Form

ASTM C547 (2012) Standard Specification for Mineral Fiber Pipe Insulation

ASTM C552 (2012b) Standard Specification for Cellular Glass Thermal Insulation

ASTM C585 (2010) Standard Practice for Inner and Outer Diameters of Thermal Insulation for Nominal Sizes of Pipe and Tubing

ASTM C612 (2010) Mineral Fiber Block and Board Thermal Insulation

ASTM C647 (2008) Properties and Tests of Mastics and Coating Finishes for Thermal Insulation

ASTM C795 (2008) Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless Steel

ASTM C920 (2011) Standard Specification for Elastomeric Joint Sealants

ASTM C921 (2010) Standard Practice for Determining the Properties of Jacketing Materials for Thermal Insulation

ASTM D2863 (2012) Measuring the Minimum Oxygen Concentration to Support Candle-Like Combustion of Plastics (Oxygen Index)

ASTM D5590 (2000; R 2010; E 2012) Standard Test Method for Determining the Resistance of Paint Films and Related Coatings to Fungal Defacement by Accelerated Four-Week Agar Plate Assay

ASTM D882 (2012) Tensile Properties of Thin Plastic Sheeting

ASTM E2231 (2009) Specimen Preparation and Mounting of Pipe and Duct Insulation Materials to Assess Surface Burning Characteristics

ASTM E84 (2012c) Standard Test Method for Surface Burning Characteristics of Building Materials

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ASTM E96/E96M (2012) Standard Test Methods for Water Vapor Transmission of Materials

FM GLOBAL (FM)

FM APP GUIDE (updated on-line) Approval Guide http://www.approvalguide.com/

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)

MSS SP-69 (2003; Notice 2012) Pipe Hangers and Supports - Selection and Application (ANSI Approved American National Standard)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 90A (2012) Standard for the Installation of Air Conditioning and Ventilating Systems

NFPA 90B (2012) Standard for the Installation of Warm Air Heating and Air Conditioning Systems

TECHNICAL ASSOCIATION OF THE PULP AND PAPER INDUSTRY (TAPPI)

TAPPI T403 OM (2010) Bursting Strength of Paper

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-A-24179 (1969; Rev A; Am 2 1980; Notice 1 1987) Adhesive, Flexible Unicellular-Plastic Thermal Insulation

MIL-A-3316 (1987; Rev C; Am 2 1990) Adhesives, Fire-Resistant, Thermal Insulation

MIL-PRF-19565 (1988; Rev C) Coating Compounds, Thermal Insulation, Fire- and Water-Resistant, Vapor-Barrier

UNDERWRITERS LABORATORIES (UL)

UL 723 (2008; Reprint Sep 2010) Test for Surface Burning Characteristics of Building Materials

UL 94 (1996; Reprint Feb 2013) Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances

1.2 SYSTEM DESCRIPTION

1.2.1 General

Provide field-applied insulation and accessories on mechanical systems as specified herein; factory-applied insulation is specified under the piping, duct or equipment to be insulated.

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1.2.2 Recycled Materials

Provide thermal insulation containing recycled materials to the extent practicable, provided that the materials meet all other requirements of this section. The minimum recycled material content of the following insulation are:

Rock Wool 75 percent slag of weight

Fiberglass 20-25 percent glass cullet by weight

Rigid Foam 9 percent recovered material

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

Submit the two SD types, SD-03 Product Data, and SD-08 Manufacturer's Instructions at the same time for each system.

SD-03 Product Data

Pipe Insulation Systems; GDuct Insulation Systems; GEquipment Insulation Systems; G

SD-08 Manufacturer's Instructions

Pipe Insulation Systems; GDuct Insulation Systems; GEquipment Insulation Systems; G

1.4 QUALITY ASSURANCE

1.4.1 Installer Qualification

Qualified installers shall have successfully completed three or more similar type jobs within the last 5 years.

1.5 DELIVERY, STORAGE, AND HANDLING

Materials shall be delivered in the manufacturer's unopened containers. Materials delivered and placed in storage shall be provided with protection from weather, humidity, dirt, dust and other contaminants. The Contracting Officer may reject insulation material and supplies that become dirty, dusty, wet, or contaminated by some other means. Packages or standard containers of insulation, jacket material, cements, adhesives, and coatings delivered for use, and samples required for approval shall have manufacturer's stamp or label attached giving the name of the manufacturer and brand, and a description of the material, date codes, and approximate shelf life (if applicable). Insulation packages and containers shall be asbestos free.

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PART 2 PRODUCTS

2.1 STANDARD PRODUCTS

Provide materials which are the standard products of manufacturers regularly engaged in the manufacture of such products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Submit a complete list of materials, including manufacturer's descriptive technical literature, performance data, catalog cuts, and installation instructions. The product number, k-value, thickness and furnished accessories including adhesives, sealants and jackets for each mechanical system requiring insulation shall be included. The product data must be copyrighted, have an identifying or publication number, and shall have been published prior to the issuance date of this solicitation. Materials furnished under this section shall be submitted together in a booklet.

2.1.1 Insulation System

Provide field-applied insulation for heating, ventilating, and cooling (HVAC) air distribution systems and piping systems that are located within, on, under, and adjacent to buildings; and for plumbing systems. Insulation shall be CFC and HCFC free.

2.1.2 Surface Burning Characteristics

Unless otherwise specified, insulation shall have a maximum flame spreadindex of 25 and a maximum smoke developed index of 50 when tested inaccordance with ASTM E84. Flame spread, and smoke developed indexes,shall be determined by ASTM E84 or UL 723. Insulation shall be tested inthe same density and installed thickness as the material to be used in theactual construction. Test specimens shall be prepared and mountedaccording to ASTM E2231.

2.2 MATERIALS

Provide insulation that meets or exceed the requirements of ASHRAE 90.1 - IP. Insulation exterior shall be cleanable, grease resistant, non-flaking and non-peeling. Materials shall be compatible and shall not contribute to corrosion, soften, or otherwise attack surfaces to which applied in either wet or dry state. Materials to be used on stainless steel surfaces shall meet ASTM C795 requirements. Calcium silicate shall not be used on chilled or cold water systems. Materials shall be asbestos free. Provide product recognized under UL 94 (if containing plastic) and listed in FM APP GUIDE.

2.2.1 Adhesives

2.2.1.1 Mineral Fiber Insulation Cement

Cement shall be in accordance with ASTM C195.

2.2.1.2 Lagging Adhesive

Lagging is the material used for thermal insulation, especially around a cylindrical object. This may include the insulation as well as the cloth/material covering the insulation. Lagging adhesives shall be nonflammable and fire-resistant and shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. Adhesive shall be MIL-A-3316, Class 1, pigmented white and

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be suitable for bonding fibrous glass cloth to faced and unfaced fibrous glass insulation board; for bonding cotton brattice cloth to faced and unfaced fibrous glass insulation board; for sealing edges of and bonding glass tape to joints of fibrous glass board; for bonding lagging cloth to thermal insulation; or Class 2 for attaching fibrous glass insulation to metal surfaces. Lagging adhesives shall be applied in strict accordance with the manufacturer's recommendations for pipe and duct insulation.

2.2.1.3 Contact Adhesive

Adhesives may be any of, but not limited to, the neoprene based, rubber based, or elastomeric type that have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. The adhesive shall not adversely affect, initially or in service, the insulation to which it is applied, nor shall it cause any corrosive effect on metal to which it is applied. Any solvent dispersing medium or volatile component of the adhesive shall have no objectionable odor and shall not contain any benzene or carbon tetrachloride. The dried adhesive shall not emit nauseous, irritating, or toxic volatile matters or aerosols when the adhesive is heated to any temperature up to 212 degrees F. The dried adhesive shall be nonflammable and fire resistant. Flexible Elastomeric Adhesive: Comply with MIL-A-24179, Type II, Class I. Provide product listed in FM APP GUIDE.

2.2.2 Caulking

ASTM C920, Type S, Grade NS, Class 25, Use A.

2.2.3 Corner Angles

Nominal 0.016 inch aluminum 1 by 1 inch with factory applied kraft backing. Aluminum shall be ASTM B209, Alloy 3003, 3105, or 5005.

2.2.4 Fittings

Fabricated Fittings are the prefabricated fittings for flexible elastomeric pipe insulation systems in accordance with ASTM C1710. Together with the flexible elastomeric tubes, they provide complete system integrity for retarding heat gain and controlling condensation drip from chilled-water and refrigeration systems. Flexible elastomeric, fabricated fittings provide thermal protection (0.25 k) and condensation resistance (0.05 Water Vapor Transmission factor). For satisfactory performance, properly installed protective vapor retarder/barriers and vapor stops shall be used on high relative humidity and below ambient temperature applications to reduce movement of moisture through or around the insulation to the colder interior surface.

2.2.5 Finishing Cement

ASTM C450: Mineral fiber hydraulic-setting thermal insulating and finishing cement. All cements that may come in contact with Austenitic stainless steel must comply with ASTM C795.

2.2.6 Fibrous Glass Cloth and Glass Tape

Fibrous glass cloth, with 20X20 maximum mesh size, and glass tape shall have maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. Tape shall be 4 inch wide rolls. Class 3 tape shall be 4.5 ounces/square yard. Elastomeric Foam

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Tape: Black vapor-retarder foam tape with acrylic adhesive containing an anti-microbial additive.

2.2.7 Staples

Outward clinching type ASTM A167, Type 304 or 316 stainless steel.

2.2.8 Jackets

2.2.8.1 Aluminum Jackets

Aluminum jackets shall be corrugated, embossed or smooth sheet, 0.016 inch nominal thickness; ASTM B209, Temper H14, Temper H16, Alloy 3003, 5005, or 3105. Corrugated aluminum jacket shall not be used outdoors. Aluminum jacket securing bands shall be Type 304 stainless steel, 0.015 inch thick, 1/2 inch wide for pipe under 12 inch diameter and 3/4 inch wide for pipe over 12 inch and larger diameter. Aluminum jacket circumferential seam bands shall be 2 by 0.016 inch aluminum matching jacket material. Bands for insulation below ground shall be 3/4 by 0.020 inch thick stainless steel, or fiberglass reinforced tape. The jacket may, at the option of the Contractor, be provided with a factory fabricated Pittsburgh or "Z" type longitudinal joint. When the "Z" joint is used, the bands at the circumferential joints shall be designed by the manufacturer to seal the joints and hold the jacket in place.

2.2.8.2 Polyvinyl Chloride (PVC) Jackets

Polyvinyl chloride (PVC) jacket and fitting covers shall have high impact strength, ultraviolet (UV) resistant rating or treatment and moderate chemical resistance with minimum thickness 0.030 inch.

2.2.8.3 Vapor Barrier/Vapor Retarder

Apply the following criteria to determine which system is required.

a. On ducts, piping and equipment operating below 95 degrees F or located outside shall be equipped with a vapor barrier.

b. Ducts, pipes and equipment that are located inside and that always operate above 95 degrees F shall be installed with a vapor retarder where required as stated in paragraph VAPOR RETARDER REQUIRED.

2.2.9 Vapor Retarder Required

ASTM C921, Type I, minimum puncture resistance 50 Beach units on all surfaces except concealed ductwork, where a minimum puncture resistance of 25 Beach units is acceptable. Minimum tensile strength, 35 pounds/inch width. ASTM C921, Type II, minimum puncture resistance 25 Beach units, tensile strength minimum 20 pounds/inch width. Jackets used on insulation exposed in finished areas shall have white finish suitable for painting without sizing. Based on the application, insulation materials that require manufacturer or fabricator applied pipe insulation jackets are cellular glass, when all joints are sealed with a vapor barrier mastic, and mineral fiber. All non-metallic jackets shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. Flexible elastomerics require (in addition to vapor barrier skin) vapor retarder jacketing for high relative humidity and below ambient temperature applications.

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2.2.9.1 White Vapor Retarder All Service Jacket (ASJ)

ASJ is for use on hot/cold pipes, ducts, or equipment indoors or outdoors if covered by a suitable protective jacket. The product shall meet all physical property and performance requirements of ASTM C1136, Type I, except the burst strength shall be a minimum of 85 psi. ASTM D2863 Limited Oxygen Index (LOI) shall be a minimum of 31.

In addition, neither the outer exposed surface nor the inner-most surface contacting the insulation shall be paper or other moisture-sensitive material. The outer exposed surface shall be white and have an emittance of not less than 0.80. The outer exposed surface shall be paintable.

2.2.9.2 Vapor Retarder/Vapor Barrier Mastic Coatings

a. The vapor barrier shall be self adhesive (minimum 2 mils adhesive, 3 mils embossed) greater than 3 plies standard grade, silver, white, black and embossed white jacket for use on hot/cold pipes. Permeability shall be less than 0.02 when tested in accordance with ASTM E96/E96M. Products shall meet UL 723 or ASTM E84 flame and smoke requirements and shall be UV resistant.

b. The vapor retarder coating shall be fire and water resistant and appropriately selected for either outdoor or indoor service. Color shall be white. The water vapor permeance of the compound shall be 0.013 perms or less at 43 mils dry film thickness as determined according to procedure B of ASTM E96/E96M utilizing apparatus described in ASTM E96/E96M. The coating shall be nonflammable, fire resistant type. To resist mold/mildew, coating shall meet ASTM D5590 with 0 growth rating. Coating shall meet MIL-PRF-19565 Type II (if selected for indoor service) and be Qualified Products Database listed. All other application and service properties shall be in accordance with ASTM C647.

2.2.9.3 Laminated Film Vapor Retarder

ASTM C1136, Type I, maximum moisture vapor transmission 0.02 perms, minimum puncture resistance 50 Beach units on all surfaces except concealed ductwork; where Type II, maximum moisture vapor transmission 0.02 perms, a minimum puncture resistance of 25 Beach units is acceptable. Vapor retarder shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. Flexible Elastomeric exterior foam with factory applied UV Jacket. Construction of laminate designed to provide UV resistance, high puncture, tear resistance and an excellent WVT rate.

2.2.9.4 Polyvinylidene Chloride (PVDC) Film Vapor Retarder

The PVDC film vapor retarder shall have a maximum moisture vapor transmission of 0.02 perms, minimum puncture resistance of 150 Beach units, a minimum tensile strength in any direction of 30 lb/inch when tested in accordance with ASTM D882, and a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84.

2.2.9.5 Polyvinylidene Chloride Vapor Retarder Adhesive Tape

Requirements must meet the same as specified for Laminated Film Vapor Retarder above.

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2.2.9.6 Vapor Barrier/Weather Barrier

The vapor barrier shall be greater than 3 ply self adhesive laminate -white vapor barrier jacket- superior performance (less than 0.0000 permeability when tested in accordance with ASTM E96/E96M). Vapor barrier shall meet UL 723 or ASTM E84 25 flame and 50 smoke requirements; and UV resistant. Minimum burst strength 185 psi in accordance with TAPPI T403 OM. Tensile strength 68 lb/inch width (PSTC-1000). Tape shall be as specified for laminated film vapor barrier above.

2.2.10 Vapor Retarder Not Required

ASTM C921, Type II, Class D, minimum puncture resistance 50 Beach units on all surfaces except ductwork, where Type IV, maximum moisture vapor transmission 0.10, a minimum puncture resistance of 25 Beach units is acceptable. Jacket shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84.

2.2.11 Wire

Soft annealed ASTM A580/A580M Type 302, 304 or 316 stainless steel, 16 or 18 gauge.

2.2.12 Insulation Bands

Insulation bands shall be 1/2 inch wide; 26 gauge stainless steel.

2.2.13 Sealants

Sealants shall be chosen from the butyl polymer type, the styrene-butadiene rubber type, or the butyl type of sealants. Sealants shall have a maximum permeance of 0.02 perms based on Procedure B for ASTM E96/E96M, and a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84.

2.3 PIPE INSULATION SYSTEMS

Insulation materials shall conform to Table 1. Insulation thickness shall be as listed in Table 2 and meet or exceed the requirements of ASHRAE 90.1 - IP. Insulation thickness shall be 1 inch. Comply with EPA requirements in accordance with Section 01 62 35 RECYCLED/RECOVERED/BIOBASED MATERIALS. Pipe insulation materials shall be limited to those listed herein and shall meet the following requirements:

2.3.1 Aboveground Cold Pipeline (-30 to 60 deg. F)

Insulation for outdoor, indoor, exposed or concealed applications, shall be as follows:

a. Cellular Glass: ASTM C552, Type II, and Type III. Supply the insulation from the fabricator with (paragraph WHITE VAPOR RETARDER ALL SERVICE JACKET (ASJ)) ASJ vapor retarder and installed with all longitudinal overlaps sealed and all circumferential joints ASJ taped or supply the insulation unfaced from the fabricator and install with all longitudinal and circumferential joints sealed with vapor barrier mastic.

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2.3.2 Aboveground Hot Pipeline (Above 60 deg. F)

Insulation for outdoor, indoor, exposed or concealed applications shall meet the following requirements. Supply the insulation with manufacturer's recommended factory-applied jacket/vapor barrier.

a. Mineral Fiber: ASTM C547, Types I, II or III, supply the insulation with manufacturer's recommended factory-applied jacket.

2.3.3 Aboveground Dual Temperature Pipeline

Selection of insulation for use over a dual temperature pipeline system (Outdoor, Indoor - Exposed or Concealed) shall be in accordance with the most limiting/restrictive case. Find an allowable material from paragraph PIPE INSULATION MATERIALS and determine the required thickness from the most restrictive case. Use the thickness listed in paragraphs INSULATION THICKNESS for cold & hot pipe applications.

2.3.4 Below-ground Pipeline Insulation

For below-ground pipeline insulation, use cellular glass, ASTM C552, type II.

2.4 DUCT INSULATION SYSTEMS

2.4.1 Factory Applied Insulation

2.4.1.1 Rigid Insulation

Rigid mineral fiber in accordance with ASTM C612, Class 2 (maximum surface temperature 400 degrees F), 3 pcf average, 1-1/2 inch thick, Type IA, IB, II, III, and IV. Alternately, minimum thickness may be calculated in accordance with ASHRAE 90.1 - IP.

2.4.1.2 Blanket Insulation

Blanket flexible mineral fiber insulation conforming to ASTM C585, Type 1, 2.0 inches thick or Type II up to 250 degrees F. Also ASTM C1290 Type III may be used.

2.4.2 Duct Insulation Jackets

2.4.2.1 All-Purpose Jacket

Provide insulation with insulation manufacturer's standard reinforced fire-retardant jacket with or without integral vapor barrier as required by the service. In exposed locations, provide jacket with a white surface suitable for field painting.

2.4.2.2 Metal Jackets

a. Aluminum Jackets: ASTM B209, Temper H14, minimum thickness of 27 gauge ( 0.016 inch), with factory-applied polyethylene and kraft paper moisture barrier on inside surface. Provide smooth surface jackets for jacket outside dimension 8 inches and larger. Provide corrugated surface jackets for jacket outside dimension 8 inches and larger. Provide stainless steel bands, minimum width of 1/2 inch.

b. Stainless Steel Jackets: ASTM A167 or ASTM A240/A240M; Type 304,

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minimum thickness of 33 gauge ( 0.010 inch), smooth surface with factory-applied polyethylene and kraft paper moisture barrier on inside surface. Provide stainless steel bands, minimum width of 1/2 inch.

2.4.2.3 Vapor Barrier/Weatherproofing Jacket

Vapor barrier/weatherproofing jacket shall be laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) less than 0.0000 permeability, (greater than 3 ply, standard grade, silver, white, black and embossed or greater than 8 ply (minimum 2.9 mils adhesive), heavy duty white or natural).

2.4.3 Weatherproof Duct Insulation

Provide ASTM C552, cellular glass thermal insulation or ASTM C534/C534M Grade 1, Type II, flexible elastomeric cellular insulation, and weatherproofing as specified in manufacturer's instruction. Multi-ply, Polymeric Blend Laminate Jacketing: Construction of laminate designed to provide UV resistance, high puncture, tear resistance and an excellent WVT rate.

2.5 EQUIPMENT INSULATION SYSTEMS

Insulate equipment and accessories as specified in Tables 5 and 6. In outside locations, provide insulation 1/2 inch thicker than specified. Increase the specified insulation thickness for equipment where necessary to equal the thickness of angles or other structural members to make a smooth, exterior surface. Submit a booklet containing manufacturer's published installation instructions for the insulation systems. The instructions must be copyrighted, have an identifying or publication number, and shall have been published prior to the issuance date of this solicitation. A booklet is also required by paragraphs titled: Pipe Insulation Systems and Duct Insulation Systems.

PART 3 EXECUTION

3.1 APPLICATION - GENERAL

Insulation shall only be applied to unheated and uncooled piping and equipment. Flexible elastomeric cellular insulation shall not be compressed at joists, studs, columns, ducts, hangers, etc. The insulation shall not pull apart after a one hour period; any insulation found to pull apart after one hour, shall be replaced.

3.1.1 Display Samples

Submit and display, after approval of materials, actual sections of installed systems, properly insulated in accordance with the specification requirements. Such actual sections must remain accessible to inspection throughout the job and will be reviewed from time to time for controlling the quality of the work throughout the construction site. Each material used shall be identified, by indicating on an attached sheet the specification requirement for the material and the material by each manufacturer intended to meet the requirement. The Contracting Officer will inspect display sample sections at the jobsite. Approved display sample sections shall remain on display at the jobsite during the construction period. Upon completion of construction, the display sample sections will be closed and sealed.

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3.1.1.1 Pipe Insulation Display Sections

Display sample sections shall include as a minimum an elbow or tee, a valve, dielectric waterways and flanges, a hanger with protection shield and insulation insert, or dowel as required, at support point, method of fastening and sealing insulation at longitudinal lap, circumferential lap, butt joints at fittings and on pipe runs, and terminating points for each type of pipe insulation used on the job, and for hot pipelines and cold pipelines, both interior and exterior, even when the same type of insulation is used for these services.

3.1.1.2 Duct Insulation Display Sections

Display sample sections for rigid and flexible duct insulation used on the job. Use a temporary covering to enclose and protect display sections for duct insulation exposed to weather

3.1.2 Installation

Except as otherwise specified, material shall be installed in accordance with the manufacturer's written instructions. Insulation materials shall not be applied until tests specified in other sections of this specification are completed. Material such as rust, scale, dirt and moisture shall be removed from surfaces to receive insulation. Insulation shall be kept clean and dry. Insulation shall not be removed from its shipping containers until the day it is ready to use and shall be returned to like containers or equally protected from dirt and moisture at the end of each workday. Insulation that becomes dirty shall be thoroughly cleaned prior to use. If insulation becomes wet or if cleaning does not restore the surfaces to like new condition, the insulation will be rejected, and shall be immediately removed from the jobsite. Joints shall be staggered on multi layer insulation. Mineral fiber thermal insulating cement shall be mixed with demineralized water when used on stainless steel surfaces.

3.1.3 Firestopping

Where pipes and ducts pass through fire walls, fire partitions, above grade floors, and fire rated chase walls, the penetration shall be sealed with fire stopping materials as specified in Section 07 84 00 FIRESTOPPING. The protection of ducts at point of passage through firewalls must be in accordance with NFPA 90A and/or NFPA 90B. All other penetrations, such as piping, conduit, and wiring, through firewalls must be protected with a material or system of the same hourly rating that is listed by UL, FM, or a NRTL.

3.1.4 Painting and Finishing

Painting shall be as specified in Section 09 90 00 PAINTS AND COATINGS.

3.1.5 Installation of Flexible Elastomeric Cellular Insulation

Install flexible elastomeric cellular insulation with seams and joints sealed with rubberized contact adhesive. Flexible elastomeric cellular insulation shall not be used on surfaces greater than 220 degrees F. Stagger seams when applying multiple layers of insulation. Protect insulation exposed to weather and not shown to have vapor barrier weatherproof jacketing with two coats of UV resistant finish or PVC or metal jacketing as recommended by the manufacturer after the adhesive is dry and cured.

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3.1.5.1 Adhesive Application

Apply a brush coating of adhesive to both butt ends to be joined and to both slit surfaces to be sealed. Allow the adhesive to set until dry to touch but tacky under slight pressure before joining the surfaces. Insulation seals at seams and joints shall not be capable of being pulled apart one hour after application. Insulation that can be pulled apart one hour after installation shall be replaced.

3.1.5.2 Adhesive Safety Precautions

Use natural cross-ventilation, local (mechanical) pickup, and/or general area (mechanical) ventilation to prevent an accumulation of solvent vapors, keeping in mind the ventilation pattern must remove any heavier-than-air solvent vapors from lower levels of the workspaces. Gloves and spectacle-type safety glasses are recommended in accordance with safe installation practices.

3.1.6 Welding

No welding shall be done on piping, duct or equipment without written approval of the Contracting Officer. The capacitor discharge welding process may be used for securing metal fasteners to duct.

3.1.7 Pipes/Ducts/Equipment That Require Insulation

Insulation is required on all pipes, ducts, or equipment, except for omitted items as specified.

3.2 PIPE INSULATION SYSTEMS INSTALLATION

3.2.1 Pipe Insulation

3.2.1.1 General

Pipe insulation shall be installed on aboveground hot and cold pipeline systems as specified below to form a continuous thermal retarder/barrier, including straight runs, fittings and appurtenances unless specified otherwise. Installation shall be with full length units of insulation and using a single cut piece to complete a run. Cut pieces or scraps abutting each other shall not be used. Pipe insulation shall be omitted on the following:

a. Pipe used solely for fire protection.

b. Chromium plated pipe to plumbing fixtures. However, fixtures for use by the physically handicapped shall have the hot water supply and drain, including the trap, insulated where exposed.

c. Sanitary drain lines.

d. Air chambers.

e. Adjacent insulation.

f. ASME stamps.

g. Access plates of fan housings.

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h. Cleanouts or handholes.

3.2.1.2 Pipes Passing Through Walls, Roofs, and Floors

a. Pipe insulation shall be continuous through the sleeve.

b. An aluminum jacket or vapor barrier/weatherproofing - self adhesive jacket (minimum 2 mils adhesive, 3 mils embossed) less than 0.0000 permeability, greater than 3 ply standard grade, silver, white, black and embossed with factory applied moisture retarder shall be provided over the insulation wherever penetrations require sealing.

c. Where pipes penetrate interior walls, the aluminum jacket or vapor barrier/weatherproofing - self adhesive jacket (minimum 2 mils adhesive, 3 mils embossed) less than 0.0000 permeability, greater than 3 plies standard grade, silver, white, black and embossed shall extend 2 inches beyond either side of the wall and shall be secured on each end with a band.

d. Where penetrating floors, the aluminum jacket shall extend from a point below the backup material to a point 10 inches above the floor with one band at the floor and one not more than 1 inch from the end of the aluminum jacket.

e. Where penetrating waterproofed floors, the aluminum jacket shall extend from below the backup material to a point 2 inches above the flashing with a band 1 inch from the end of the aluminum jacket.

f. Where penetrating exterior walls, the aluminum jacket required for pipe exposed to weather shall continue through the sleeve to a point 2 inches beyond the interior surface of the wall.

g. Where penetrating roofs, pipe shall be insulated as required for interior service to a point flush with the top of the flashing and sealed with flashing sealant. The insulation for exterior application shall butt tightly to the top of flashing and interior insulation. The exterior aluminum jacket shall extend 2 inches down beyond the end of the insulation to form a counter flashing. The flashing and counter flashing shall be sealed underneath with metal jacketing/flashing sealant.

h. For hot water pipes supplying lavatories or other similar heated service that requires insulation, the insulation shall be terminated on the backside of the finished wall. The insulation termination shall be protected with two coats of vapor barrier coating with a minimum total thickness of 1/16 inch applied with glass tape embedded between coats (if applicable). The coating shall extend out onto the insulation 2 inches and shall seal the end of the insulation. Glass tape seams shall overlap 1 inch. The annular space between the pipe and wall penetration shall be caulked with approved fire stop material. The pipe and wall penetration shall be covered with a properly sized (well fitting) escutcheon plate. The escutcheon plate shall overlap the wall penetration at least 3/8 inches.

i. For domestic cold water pipes supplying lavatories or other similar cooling service that requires insulation, the insulation shall be terminated on the finished side of the wall (i.e., insulation must cover the pipe throughout the wall penetration). The insulation shall

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be protected with two coats of weather barrier mastic (breather emulsion type weatherproof mastic impermeable to water and permeable to air) with a minimum total thickness of 1/16 inch. The mastic shall extend out onto the insulation 2 inches and shall seal the end of the insulation. The annular space between the outer surface of the pipe insulation and the wall penetration shall be caulked with an approved fire stop material having vapor retarder properties. The pipe and wall penetration shall be covered with a properly sized (well fitting) escutcheon plate. The escutcheon plate shall overlap the wall penetration by at least 3/8 inches.

3.2.1.3 Pipes Passing Through Hangers

a. Insulation, whether hot or cold application, shall be continuous through hangers. All horizontal pipes 2 inches and smaller shall be supported on hangers with the addition of a Type 40 protection shield to protect the insulation in accordance with MSS SP-69. Whenever insulation shows signs of being compressed, or when the insulation or jacket shows visible signs of distortion at or near the support shield, insulation inserts as specified below for piping larger than 2 inches shall be installed, or factory insulated hangers (designed with a load bearing core) can be used.

b. Horizontal pipes larger than 2 inches at 60 degrees F and above shall be supported on hangers in accordance with MSS SP-69, and Section 22 00 00 PLUMBING, GENERAL PURPOSE.

c. Horizontal pipes larger than 2 inches and below 60 degrees F shall be supported on hangers with the addition of a Type 40 protection shield in accordance with MSS SP-69. An insulation insert of cellular glass, prefabricated insulation pipe hangers, or perlite above 80 degrees F shall be installed above each shield. The insert shall cover not less than the bottom 180-degree arc of the pipe. Inserts shall be the same thickness as the insulation, and shall extend 2 inches on each end beyond the protection shield. When insulation inserts are required in accordance with the above, and the insulation thickness is less than 1 inch, wooden or cork dowels or blocks may be installed between the pipe and the shield to prevent the weight of the pipe from crushing the insulation, as an option to installing insulation inserts. The insulation jacket shall be continuous over the wooden dowel, wooden block, or insulation insert.

d. Vertical pipes shall be supported with either Type 8 or Type 42 riser clamps with the addition of two Type 40 protection shields in accordance with MSS SP-69 covering the 360-degree arc of the insulation. An insulation insert of cellular glass or calcium silicate shall be installed between each shield and the pipe. The insert shall cover the 360-degree arc of the pipe. Inserts shall be the same thickness as the insulation, and shall extend 2 inches on each end beyond the protection shield. When insulation inserts are required in accordance with the above, and the insulation thickness is less than 1 inch, wooden or cork dowels or blocks may be installed between the pipe and the shield to prevent the hanger from crushing the insulation, as an option instead of installing insulation inserts. The insulation jacket shall be continuous over the wooden dowel, wooden block, or insulation insert. The vertical weight of the pipe shall be supported with hangers located in a horizontal section of the pipe. When the pipe riser is longer than 30 feet, the weight of the pipe shall be additionally supported with hangers in the vertical run of the pipe

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that are directly clamped to the pipe, penetrating the pipe insulation. These hangers shall be insulated and the insulation jacket sealed as indicated herein for anchors in a similar service.

e. Inserts shall be covered with a jacket material of the same appearance and quality as the adjoining pipe insulation jacket, shall overlap the adjoining pipe jacket 1-1/2 inches, and shall be sealed as required for the pipe jacket. The jacket material used to cover inserts in flexible elastomeric cellular insulation shall conform to ASTM C1136, Type 1, and is allowed to be of a different material than the adjoining insulation material.

3.2.1.4 Flexible Elastomeric Cellular Pipe Insulation

Flexible elastomeric cellular pipe insulation shall be tubular form for pipe sizes 6 inches and less. Grade 1, Type II sheet insulation used on pipes larger than 6 inches shall not be stretched around the pipe. On pipes larger than 12 inches, the insulation shall be adhered directly to the pipe on the lower 1/3 of the pipe. Seams shall be staggered when applying multiple layers of insulation. Sweat fittings shall be insulated with miter-cut pieces the same size as on adjacent piping. Screwed fittings shall be insulated with sleeved fitting covers fabricated from miter-cut pieces and shall be overlapped and sealed to the adjacent pipe insulation. Type II requires an additional exterior vapor retarder/barrier covering for high relative humidity and below ambient temperature applications.

3.2.1.5 Pipes in high abuse areas.

In high abuse areas such as janitor closets and traffic areas in equipment rooms, kitchens, and mechanical rooms, aluminum or flexible laminate cladding (comprised of elastomeric, plastic or metal foil laminate) laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket, - less than 0.0000 permeability; (greater than 3 ply, standard grade, silver, white, black and embossed) aluminum jackets shall be utilized. Pipe insulation to the 6 foot level shall be protected.

3.2.1.6 Pipe Insulation Material and Thickness

TABLE 1

Insulation Material for Piping

Service

Material Specification Type Class VR/VB Req'd

Cold Domestic Water Piping, Makeup Water & Drinking Fountain Drain Piping

Cellular Glass ASTM C552 YesHot Domestic Water Supply & Recirculating Piping (Max 200 F)

Mineral Fiber ASTM C547 No

Refrigerant Suction Piping (35 degrees F nominal)Flexible Elastomeric Cellular

ASTM C534/C534M No

Exposed Lavatory Drains, Exposed Domestic Water Piping & Drains to Areas for Handicapped Personnel

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TABLE 1

Insulation Material for Piping

Service

Material Specification Type Class VR/VB Req'd

Mineral Fiber ASTM C547 No

Condensate Drain Located Inside Building

Cellular Glass ASTM C552 Yes

Note: VR/VB = Vapor Retarder/Vapor Barrier

TABLE 2

Piping Insulation Thickness (inch) Do not use integral wicking material in Chilled water applicationsexposed to outdoor ambient conditions in climatic zones 1 through 4.

Service

Material Tube And Pipe Size (inch)

Cold Domestic Water Piping, Makeup Water & Drinking Fountain Drain Piping

Cellular Glass 1.5 1.5 1.5 1.5 1.5

Hot Domestic Water Supply & Recirculating Piping (Max 200 F)

Mineral Fiber 1 1 1 1.5 1.5

Refrigerant Suction Piping (35 degrees F nominal)

Flexible Elastomeric Cellular 1 1 1 N/A N/A

Compressed Air Discharge

Mineral Fiber 1.5 1.5 2 2 2

Exposed Lavatory Drains, Exposed Domestic Water Piping & Drains to Areas for Handicapped Personnel

Mineral Fiber 1 1 1 1.5 1.5

Condensate Drain Located Inside Building

Cellular Glass 1.5 1.5 1.5 1.5 1.5

3.2.2 Aboveground Cold Pipelines

The following cold pipelines for minus 30 to plus 60 degrees F, shall be insulated in accordance with Table 2 except those piping listed in subparagraph Pipe Insulation in PART 3 as to be omitted. This includes but is not limited to the following:

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a. Make-up water.

b. Refrigerant suction lines.

c. Dual temperature water, i.e. heat recovery glycol solution water.

d. Air conditioner condensate drains.

e. Exposed lavatory drains and domestic water lines serving plumbing fixtures for handicap persons.

f. Domestic cold and chilled drinking water.

3.2.2.1 Insulation Material and Thickness

Insulation thickness for cold pipelines shall be determined using Table 2.

3.2.2.2 Factory or Field applied Jacket

Insulation shall be covered with a factory applied vapor retarder jacket/vapor barrier or field applied seal welded PVC jacket or greater than 3 ply laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - less than 0.0000 permeability, standard grade, sliver, white, black and embossed for use with Mineral Fiber, Cellular Glass, and Phenolic Foam Insulated Pipe. Insulation inside the building, to be protected with an aluminum jacket or greater than 3ply vapor barrier/weatherproofing self-adhesive (minimum 2 mils adhesive, 3 mils embossed) product, less than 0.0000 permeability, standard grade, Embossed Silver, White & Black, shall have the insulation and vapor retarder jacket installed as specified herein. The aluminum jacket or greater than 3ply vapor barrier/weatherproofing self-adhesive (minimum 2 mils adhesive, 3 mils embossed) product, less than 0.0000 permeability, standard grade, embossed silver, White & Black, shall be installed as specified for piping exposed to weather, except sealing of the laps of the aluminum jacket is not required. In high abuse areas such as janitor closets and traffic areas in equipment rooms, kitchens, and mechanical rooms, aluminum jackets or greater than 3ply vapor barrier/weatherproofing self-adhesive (minimum 2 mils adhesive, 3 mils embossed) product, less than 0.0000 permeability, standard grade, embossed silver, white & black, shall be provided for pipe insulation to the 6 ft level.

3.2.2.3 Installing Insulation for Straight Runs Hot and Cold Pipe

a. Insulation shall be applied to the pipe with joints tightly butted. All butted joints and ends shall be sealed with joint sealant and sealed with a vapor retarder coating, greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape or PVDC adhesive tape.

b. Longitudinal laps of the jacket material shall overlap not less than 1-1/2 inches. Butt strips 3 inches wide shall be provided for circumferential joints.

c. Laps and butt strips shall be secured with adhesive and stapled on 4 inch centers if not factory self-sealing. If staples are used, they shall be sealed in accordance with item "e." below. Note that staples are not required with cellular glass systems.

d. Factory self-sealing lap systems may be used when the ambient

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temperature is between 40 and 120 degrees F during installation. The lap system shall be installed in accordance with manufacturer's recommendations. Stapler shall be used only if specifically recommended by the manufacturer. Where gaps occur, the section shall be replaced or the gap repaired by applying adhesive under the lap and then stapling.

e. All Staples, including those used to repair factory self-seal lap systems, shall be coated with a vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape. All seams, except those on factory self-seal systems shall be coated with vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape.

f. Breaks and punctures in the jacket material shall be patched by wrapping a strip of jacket material around the pipe and securing it with adhesive, stapling, and coating with vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape. The patch shall extend not less than 1-1/2 inches past the break.

g. At penetrations such as thermometers, the voids in the insulation shall be filled and sealed with vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape.

h. Installation of flexible elastomeric cellular pipe insulation shall be by slitting the tubular sections and applying them onto the piping or tubing. Alternately, whenever possible slide un-slit sections over the open ends of piping or tubing. All seams and butt joints shall be secured and sealed with adhesive. When using self seal products only the butt joints shall be secured with adhesive. Insulation shall be pushed on the pipe, never pulled. Stretching of insulation may result in open seams and joints. All edges shall be clean cut. Rough or jagged edges of the insulation shall not be permitted. Proper tools such as sharp knives shall be used. Grade 1, Type II sheet insulation when used on pipe larger than 6 inches shall not be stretched around the pipe. On pipes larger than 12 inches, adhere sheet insulation directly to the pipe on the lower 1/3 of the pipe.

3.2.2.4 Insulation for Fittings and Accessories

a. Pipe insulation shall be tightly butted to the insulation of the fittings and accessories. The butted joints and ends shall be sealed with joint sealant and sealed with a vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape.

b. Precut or preformed insulation shall be placed around all fittings and accessories except as modified herein: 5 for anchors; 10, 11, and 13 for fittings; 14 for valves; and 17 for flanges and unions. Insulation shall be the same insulation as the pipe insulation, including same density, thickness, and thermal conductivity. Where precut/preformed is unavailable, rigid preformed pipe insulation sections may be segmented into the shape required. Insulation of the same thickness and conductivity as the adjoining pipe insulation shall be used. If nesting size insulation is used, the insulation shall be overlapped 2

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inches or one pipe diameter.

c. Upon completion of insulation installation on flanges, unions, valves, anchors, fittings and accessories, terminations, seams, joints and insulation not protected by factory vapor retarder jackets or PVC fitting covers shall be protected with PVDC or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape or two coats of vapor retarder coating with a minimum total thickness of 1/16 inch, applied with glass tape embedded between coats. Tape seams shall overlap 1 inch. The coating shall extend out onto the adjoining pipe insulation 2 inches. Fabricated insulation with a factory vapor retarder jacket shall be protected with either greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape, standard grade, silver, white, black and embossed or PVDC adhesive tape or two coats of vapor retarder coating with a minimum thickness of 1/16 inch and with a 2 inch wide glass tape embedded between coats. Where fitting insulation butts to pipe insulation, the joints shall be sealed with a vapor retarder coating and a 4 inch wide ASJ tape which matches the jacket of the pipe insulation.

d. Anchors attached directly to the pipe shall be insulated for a sufficient distance to prevent condensation but not less than 6 inches from the insulation surface.

e. Insulation shall be marked showing the location of unions, strainers, and check valves.

3.2.2.5 Optional PVC Fitting Covers

At the option of the Contractor, premolded, one or two piece PVC fitting covers may be used in lieu of the vapor retarder and embedded glass tape. Factory precut or premolded insulation segments shall be used under the fitting covers for elbows. Insulation segments shall be the same insulation as the pipe insulation including same density, thickness, and thermal conductivity. The covers shall be secured by PVC vapor retarder tape, adhesive, seal welding or with tacks made for securing PVC covers. Seams in the cover, and tacks and laps to adjoining pipe insulation jacket, shall be sealed with vapor retarder tape to ensure that the assembly has a continuous vapor seal.

3.2.3 Aboveground Hot Pipelines

3.2.3.1 General Requirements

All hot pipe lines above 60 degrees F, except those piping listed in subparagraph Pipe Insulation in PART 3 as to be omitted, shall be insulated in accordance with Table 2. This includes but is not limited to the following:

a. Domestic hot water supply & re-circulating system.

b. Compressed air discharge.

3.2.3.2 Insulation for Fittings and Accessories

a. General. Pipe insulation shall be tightly butted to the insulation of the fittings and accessories. The butted joints and ends shall be sealed with joint sealant. Insulation shall be marked showing the location of unions, strainers, check valves and other components that

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would otherwise be hidden from view by the insulation.

b. Precut or Preformed. Precut or preformed insulation shall be placed around all fittings and accessories. Insulation shall be the same insulation as the pipe insulation, including same density, thickness, and thermal conductivity.

c. Rigid Preformed. Where precut/preformed is unavailable, rigid preformed pipe insulation sections may be segmented into the shape required. Insulation of the same thickness and conductivity as the adjoining pipe insulation shall be used. If nesting size insulation is used, the insulation shall be overlapped 2 inches or one pipe diameter.

3.2.4 Piping Exposed to Weather

Piping exposed to weather shall be insulated and jacketed as specified for the applicable service inside the building. After this procedure, a laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - less than 0.0000 permeability (greater than 3 ply, standard grade, silver, white, black and embossed aluminum jacket or PVC jacket shall be applied. PVC jacketing requires no factory-applied jacket beneath it, however an all service jacket shall be applied if factory applied jacketing is not furnished. Flexible elastomeric cellular insulation exposed to weather shall be treated in accordance with paragraph INSTALLATION OF FLEXIBLE ELASTOMERIC CELLULAR INSULATION in PART 3.

3.2.4.1 Aluminum Jacket

The jacket for hot piping may be factory applied. The jacket shall overlap not less than 2 inches at longitudinal and circumferential joints and shall be secured with bands at not more than 12 inch centers. Longitudinal joints shall be overlapped down to shed water and located at 4 or 8 o'clock positions. Joints on piping 60 degrees F and below shall be sealed with metal jacketing/flashing sealant while overlapping to prevent moisture penetration. Where jacketing on piping 60 degrees F and below abuts an un-insulated surface, joints shall be caulked to prevent moisture penetration. Joints on piping above 60 degrees F shall be sealed with a moisture retarder.

3.2.4.2 Insulation for Fittings

Flanges, unions, valves, fittings, and accessories shall be insulated and finished as specified for the applicable service. Two coats of breather emulsion type weatherproof mastic (impermeable to water, permeable to air) recommended by the insulation manufacturer shall be applied with glass tape embedded between coats. Tape overlaps shall be not less than 1 inch and the adjoining aluminum jacket not less than 2 inches. Factory preformed aluminum jackets may be used in lieu of the above. Molded PVC fitting covers shall be provided when PVC jackets are used for straight runs of pipe. PVC fitting covers shall have adhesive welded joints and shall be weatherproof laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - less than 0.0000 permeability, (greater than 3 ply, standard grade, silver, white, black and embossed, and UV resistant.

3.2.4.3 PVC Jacket

PVC jacket shall be ultraviolet resistant and adhesive welded weather tight

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with manufacturer's recommended adhesive. Installation shall include provision for thermal expansion.

3.3 DUCT INSULATION SYSTEMS INSTALLATION

Corner angles shall be installed on external corners of insulation on ductwork in exposed finished spaces before covering with jacket. Duct insulation shall be omitted on exposed supply and return ducts in air conditioned spaces where the difference between supply air temperature and room air temperature is less than 15 degrees F unless otherwise shown. Air conditioned spaces shall be defined as those spaces directly supplied with cooled conditioned air (or provided with a cooling device such as a fan-coil unit) and heated conditioned air (or provided with a heating device such as a unit heater, radiator or convector).

3.3.1 Duct Insulation Thickness

Duct insulation thickness shall be in accordance with Table 4.

Table 4 - Minimum Duct Insulation (inches)

Cold Air Ducts 2.0

Relief Ducts 1.5

Fresh Air Intake Ducts 1.5

Warm Air Ducts 2.0

Relief Ducts 1.5

Fresh Air Intake Ducts 1.5

3.3.2 Insulation and Vapor Retarder/Vapor Barrier for Cold Air Duct

Insulation and vapor retarder/vapor barrier shall be provided for the following cold air ducts and associated equipment.

a. Supply ducts.

b. Return air ducts.

c. Relief ducts.

d. Flexible run-outs (field-insulated).

e. Plenums.

f. Duct-mounted coil casings.

g. Coil headers and return bends.

h. Coil casings.

i. Fresh air intake ducts.

j. Filter boxes.

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k. Mixing boxes (field-insulated).

l. Supply fans (field-insulated).

m. Site-erected air conditioner casings.

n. Ducts exposed to weather.

Insulation for rectangular ducts shall be flexible type where concealed, minimum density 3/4 pcf, and rigid type where exposed, minimum density 3 pcf. Insulation for both concealed or exposed round/oval ducts shall be flexible type, minimum density 3/4 pcf or a semi rigid board, minimum density 3 pcf, formed or fabricated to a tight fit, edges beveled and joints tightly butted and staggered. Insulation for all exposed ducts shall be provided with either a white, paint-able, factory-applied Type I jacket or a field applied vapor retarder/vapor barrier jacket coating finish as specified, the total field applied dry film thickness shall be approximately 1/16 inch. Insulation on all concealed duct shall be provided with a factory-applied Type I or II vapor retarder/vapor barrier jacket. Duct insulation shall be continuous through sleeves and prepared openings except firewall penetrations. Duct insulation terminating at fire dampers, shall be continuous over the damper collar and retaining angle of fire dampers, which are exposed to unconditioned air and which may be prone to condensate formation. Duct insulation and vapor retarder/vapor barrier shall cover the collar, neck, and any un-insulated surfaces of diffusers, registers and grills. Vapor retarder/vapor barrier materials shall be applied to form a complete unbroken vapor seal over the insulation. Sheet Metal Duct shall be sealed in accordance with Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEM.

3.3.2.1 Installation on Concealed Duct

a. For rectangular, oval or round ducts, flexible insulation shall be attached by applying adhesive around the entire perimeter of the duct in 6 inch wide strips on 12 inch centers.

b. For rectangular and oval ducts, 24 inches and larger insulation shall be additionally secured to bottom of ducts by the use of mechanical fasteners. Fasteners shall be spaced on 16 inch centers and not more than 16 inches from duct corners.

c. For rectangular, oval and round ducts, mechanical fasteners shall be provided on sides of duct risers for all duct sizes. Fasteners shall be spaced on 16 inch centers and not more than 16 inches from duct corners.

d. Insulation shall be impaled on the mechanical fasteners (self stick pins) where used and shall be pressed thoroughly into the adhesive. Care shall be taken to ensure vapor retarder/vapor barrier jacket joints overlap 2 inches. The insulation shall not be compressed to a thickness less than that specified. Insulation shall be carried over standing seams and trapeze-type duct hangers.

e. Where mechanical fasteners are used, self-locking washers shall be installed and the pin trimmed and bent over.

f. Jacket overlaps shall be secured with staples and tape as necessary to ensure a secure seal. Staples, tape and seams shall be coated with a brush coat of vapor retarder coating or PVDC adhesive tape or greater

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than 3 ply laminate (minimum 2 mils adhesive, 3 mils embossed) - less than 0.0000 perm adhesive tape.

g. Breaks in the jacket material shall be covered with patches of the same material as the vapor retarder jacket. The patches shall extend not less than 2 inches beyond the break or penetration in all directions and shall be secured with tape and staples. Staples and tape joints shall be sealed with a brush coat of vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate (minimum 2 mils adhesive, 3 mils embossed) - less than 0.0000 perm adhesive tape.

h. At jacket penetrations such as hangers, thermometers, and damper operating rods, voids in the insulation shall be filled and the penetration sealed with a brush coat of vapor retarder coating or PVDC adhesive tape greater than 3 ply laminate (minimum 2 mils adhesive, 3 mils embossed) - less than 0.0000 perm adhesive tape.

i. Insulation terminations and pin punctures shall be sealed and flashed with a reinforced vapor retarder coating finish or tape with a brush coat of vapor retarder coating.. The coating shall overlap the adjoining insulation and un-insulated surface 2 inches. Pin puncture coatings shall extend 2 inches from the puncture in all directions.

j. Where insulation standoff brackets occur, insulation shall be extended under the bracket and the jacket terminated at the bracket.

3.3.2.2 Installation on Exposed Duct Work

a. For rectangular ducts, rigid insulation shall be secured to the duct by mechanical fasteners on all four sides of the duct, spaced not more than 12 inches apart and not more than 3 inches from the edges of the insulation joints. A minimum of two rows of fasteners shall be provided for each side of duct 12 inches and larger. One row shall be provided for each side of duct less than 12 inches. Mechanical fasteners shall be as corrosion resistant as G60 coated galvanized steel, and shall indefinitely sustain a 50 lb tensile dead load test perpendicular to the duct wall.

b. Form duct insulation with minimum jacket seams. Fasten each piece of rigid insulation to the duct using mechanical fasteners. When the height of projections is less than the insulation thickness, insulation shall be brought up to standing seams, reinforcing, and other vertical projections and shall not be carried over. Vapor retarder/barrier jacket shall be continuous across seams, reinforcing, and projections. When height of projections is greater than the insulation thickness, insulation and jacket shall be carried over. Apply insulation with joints tightly butted. Neatly bevel insulation around name plates and access plates and doors.

c. Impale insulation on the fasteners; self-locking washers shall be installed and the pin trimmed and bent over.

d. Seal joints in the insulation jacket with a 4 inch wide strip of tape. Seal taped seams with a brush coat of vapor retarder coating.

e. Breaks and ribs or standing seam penetrations in the jacket material shall be covered with a patch of the same material as the jacket. Patches shall extend not less than 2 inches beyond the break or penetration and shall be secured with tape and stapled. Staples and

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joints shall be sealed with a brush coat of vapor retarder coating.

f. At jacket penetrations such as hangers, thermometers, and damper operating rods, the voids in the insulation shall be filled and the penetrations sealed with a flashing sealant.

g. Insulation terminations and pin punctures shall be sealed and flashed with a reinforced vapor retarder coating finish. The coating shall overlap the adjoining insulation and un-insulated surface 2 inches. Pin puncture coatings shall extend 2 inches from the puncture in all directions.

h. Oval and round ducts, flexible type, shall be insulated with factory Type I jacket insulation with minimum density of 3/4 pcf.

3.3.3 Insulation for Warm Air Duct

Insulation and vapor barrier shall be provided for the following warm air ducts and associated equipment:.

a. Supply ducts.

b. Return air ducts.

c. Relief air ducts

d. Flexible run-outs (field insulated).

e. Plenums.

f. Duct-mounted coil casings.

g. Coil-headers and return bends.

h. Coil casings.

i. Fresh air intake ducts.

j. Filter boxes.

k. Mixing boxes.

l. Supply fans.

m. Site-erected air conditioner casings.

n. Ducts exposed to weather.

Insulation for rectangular ducts shall be flexible type where concealed, and rigid type where exposed. Insulation on exposed ducts shall be provided with a white, paint-able, factory-applied Type II jacket, or finished with adhesive finish. Flexible type insulation shall be used for round ducts, with a factory-applied Type II jacket. Insulation on concealed duct shall be provided with a factory-applied Type II jacket. Adhesive finish where indicated to be used shall be accomplished by applying two coats of adhesive with a layer of glass cloth embedded between the coats. The total dry film thickness shall be approximately 1/16 inch. Duct insulation shall be continuous through sleeves and prepared openings. Duct insulation shall terminate at fire dampers and flexible connections.

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3.3.3.1 Installation on Concealed Duct

a. For rectangular, oval and round ducts, insulation shall be attached by applying adhesive around the entire perimeter of the duct in 6 inch wide strips on 12 inch centers.

b. For rectangular and oval ducts 24 inches and larger, insulation shall be secured to the bottom of ducts by the use of mechanical fasteners. Fasteners shall be spaced on 18 inch centers and not more than 18 inches from duct corner.

c. For rectangular, oval and round ducts, mechanical fasteners shall be provided on sides of duct risers for all duct sizes. Fasteners shall be spaced on 18 inch centers and not more than 18 inches from duct corners.

d. The insulation shall be impaled on the mechanical fasteners where used. The insulation shall not be compressed to a thickness less than that specified. Insulation shall be carried over standing seams and trapeze-type hangers.

e. Self-locking washers shall be installed where mechanical fasteners are used and the pin trimmed and bent over.

f. Insulation jacket shall overlap not less than 2 inches at joints and the lap shall be secured and stapled on 4 inch centers.

3.3.3.2 Installation on Exposed Duct

a. For rectangular ducts, the rigid insulation shall be secured to the duct by the use of mechanical fasteners on all four sides of the duct, spaced not more than 16 inches apart and not more than 6 inches from the edges of the insulation joints. A minimum of two rows of fasteners shall be provided for each side of duct 12 inches and larger and a minimum of one row for each side of duct less than 12 inches.

b. Duct insulation with factory-applied jacket shall be formed with minimum jacket seams, and each piece of rigid insulation shall be fastened to the duct using mechanical fasteners. When the height of projection is less than the insulation thickness, insulation shall be brought up to standing seams, reinforcing, and other vertical projections and shall not be carried over the projection. Jacket shall be continuous across seams, reinforcing, and projections. Where the height of projections is greater than the insulation thickness, insulation and jacket shall be carried over the projection.

c. Insulation shall be impaled on the fasteners; self-locking washers shall be installed and pin trimmed and bent over.

d. Joints on jacketed insulation shall be sealed with a 4 inch wide strip of tape and brushed with vapor retarder coating.

e. Breaks and penetrations in the jacket material shall be covered with a patch of the same material as the jacket. Patches shall extend not less than 2 inches beyond the break or penetration and shall be secured with adhesive and stapled.

f. Insulation terminations and pin punctures shall be sealed with tape and

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brushed with vapor retarder coating.

g. Oval and round ducts, flexible type, shall be insulated with factory Type I jacket insulation, minimum density of 3/4 pcf attached by staples spaced not more than 16 inches and not more than 6 inches from the degrees of joints. Joints shall be sealed in accordance with item "d." above.

3.3.4 Ducts Handling Air for Dual Purpose

For air handling ducts for dual purpose below and above 60 degrees F, ducts shall be insulated as specified for cold air duct.

3.3.5 Duct Test Holes

After duct systems have been tested, adjusted, and balanced, breaks in the insulation and jacket shall be repaired in accordance with the applicable section of this specification for the type of duct insulation to be repaired.

3.3.6 Duct Exposed to Weather

3.3.6.1 Installation

Ducts exposed to weather shall be insulated and finished as specified for the applicable service for exposed duct inside the building. After the above is accomplished, the insulation shall then be further finished as detailed in the following subparagraphs.

3.3.6.2 Round Duct

Laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - Less than 0.0000 permeability, (greater than 3 ply, standard grade, silver, white, black and embossed or greater than 8 ply, heavy duty, white and natural) membrane shall be applied overlapping material by 3 inches no bands or caulking needed - see manufacturer's recommended installation instructions. Aluminum jacket with factory applied moisture retarder shall be applied with the joints lapped not less than 3 inches and secured with bands located at circumferential laps and at not more than 12 inch intervals throughout. Horizontal joints shall lap down to shed water and located at 4 or 8 o'clock position. Joints shall be sealed with metal jacketing sealant to prevent moisture penetration. Where jacketing abuts an un-insulated surface, joints shall be sealed with metal jacketing sealant.

3.3.6.3 Fittings

Fittings and other irregular shapes shall be finished as specified for rectangular ducts.

3.3.6.4 Rectangular Ducts

Two coats of weather barrier mastic reinforced with fabric or mesh for outdoor application shall be applied to the entire surface. Each coat of weatherproof mastic shall be 1/16 inch minimum thickness. The exterior shall be a metal jacketing applied for mechanical abuse and weather protection, and secured with screws or vapor barrier/weatherproofing jacket less than 0.0000 permeability greater than 3 ply, standard grade, silver, white, black, and embossed or greater than 8 ply, heavy duty white and

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natural. Membrane shall be applied overlapping material by 3 inches. No bands or caulking needed-see manufacturing recommend installation instructions.

3.4 EQUIPMENT INSULATION SYSTEMS INSTALLATION

3.4.1 General

Removable insulation sections shall be provided to cover parts of equipment that must be opened periodically for maintenance including vessel covers, fasteners, flanges and accessories. Equipment insulation shall be omitted on the following:

a. Hand-holes.

b. Boiler manholes.

c. Cleanouts.

d. ASME stamps.

e. Manufacturer's nameplates.

f. Duct Test/Balance Test Holes.

3.4.2 Insulation for Cold Equipment

Cold equipment below 60 degrees F: Insulation shall be furnished on equipment handling media below 60 degrees F including the following:

a. Pumps.

b. Refrigeration equipment parts that are not factory insulated.

c. Drip pans under chilled equipment.

d. Water softeners.

e. Duct mounted coils.

f. Pneumatic water tanks.

g. Roof drain bodies.

h. Air handling equipment parts that are not factory insulated.

i. Expansion and air separation tanks.

3.4.2.1 Insulation Type

Insulation shall be suitable for the temperature encountered. Material and thicknesses shall be as shown in Table 5:

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TABLE 5

Insulation Thickness for Cold Equipment (inches)

Equipment handling media at indicated temperature

Material Thickness (inches)

35 to 60 degrees F

Cellular Glass 1.5

Flexible Elastomeric Cellular 1

1 to 34 degrees F

Cellular Glass 3

Flexible Elastomeric Cellular 1.5

Minus 30 to 0 degrees F

Cellular Glass 3.5

Flexible Elastomeric Cellular 1.75

3.4.2.2 Pump Insulation

a. Insulate pumps by forming a box around the pump housing. The box shall be constructed by forming the bottom and sides using joints that do not leave raw ends of insulation exposed. Joints between sides and between sides and bottom shall be joined by adhesive with lap strips for rigid mineral fiber and contact adhesive for flexible elastomeric cellular insulation. Joints between top cover and sides shall fit tightly forming a female shiplap joint on the side pieces and a male joint on the top cover, thus making the top cover removable.

b. Exposed insulation corners shall be protected with corner angles.

c. Upon completion of installation of the insulation, including removable sections, two coats of vapor retarder coating shall be applied with a layer of glass cloth embedded between the coats. The total dry thickness of the finish shall be 1/16 inch. A parting line shall be provided between the box and the removable sections allowing the removable sections to be removed without disturbing the insulation coating. Flashing sealant shall be applied to parting line, between equipment and removable section insulation, and at all penetrations.

3.4.2.3 Other Equipment

a. Insulation shall be formed or fabricated to fit the equipment. To ensure a tight fit on round equipment, edges shall be beveled and joints shall be tightly butted and staggered.

b. Insulation shall be secured in place with bands or wires at intervals as recommended by the manufacturer but not more than 12 inch centers except flexible elastomeric cellular which shall be adhered with

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contact adhesive. Insulation corners shall be protected under wires and bands with suitable corner angles.

c. Cellular glass shall be installed in accordance with manufacturer's instructions. Joints and ends shall be sealed with joint sealant, and sealed with a vapor retarder coating.

d. Insulation on heads of heat exchangers shall be removable. Removable section joints shall be fabricated using a male-female shiplap type joint. The entire surface of the removable section shall be finished by applying two coats of vapor retarder coating with a layer of glass cloth embedded between the coats. The total dry thickness of the finish shall be 1/16 inch.

e. Exposed insulation corners shall be protected with corner angles.

f. Insulation on equipment with ribs shall be applied over 6 by 6 inches by 12 gauge welded wire fabric which has been cinched in place, or if approved by the Contracting Officer, spot welded to the equipment over the ribs. Insulation shall be secured to the fabric with J-hooks and 2 by 2 inches washers or shall be securely banded or wired in place on 12 inch centers.

3.4.2.4 Vapor Retarder/Vapor Barrier

Upon completion of installation of insulation, penetrations shall be caulked. Two coats of vapor retarder coating or vapor barrier jacket shall be applied over insulation, including removable sections, with a layer of open mesh synthetic fabric embedded between the coats. The total dry thickness of the finish shall be 1/16 inch. Flashing sealant or vapor barrier tape shall be applied to parting line between equipment and removable section insulation.

3.4.3 Insulation for Hot Equipment

Insulation shall be furnished on equipment handling media above 60 degrees F including the following:

a. Converters.

b. Heat exchangers.

c. Hot water generators.

d. Water heaters.

e. Pumps handling media above 130 degrees F.

f. Hot water storage tanks.

g. Air separation tanks.

h. Surge tanks.

3.4.3.1 Insulation

Insulation shall be suitable for the temperature encountered. Shell and tube-type heat exchangers shall be insulated for the temperature of the shell medium.

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Insulation thickness for hot equipment shall be determined using Table 6:

TABLE 6

Insulation Thickness for Hot Equipment (inches)

Equipment handling steam a at indicated pressure or temperature limit

Material Thickness (inches)

15 psig or 250 degrees F

Rigid Mineral Fiber 2

Flexible Mineral Fiber 2

Calcium Silicate/Perlite 4

Cellular Glass 3

Faced Phenolic Foam 1.5

Flexible Elastomeric Cellular (<200 F) 1

3.4.3.2 Insulation of Pumps

Insulate pumps by forming a box around the pump housing. The box shall be constructed by forming the bottom and sides using joints that do not leave raw ends of insulation exposed. Bottom and sides shall be banded to form a rigid housing that does not rest on the pump. Joints between top cover and sides shall fit tightly. The top cover shall have a joint forming a female shiplap joint on the side pieces and a male joint on the top cover, making the top cover removable. Two coats of Class I adhesive shall be applied over insulation, including removable sections, with a layer of glass cloth embedded between the coats. A parting line shall be provided between the box and the removable sections allowing the removable sections to be removed without disturbing the insulation coating. The total dry thickness of the finish shall be 1/16 inch. Caulking shall be applied to parting line of the removable sections and penetrations.

3.4.3.3 Other Equipment

a. Insulation shall be formed or fabricated to fit the equipment. To ensure a tight fit on round equipment, edges shall be beveled and joints shall be tightly butted and staggered.

b. Insulation shall be secured in place with bands or wires at intervals as recommended by the manufacturer but not greater than 12 inch centers except flexible elastomeric cellular which shall be adhered. Insulation corners shall be protected under wires and bands with suitable corner angles.

c. On high vibration equipment, cellular glass insulation shall be set in a coating of bedding compound as recommended by the manufacturer, and joints shall be sealed with bedding compound. Mineral fiber joints shall be filled with finishing cement.

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d. Insulation on heads of heat exchangers shall be removable. The removable section joint shall be fabricated using a male-female shiplap type joint. Entire surface of the removable section shall be finished as specified.

e. Exposed insulation corners shall be protected with corner angles.

f. On equipment with ribs, such as boiler flue gas connection, draft fans, and fly ash or soot collectors, insulation shall be applied over 6 by 6 inch by 12 gauge welded wire fabric which has been cinched in place, or if approved by the Contracting Officer, spot welded to the equipment over the ribs. Insulation shall be secured to the fabric with J-hooks and 2 by 2 inch washers or shall be securely banded or wired in place on 12 inch (maximum) centers.

g. On equipment handling media above 600 degrees F, insulation shall be applied in two or more layers with joints staggered.

h. Upon completion of installation of insulation, penetrations shall be caulked. Two coats of adhesive shall be applied over insulation, including removable sections, with a layer of glass cloth embedded between the coats. The total dry thickness of the finish shall be 1/16 inch. Caulking shall be applied to parting line between equipment and removable section insulation.

3.4.4 Equipment Handling Dual Temperature Media

Below and above 60 degrees F: equipment handling dual temperature media shall be insulated as specified for cold equipment.

3.4.5 Equipment Exposed to Weather

3.4.5.1 Installation

Equipment exposed to weather shall be insulated and finished in accordance with the requirements for ducts exposed to weather in paragraph DUCT INSULATION INSTALLATION.

3.4.5.2 Optional Panels

At the option of the Contractor, prefabricated metal insulation panels may be used in lieu of the insulation and finish previously specified. Thermal performance shall be equal to or better than that specified for field applied insulation. Panels shall be the standard catalog product of a manufacturer of metal insulation panels. Fastenings, flashing, and support system shall conform to published recommendations of the manufacturer for weatherproof installation and shall prevent moisture from entering the insulation. Panels shall be designed to accommodate thermal expansion and to support a 250 pound walking load without permanent deformation or permanent damage to the insulation. Exterior metal cover sheet shall be aluminum and exposed fastenings shall be stainless steel or aluminum.

-- End of Section --

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SECTION 23 08 00.00 10

COMMISSIONING OF HVAC SYSTEMS01/08

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASSOCIATED AIR BALANCE COUNCIL (AABC)

ACG Commissioning Guideline (2005) Commissioning Guideline

NATIONAL ENVIRONMENTAL BALANCING BUREAU (NEBB)

NEBB Commissioning Standard (2009) Procedural Standards for Whole Building Systems Commissioning of New Construction; 3rd Edition

SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)

SMACNA 1429 (1994) HVAC Systems Commissioning Manual, 1st Edition

U.S. GREEN BUILDING COUNCIL (USGBC)

LEED NC (2009) Leadership in Energy and Environmental Design(tm) New Construction Rating System

1.2 DEFINITIONS

In some instances, terminology differs between the Contract and the Commissioning Standard primarily because the intent of this Section is to use the industry standards specified, along with additional requirements listed herein to produce optimal results. The following table of similar terms is provided for clarification only. Contract requirements take precedent over the corresponding ACG, NEBB, or TABB requirements where differences exist.

SIMILAR TERMS

Contract Term ACG NEBB TABB

Commissioning Standard

ACG Commissioning Guideline

Procedural Standards for Building Systems Commissioning

SMACNA HVAC Commissioning Guidelines

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SIMILAR TERMS

Contract Term ACG NEBB TABB

Commissioning Specialist

ACG Certified Commissioning Agent

NEBB Qualified Commissioning Administrator

TABB Certified Commissioning Supervisor

1.3 SYSTEM DESCRIPTION

1.3.1 General

Perform Commissioning in accordance with the requirements of the standard under which the Commissioning Firm's qualifications are approved, i.e., ACG Commissioning Guideline, NEBB Commissioning Standard, or SMACNA 1429 unless otherwise stated herein. Consider mandatory all recommendations and suggested practices contained in the Commissioning Standard. Use the Commissioning Standard for all aspects of Commissioning, including qualifications for the Commissioning Firm and Specialist and calibration of Commissioning instruments. Where the instrument manufacturer calibration recommendations are more stringent than those listed in the Commissioning Standard, the manufacturer's recommendations shall be adhered to. All quality assurance provisions of the Commissioning Standard such as performance guarantees shall be part of this contract. For systems or system components not covered in the Commissioning Standard, Commissioning procedures shall be developed by the Commissioning Specialist. Where new procedures, requirements, etc., applicable to the Contract requirements have been published or adopted by the body responsible for the Commissioning Standard used (ACG, NEBB, or TABB), the requirements and recommendations contained in these procedures and requirements shall be considered mandatory.

1.3.2 Energy

Formal LEED NC certification is not required.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Commissioning Plan; G,

SD-03 Product Data

Pre-Functional Performance Test Checklists; G,Functional Performance Tests; G,

SD-06 Test Reports

Commissioning Report; G

SD-07 Certificates

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Commissioning Firm; GCommissioning Specialist; G

1.5 QUALITY ASSURANCE

1.5.1 Commissioning Firm

Submit certification of the proposed Commissioning Firm's qualifications to perform the duties specified herein and in other related Sections, no later than 21 days after the Notice to Proceed. Include in the documentation the date that the Certification was initially granted and the date when the current Certification expires. The firm is either a member of ACG or certified by the NEBB or the TABB and certified in all categories and functions where measurements or performance are specified on the plans and specifications. Any lapses in Certification of the proposed Commissioning Firm or disciplinary action taken by ACG, NEBB, or TABB against the proposed Commissioning Firm shall be described in detail. The certification shall be maintained for the entire duration of duties specified herein. If, for any reason, the firm loses subject certification during this period, immediately notify the Contracting Officer and submit another Commissioning Firm for approval. Any firm that has been the subject of disciplinary action by the ACG, the NEBB, or the TABB within the five years preceding Contract Award is not eligible to perform any duties related to the HVAC systems, including Commissioning. All work specified in this Section and in other related Sections to be performed by the Commissioning Firm shall be considered invalid if the Commissioning Firm loses its certification prior to Contract completion and must be performed by an approved successor. These Commissioning services are to assist the prime Contractor in performing the quality oversight for which it is responsible. The Commissioning Firm shall be a subcontractor of the prime Contractor and shall be financially and corporately independent of all other subcontractors. The Commissioning Firm shall report to and be paid by the Government.

1.5.2 Commissioning Specialist

1.5.2.1 General

Submit certification of the proposed Commissioning Specialist's qualifications to perform the duties specified herein and in other related Sections, no later than 21 days after the Notice to Proceed. The documentation shall include the date that the Certification was initially granted and the date when the current Certification expires. The Commissioning Specialist shall be an ACG Certified Commissioning Agent, a NEBB Qualified Commissioning Administrator, or a TABB Certified Commissioning Supervisor and shall be an employee of the approved Commissioning Firm. Any lapses in Certification of the proposed Commissioning Specialist or disciplinary action taken by ACG, NEBB, or TABB against the proposed Commissioning Specialist shall be described in detail. The certification shall be maintained for the entire duration of duties specified herein. If, for any reason, the Commissioning Specialist loses subject certification during this period, immediately notify the Contracting Officer and submit another Commissioning Specialist for approval. Any individual that has been the subject of disciplinary action by the ACG, the NEBB, or the TABB within the five years preceding Contract Award is not eligible to perform any duties related to the HVAC systems, including Commissioning. All work specified in this Section and in other related Sections performed by the Commissioning Specialist shall be

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considered invalid if the Commissioning Specialist loses certification prior to Contract completion and must be performed by the approved successor.

1.5.2.2 Responsibilities

Perform all Commissioning work specified herein and in related sections under the direct guidance of the Commissioning Specialist. The Commissioning Specialist shall prepare, no later than 28 days after the approval of the Commissioning Specialist, the Commissioning Plan which will be a comprehensive schedule and will include all submittal requirements for procedures, notifications, reports and the Commissioning Report. After approval of the Commissioning Plan, revise the Contract NAS schedule to reflect the schedule requirements in the Commissioning Plan.

1.6 SEQUENCING AND SCHEDULING

Begin the work described in this Section only after all work required in related Sections has been successfully completed, and all test and inspection reports and operation and maintenance manuals required in these Sections have been submitted and approved. Pre-Functional Performance Test Checklists shall be performed at appropriate times during the construction phase of the Contract.

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

3.1 COMMISSIONING TEAM AND TEST FORMS AND CHECKLISTS

Designate Contractor team members to participate in the Pre- Functional Performance Test Checklists and the Functional Performance Tests specified herein. In addition, the Government team members will include a representative of the Contracting Officer, the Design Agent's Representative, and the Using Agency's Representative. The team members shall be as follows:

Designation Function

A Contractor's Commissioning Specialist

M Contractor's Mechanical Representative

E Contractor's Electrical Representative

T Contractor's Testing, Adjusting, and Balancing (TAB) Specialist

C Contractor's Controls Representative

D Design Agency Representative

O Contracting Officer's Representative

U Using Agency's Representative

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Appendices A and B shall be completed by the commissioning team. Acceptance by each commissioning team member of each Pre- Functional Performance Test Checklist item shall be indicated by initials and date unless an "X" is shown indicating that participation by that individual is not required. Acceptance by each commissioning team member of each functional performance test item shall be indicated by signature and date.

3.2 TESTS

Perform the pre-functional performance test checklists and functional performance tests in a manner that essentially duplicates the checking, testing, and inspection methods established in the related Sections. Where checking, testing, and inspection methods are not specified in other Sections, establish methods which will provide the information required. Testing and verification required by this section shall be performed during the Commissioning phase. Requirements in related Sections are independent from the requirements of this Section and shall not be used to satisfy any of the requirements specified in this Section. Provide all materials, services, and labor required to perform the pre- functional performance tests checks and functional performance tests. A functional performance test shall be aborted if any system deficiency prevents the successful completion of the test or if any participating non-Government commissioning team member of which participation is specified is not present for the test.

3.2.1 Pre-Functional Performance Test Checklists

Perform Pre-Functional Performance Test Checklists, for the items indicated in Appendix A, at least 28 days prior to the start of Pre-Functional Performance Test Checks.. Correct and re-inspect deficiencies discovered during these checks in accordance with the applicable contract requirements. Submit the schedule for the test checks at least 14 days prior to the start of Pre-Functional Performance Test Checks.

3.2.2 Functional Performance Tests

Submit test procedures at least 28 days prior to the start of Functional Performance Tests. Submit the schedule for the tests at least 14 days prior to the start of Functional Performance Tests. Perform Functional Performance Tests for the items indicated in Appendix B. Begin Functional Performance Tests only after all Pre-Functional Performance Test Checklists have been successfully completed. Tests shall prove all modes of the sequences of operation, and shall verify all other relevant contract requirements. Begin Tests with equipment or components and progress through subsystems to complete systems. Upon failure of any Functional Performance Test item, correct all deficiencies in accordance with the applicable contract requirements. The item shall then be retested until it has been completed with no errors.

3.3 COMMISSIONING REPORT

Submit the Commissioning Report, no later than 14 days after completion of Functional Performance Tests, consisting of completed Pre- Functional Performance Test Checklists and completed Functional Performance Tests organized by system and by subsystem and submitted as one package. The Commissioning Report shall also include all HVAC systems test reports, inspection reports (Preparatory, Initial and Follow-up inspections), start-up reports, TAB report, TAB verification report, Controls start-up test reports and Controls Performance Verification Test (PVT) report. The results of failed tests shall be included along with a description of the

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corrective action taken.

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APPENDIX A

PRE-FUNCTIONAL PERFORMANCE TEST CHECKLISTS

Pre-Functional Performance Test Checklist - Rooftop Air Handling Unit

For Rooftop Air Handling Unit: _____

Checklist Item A M E T C O

Installation a. Inspection and access doors are operable and sealed. ___ ___ X ___ X ___

b. Condensate drainage is unobstructed. (Visually verify pan drains completely by pouring a cup of water into drain pan.) ___ ___ X X X ___ c. Fan belt adjusted. ___ ___ X ___ X ___

Electrical A M E T C O

a. Power available to unit disconnect. ___ X ___ X X ___

b. Power available to unit control panel. ___ X ___ X X ___ c. Proper motor rotation verified. ___ X ___ ___ X ___

d. Verify that power disconnect is located within sight of the unit it controls. ___ X ___ X X ___

Coils A M E T C O

a. Propane gas piping properly connected. ___ ___ X X X ___ b. Refrigerant piping properly connected. ___ ___ X X X ___

Controls A M E T C O

a. Control valves/actuators properly installed. ___ X X X ___ ___

b. Control valves/actuators operable. ___ X X X ___ ___

c. O/A dampers/actuators properly installed. ___ X X X ___ ___

d. O/A dampers/actuators operable. ___ X X X ___ ___

Pre-Functional Performance Test Checklist - Rooftop Air Handling Unit (cont)

A M E T C O

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e. Dampers/actuators properly installed & dampers leak checked. ___ X X X ___ ___

f. Dampers/actuators operable. ___ X X X ___ ___

Testing, Adjusting, and Balancing (TAB) A M E T C O

a. Construction filters removed and replaced. ___ ___ X ___ X ___

b. TAB report approved. ___ X X ___ X

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Pre-Functional Performance Test Checklist - DX Air Cooled Condensing Unit (including Rooftop Unit ACCU)

For Condensing Unit: _____

Checklist Item A M E T C O

Installation

a. Check condenser fans for proper rotation. ___ ___ X ___ X ___

Electrical A M E T C O

a. Power available to unit disconnect. ___ X ___ X X ___

b. Power available to unit control panel. ___ X ___ X ___ ___

c. Verify that power disconnect is located within sight of the unit it controls ___ X ___ X ___ ___

Controls A M E T C O

a. Unit safety/protection devices tested. ___ ___ X X ___ ___

b. Control system and interlocks installed. ___ ___ X X ___ ___

c. Control system and interlocks operational. ___ ___ X X ___ ___

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Pre-Functional Performance Test Checklist - Pumps

For Pump: _____

Checklist Item A M E T C O

Installation

a. Piping system installed. ___ ___ X X X ___

Electrical A M E T C O

a. Power available to pump disconnect. ___ X ___ X X ___

b. Pump rotation verified. ___ X ___ X X ___

c. Control system interlocks functional. ___ X ___ X ___ ___

Testing, Adjusting, and Balancing (TAB) A M E T C O

a. Pressure/temperature gauges installed. ___ ___ X ___ X ___

b. TAB Report approved. ___ ___ X ___ X ___

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Pre-Functional Performance Test Checklist - VRF Fan Coil Unit

For Fan Coil Unit: _____

Checklist Item

Installation A M E T C O

a. Access doors/removable panels are operable and sealed. ___ ___ X ___ X ___

b. Condensate drainage is unobstructed. ___ ___ X X X ___

c. Fan belt adjusted. ___ ___ X ___ X ___

Electrical A M E T C O

a. Power available to unit disconnect. ___ ___ ___ X ___ ___

b. Power available to unit control panel. ___ ___ ___ X ___ ___

c. Proper motor rotation verified. ___ ___ ___ ___ X ___

d. Verify that power disconnect is located within sight of the unit it controls. ___ ___ ___ X ___ ___

Coils A M E T C O

a. Refrigerant piping properly connected. ___ ___ X ___ ___ ___

Controls A M E T C O

a. Control valves/actuators properly installed. ___ ___ X ___ ___ ___

b. Control valves/actuators operable. ___ ___ X X ___ ___

c. Verify proper location and installation of thermostat. ___ ___ X ___ ___ ___

Testing, Adjusting, and Balancing (TAB) A M E T C O

a. TAB Report approved. ___ ___ X ___ X ___

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Pre-Functional Performance Test Checklist - DS- & DHP-Ductless Split System

For Unit: _____

Checklist Item

Installation A M E T C O

a. Access doors/removable panels are operable and sealed. ___ ___ X ___ X ___

b. Condensate drainage is obstructed. ___ ___ X X X ___

c. Fan belt adjusted. ___ ___ X ___ X ___

Electrical A M E T C O

a. Power available to unit disconnect. ___ ___ ___ X ___ ___

b. Power available to unit control panel. ___ ___ ___ X ___ ___

c. Proper motor rotation verified. ___ ___ ___ ___ X ___

d. Verify that power disconnect is located within sight of the unit it controls. ___ ___ ___ X ___ ___

Coils A M E T C O

a. Refrigerant piping properly connected. ___ __ X ___ ___ ___

Controls A M E T C O

a. Verify proper location and installationof thermostat ___ ___ X ___ ___ ___

Testing, Adjusting, and Balancing (TAB) A M E T C O

a. TAB Report approved. ___ ___ X ___ X ___

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Pre-Functional Performance Test Checklist - Unit Heater

For Unit Heater: _____

Checklist Item

Electrical A M E T C O

a. Power available to unit disconnect. ___ ___ ___ X ___ ___

b. Proper motor rotation verified. ___ ___ ___ X X ___

c. Verify that power disconnect is located within sight of the unit it controls. ___ ___ ___ X ___ ___

d. Power available to electric heating coil. ___ ___ ___ X ___ ___

Controls A M E T C O

a. Verify proper location and installation of thermostat. ___ ___ X ___ ___ ___

Testing, Adjusting, and Balancing (TAB) A M E T C O

a. TAB Report approved. ___ ___ X ___ X ___

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Pre-Functional Performance Test Checklist - Exhaust Fan

For Exhaust Fan: _____

Checklist Item

Installation A M E T C O

a. Fan belt adjusted. ___ ___ X ___ X ___

Electrical A M E T C O

a. Power available to fan disconnect. ___ ___ ___ X ___ ___

b. Proper motor rotation verified. ___ ___ ___ ___ X ___

c. Verify that power disconnect is located within sight of the unit it controls. ___ ___ ___ X ___ ___

Controls A M E T C O

a. Control interlocks properly installed. ___ ___ ___ X ___ ___

b. Control interlocks operable. ___ ___ ___ X ___ ___

c. Dampers/actuators properly installed. ___ ___ X ___ ___ ___

d. Dampers/actuators operable. ___ ___ X ___ ___ ___

e. Verify proper location and installation of thermostat. ___ ___ X ___ ___ ___

Testing, Adjusting, and Balancing (TAB) A M E T C O

a. TAB Report approved. ___ ___ X ___ X ___

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Pre-Functional Performance Test Checklist - HVAC System Controls

For HVAC System: _____

Checklist Item

Installation A M E T C O

a. Layout of control panel matches drawings. ___ ___ X X ___ ___

b. Framed instructions mounted in or near control panel. ___ ___ X X ___ ___

c. Components properly labeled (on inside and outside of panel). ___ ___ X X ___ ___

d. Control components piped and/or wired to each labeled terminal strip. ___ ___ X X ___ ___

e. EMCS connection made to each labeled terminal strip as shown. ___ ___ X X ___ ___

f. Control wiring and tubing labeled at all terminations, splices, and junctions. ___ ___ X X ___ ___

Main Power and Control Air

a. 120 volt AC power available to panel. ___ ___ ___ X ___ ___

b. 20 psig compressed air available to panel. ___ ___ X X ___ ___

Testing, Adjusting, and Balancing (TAB) A M E T C O

a. TAB Report submitted. ___ ___ X ___ X ___

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Pre-Functional Performance Test Checklist - Single Zone Air Handling Unit

For Air Handling Unit: _____

Checklist Item

Installation A M E T C O

a. Inspection and access doors are operable and sealed. ___ ___ X ___ X ___

b. Condensate drainage is unobstructed. ___ ___ X X X ___

c. Fan belt adjusted. ___ ___ X ___ X ___

Electrical A M E T C O

a. Power available to unit disconnect. ___ ___ ___ X X ___

b. Power available to unit control panel. ___ ___ ___ X ___ ___

c. Proper motor rotation verified. ___ ___ ___ ___ X ___

d. Verify that power disconnect is located within sight of the unit it controls. ___ ___ ___ X ___ ___

e. Power available to electric heating coil. ___ ___ ___ X ___ ___

Coils A M E T C O

a. Refrigerant piping properly connected. ___ ___ X X X ___

Controls A M E T C O

a. Dampers/actuators properly installed. ___ ___ X ___ ___ ___

b. Dampers/actuators operable. ___ ___ X ___ ___ ___

c. Verify proper location and installation of thermostat. ___ ___ X ___ ___ ___

Testing, Adjusting, and Balancing (TAB) A M E T C O

a. TAB Report approved. ___ ___ X ___ X ___

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Pre-Functional Performance Test Checklist - Make-Up Air Handling Unit

For Make-Up Air Handling Unit: _____

Checklist Item

Installation A M E T C O

a. Inspection and access doors are operable and sealed. ___ ___ X ___ X ___

b. Condensate drainage is obstructed.(Visually verify pan drains completely bypouring a cup of water into drain pan.) ___ ___ X X X ___

c. Fan belt adjusted. ___ ___ X ___ X ___

Electrical A M E T C O

a. Power available to unit disconnect. ___ X ___ X X ___

b. Power available to unit control panel. ___ X ___ X X ___

c. Proper motor rotation verified. ___ X ___ ___ X ___

d. Verify that power disconnect is located within sight of the unit it controls. ___ X ___ X X ___

e. Power available to electric heating coil ___ X ___ X X ___

Coils A M E T C O

a. Refrigerant piping properly connected. ___ __ X X X ___

Controls A M E T C O

a. Control valves/actuators properly installed. ___ X X X ___ ___

b. Control valves/actuators operable. ___ X X X ___ ___

c. O/A dampers/actuators properly installed. ___ X X X ___ ___

d. O/A dampers/actuators operable. ___ X X X ___ ___

e. Zone dampers/actuators properlyinstalled & dampers leak checked. ___ X X X ___ ___

f. Zone dampers/actuators operable. ___ X X X ___ ___

Testing, Adjusting, and Balancing (TAB) A M E T C O

a. Construction filters removed and replaced. X Xb. TAB Report approved. ___ ___ X X __ X ___

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Pre-Functional Performance Test Checklist - Energy Recovery System

For Energy Recovery System: _____

Checklist Item

Installation A M E T C O

a. Recovery system piping installed. ___ ___ X ___ X ___

Startup A M E T C O

a. Startup and checkout complete. ___ ___ X X X ___

Controls A M E T C O

a. Control valves/actuators properly installed. ___ ___ X ___ ___ ___

b. Control valves/actuators operable. ___ ___ X ___ ___ ___

- End of Appendix A -

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APPENDIX B

FUNCTIONAL PERFORMANCE TESTS CHECKLISTS

Functional Performance Test - Pump P-

NOTE: Prior to performing this test, for closed loop systems ensure that the system is pressurized and the make-up water system is operational.

1. Activate pump start using control system commands.

a. Verify correct operation in:

HAND__________ OFF__________ AUTO__________

b. Verify pressure drop across strainer:

Strainer inlet pressure __________ psig

Strainer outlet pressure _________ psig

c. Verify pump inlet/outlet pressure reading, compare to Testing, Adjusting, and Balancing (TAB) Report and pump design conditions.

DESIGN TAB ACTUAL

Pump inlet pressure psig _________ __________ __________

Pump outlet pressure psig _________ __________ __________

d. Operate pump at shutoff and at 100 percent of designed flow when all components are in full flow. Plot test readings on pump curve and compare results against readings taken from flow measuring devices.

SHUTOFF 100 percent

Pump inlet pressure psig __________ __________

Pump outlet pressure psig __________ __________

Pump flow rate gpm __________ __________

SETPOINTDifferential Pressure Transmitter ________

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Functional Performance Test (cont) - Pump P-

e. For variable speed pumps, operate pump at shutoff (shutoff to be done in manual on variable speed drive at the minimum rpm that the system is being controlled at) and at minimum flow or when all components are in full by-pass. Plot test readings on pump curve and compare results against readings taken from flow measuring devices.

SHUTOFF 100 percent Pump inlet pressure psig __________ __________

Pump outlet pressure psig __________ __________

Pump flow rate gpm __________ __________

SETPOINT Differential Pressure Transmitter ________

2. Measure motor amperage each phase and voltage phase to phase and phase to ground for both the full flow and the minimum flow conditions. Compare amperage to nameplate FLA.

a. Full flow:

Nameplate FLA __________

Amperage Phase 1 __________ Phase 2__________ Phase 3__________

Voltage Ph1-Ph2 __________ Ph1-Ph3__________ Ph2-Ph3__________ Voltage Ph1-gnd __________ Ph2-gnd__________ Ph3-gnd__________

b. Minimum flow:

Amperage Phase 1 __________ Phase 2__________ Phase 3__________

Voltage Ph1-Ph2 __________ Ph1-Ph3__________ Ph2-Ph3__________ Voltage Ph1-gnd __________ Ph2-gnd__________ Ph3-gnd__________

3. Note unusual vibration, noise, etc.

___________________________________________________________________________

___________________________________________________________________________

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Functional Performance Test (cont) - Pump P-

4. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications.

Signature and Date

Contractor's Commissioning Specialist _____________________________

Contractor's Mechanical Representative _____________________________

Contractor's Electrical Representative _____________________________

Contractor's TAB Representative _____________________________

Contractor's Controls Representative _____________________________

Contracting Officer's Representative _____________________________

Design Agency Representative _____________________________

Using Agency's Representative _____________________________

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Functional Performance Test Checklist - Single Zone Air Handling Unit

For Air Handling Unit: _____

1. Functional Performance Test: Contractor shall verify operation of air handling unit in accordance with specification including the following:

a. Ensure that a slight negative pressure exists on inboard side of the outside air dampers throughout the operation of the dampers. Modulate OA, RA, and EA dampers from fully open to fully closed positions.

a. The following shall be verified when the supply fan operating mode is initiated:

(1) All dampers in normal position prior to fan start___________.

(2) All valves in normal position prior to fan start____________.

(3) System safeties allow start if safety conditions are met. ___

b. Occupied mode of operation - economizer de-energized.

(1) Outside air damper at minimum position.______________________

(2) Return air damper open.______________________________________

(3) Relief air damper at minimum position.____________

c. Occupied mode of operation - economizer energized.

(1) Outside air damper modulated to maintain mixed air temperature set point. Setpoint _______deg F Actual _____deg F O/A damper position ___________ percent Return Air Temperature_____deg F Outside Air Temperature _______ deg F

(2) Relief air damper modulates with outside air damper according to sequence of operation. Relief air damper position ________ percent

(3) Chilled water control valve modulating to maintain space cooling temperature set point. Setpoint _______deg F Actual _____deg F Return sensor overrides to normal operation.

d. Unoccupied mode of operation. (1) Observe fan starts when space temperature calls for heating/cooling ____. (2) All dampers in normal position. _________________________ (3) Verify low limit space temperature is maintained as specified in sequence of operation. ______________________________________

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Functional Performance Test Checklist (cont) - Single Zone Air Handling Unit

e. The following shall be verified when the supply fan off mode is initiated:

(1) All dampers in normal position.______________________________

(2) All valves in normal position._______________________________

(3) Fan de-energizes. ___________________________________________

f. Verify DX coil operation by varying thermostat set point from cooling set point to heating set point and returning to cooling set point________.

g. Verify safety shut down initiated by low temperature protection thermostat________.

h. Verify occupancy schedule is programmed into time clock/UMCS________.

2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications.

Signature and Date

Contractor's Commissioning Specialist ____________________________ Contractor's Mechanical Representative _____________________________

Contractor's Electrical Representative _____________________________

Contractor's TAB Representative _____________________________

Contractor's Controls Representative _____________________________

Design Agency Representative _____________________________

Contracting Officer's Representative _____________________________

Using Agency's Representative _____________________________

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Functional Performance Test Checklist - Rooftop Air Handling Unit

For Rooftop Air Handling Unit: _____

1. Functional Performance Test: Contractor shall verify operation of air handling unit in accordance with specification including the following:

a. Ensure that a slight negative pressure exists on inboard side of the outside air dampers throughout the operation of the dampers. Modulate OA, RA, and EA dampers from fully open to fully closed positions.

b. The following shall be verified when the supply and return fans operating mode is initiated:

(1) All dampers in normal position. _____________________________

(2) All valves in normal position. ______________________________

(3) System safeties allow start if safety conditions are met. ___

b. Occupied mode of operation - economizer de-energized.

(1) Outside air damper at minimum position. _____________________

c. Occupied mode of operation. Note outside air temperature sensors may need to be simulated.

(1) Outside air damper modulates to maintain mixed air temperature set point. Setpoint _______deg F Actual _____deg F Return Air Temperature _______deg F Outside Air Temperature _______deg F

___________________________________________

(2)DX solenoid valve modulating to maintain cold deck supply air temperature set point. Setpoint ______deg F Actual _____deg F (3)Propane Gas control valve modulating to maintain hot deck supply air temperature set point input from outside air temperature controller. Setpoint _______deg F Actual _____deg F O/A ______ deg FReturn temperature sensors to normal operation.

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Functional Performance Test Checklist (cont) - Rooftop Air Handling Unit

d. Unoccupied mode of operation note time clock and space temperature sensor may require simulation.(4) Observe fan starts when space temperature calls for heating/cooling. (5) All dampers in normal position. ___________________________(6) Verify low limit space temperature is maintained as specified in sequence of operation. _____________________________________

e. The following shall be verified when the supply and return fans off mode is initiated:

(1) All dampers in normal position. ____________________________

(2) All valves in normal position. _____________________________

(3) Fan de-energizes. __________________________________________Note: return time clock and space temperature sensors to normal operation.

f. Verify zone damper operation by varying zone thermostat set points from cooling set point to heating set point and returning to cooling set point. ________________________________________________________________

g. Verify safety shut down initiated by low temperature protection thermostat. _____________________________________________________________

h. Index room thermostats to full cooling then to full heating. Measure and record cold deck, hot deck, and supply air temperatures and determine damper leakage.

Cold supply air temperature __________ degrees FHot supply air temperature __________ degrees F

Zone _______Zone ____ Supply Air Temperature at Max Cooling _______deg FZone ____ Supply Air Temperature at Max Heating _______deg FZone ____Hot Deck Damper leakage at Max cooling _______CFMZone ____Cold Deck Damper leakage at Max heating _______CFM

Zone _______Zone ____ Supply Air Temperature at Max Cooling _______deg FZone ____ Supply Air Temperature at Max Heating _______deg FZone ____Hot Deck Damper leakage at Max cooling _______CFMZone ____Cold Deck Damper leakage at Max heating _______CFM

i. Verify occupancy schedule is programmed into time clock/UMCS________.

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Functional Performance Test Checklist (cont) - Rooftop Air Handling Unit

2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications.

Signature and Date

Contractor's Commissioning Specialist _____________________________

Contractor's Mechanical Representative _____________________________

Contractor's Electrical Representative _____________________________

Contractor's TAB Representative _____________________________

Contractor's Controls Representative _____________________________

Design Agency Representative _____________________________

Contracting Officer's Representative _____________________________

Using Agency's Representative _____________________________

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Functional Performance Test Checklist - Air Cooled Condensing Unit (including Rooftop Unit ACCU)

For Condensing Unit: _____

1. Functional Performance Test: Contractor shall demonstrate operation of refrigeration system in accordance with specifications including the following: Start building air handler to provide load for condensing unit. Activate controls system start sequence as follows.

a. Start air handling unit. Verify control system energizes condensing unit start sequence. __________________________________________

b. Verify and record data in 2 and 3 below. c. Shut off air handling equipment to verify condensing unit de-energizes. ___________________________________________________________

d. Restart air handling equipment one minute after condensing unit shut down. Verify condensing unit restart sequence. _____________________

2. Verify condensing unit amperage each phase and voltage phase to phase and phase to ground. Motor Full-Load Amps __________ Amperage Phase 1 __________ Phase 2__________ Phase 3_______

Voltage Ph1-Ph2 __________ Ph1-Ph3__________ Ph2-Ph3_______ Voltage Ph1-gnd __________ Ph2-gnd__________ Ph3-gnd_______

3. Record the following information: Ambient dry bulb temperature __________ degrees F Suction pressure __________ psig Discharge pressure __________ psig 4. Unusual vibration, noise, etc. ___________________________________________________________________________

___________________________________________________________________________

5. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and DateContractor's Commissioning Specialist _____________________________

Contractor's Mechanical Representative _____________________________

Contractor's Electrical Representative _____________________________

Contractor's TAB Representative _____________________________

Contractor's Controls Representative _____________________________

Design Agency Representative _____________________________

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Contracting Officer's Representative _____________________________

Using Agency's Representative _____________________________

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Functional Performance Test Checklist - VRF Fan Coil Units

The Contracting Officer will select fan coil units to be spot-checked during the functional performance test. The number of terminals shall not exceed 10 percent. DX systems must be in operation providing design refrigerant temperatures.

1. Functional Performance Test: Contractor shall demonstrate operation of selected fan coils in accordance with specifications including the following:

a. Cooling/heating fan coils:

(1) Verify fan coil unit response to room temp set point adjustment. 1. Check blower fan airflow. _____ cfm 2. Check cooling mode inlet air temperature. _____deg F 3. Check cooling mode outlet air temperature. _____deg F 4. Calculate cooling coil sensible capacity and compare to design: 5. Calculated _________BTU/hr Design_____BTU/hr 6. Check heating mode inlet air temperature. _____ deg F 7. Check heating mode outlet air temperature. _____deg F 8. Calculate heating coil capacity and compare to design: Calculated______BTU/hr design_______BTU/hr 2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date

Contractor's Commissioning Specialist ____________________________ Contractor's Mechanical Representative _____________________________

Contractor's Electrical Representative ______________________________

Contractor's TAB Representative ______________________________

Contractor's Controls Representative _____________________________

Design Agency Representative _____________________________

Contracting Officer's Representative _____________________________

Using Agency's Representative _____________________________

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Functional Performance Test Checklist - Ductless Split System Units

The Contracting Officer will select fan coil units to be spot-checked during the functional performance test. The number of terminals shall not exceed 10 percent. DX systems must be in operation providing design refrigerant temperatures.

1. Functional Performance Test: Contractor shall demonstrate operation of selected fan coils in accordance with specifications including the following:

a. Cooling/heating fan coils:

(1) Verify fan coil unit response to room temp set point adjustment. 1. Check blower fan airflow. _____ cfm 2. Check cooling mode inlet air temperature. _____deg F 3. Check cooling mode outlet air temperature. _____deg F 4. Calculate cooling coil sensible capacity and compare to design: 5. Calculated _________BTU/hr Design_____BTU/hr 6. Check heating mode inlet air temperature. _____ deg F 7. Check heating mode outlet air temperature. _____deg F 8. Calculate heating coil capacity and compare to design: Calculated______BTU/hr design_______BTU/hr 2. Record the following information:

Ambient dry bulb temperature. deg F

3. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date

Contractor's Commissioning Specialist ____________________________ Contractor's Mechanical Representative _____________________________

Contractor's Electrical Representative ______________________________

Contractor's TAB Representative ______________________________

Contractor's Controls Representative _____________________________

Design Agency Representative _____________________________

Contracting Officer's Representative _____________________________

Using Agency's Representative _____________________________

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Functional Performance Test Checklist - Unit Heaters

The Contracting Officer will select unit heaters to be spot-checked during the functional performance test. The number of terminals shall not exceed 10 percent.

1. Functional Performance Test: Contractor shall demonstrate operation of selected unit heaters:

a. Verify unit heater response to room temperature set point adjustment.___________________________________ b. Check heating mode inlet air temperature. _____ deg F c. Check heating mode outlet air temperature. _____ deg F d. Record manufacturer's submitted fan capacity _____cfm e. Calculate unit heater capacity using manufacturer's fan capacity and recorded temperatures and compare to design. f. Calculated_____BTU/hr Design______BTU/hr

2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications.

Signature and Date

Contractor's Commissioning Specialist _____________________________

Contractor's Mechanical Representative _____________________________

Contractor's Electrical Representative _____________________________

Contractor's TAB Representative _____________________________

Contractor's Controls Representative _____________________________

Design Agency Representative _____________________________

Contracting Officer's Representative _____________________________

Using Agency's Representative _____________________________

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Functional Performance Test Checklist - HVAC Controls

For HVAC System: _____

The Contracting Officer will select HVAC control systems to undergo functional performance testing. The number of systems shall not exceed 10 percent. Perform this test simultaneously with FPT for AHU or other controlled equipment.

1. Functional Performance Test: Contractor shall verify operation of HVAC controls by performing the Performance Verification Test (PVT) test for that system. Contractor to provide blank PVT test procedures previously done by the controls Contractor.

2. Verify interlock with UMCS system______.

3. Verify all required I/O points function from the UMCS system_____.

4. Certification: We the undersigned have witnessed the Performance Verification Test and certify that the item tested has met the performance requirements in this section of the specifications.

Signature and Date

Contractor's Commissioning Specialist _________________________

Contractor's Mechanical Representative ___________________________

Contractor's Electrical Representative ___________________________

Contractor's TAB Representative ___________________________ Contractor's Controls Representative ___________________________

Design Agency Representative ___________________________

Contractor's Officer's Representative ___________________________ Using Agency's Representative ___________________________

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Functional Performance Test Checklist - Energy Recovery System

For Energy Recovery System: _____

1. Functional Performance Test: Contractor shall demonstrate operation of energy recovery system in accordance with specifications including the following: Start equipment to provide energy source for recovery system.

a. Verify energy source is providing recoverable energy.____________

b. Verify recovery system senses available energy and activates.____

2. Verify recovery system inlet/outlet readings, compare to design conditions and manufacturer's performance data.

Design Actual Primary loop inlet temp (degrees F) __________ __________ Primary loop outlet temp (degrees F) __________ __________ Primary loop flow rate gpm __________ __________ Primary loop energy BTU/hr __________ __________ Secondary loop energy BTU/hr __________ __________

3. Verify that recovery system deactivates when recoverable energy is no longer available. __________________________________________________

4. Check and report unusual vibration, noise, etc. ___________________________________________________________________________

___________________________________________________________________________

5. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications.

Signature and Date

Contractor's Commissioning Specialist __________________________

Contractor's Mechanical Representative ___________________________

Contractor's Electrical Representative ___________________________

Contractor's TAB Representative ___________________________

Contractor's Controls Representative ___________________________

Design Agency Representative __________________________

Contractor's Officer's Representative ___________________________

Using Agency's Representative ___________________________

- End of Appendix B -

-End of document -- End of Section --

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***************************************************************************This specification section applies to MCB Camp Lejeune and MCAS New River

projects only.***************************************************************************

SECTION 23 09 23.13 22

BACnet DIRECT DIGITAL CONTROL SYSTEMS FOR HVAC05/13

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.

AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA)

AMCA 500-D (2012) Laboratory Methods of Testing Dampers for Rating

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)

ASHRAE 135 (2010; INT 1-3 2011; Addenda AD & AE 2011; Errata 2012; Addenda AK, AO and I 2012; Errata 2012; INT 4-8 2012) BACnet—A Data Communication Protocol for Building Automation and Control Networks

ASME INTERNATIONAL (ASME)

ASME B16.5 (2013) Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B31.1 (2012; INT 2-6, 8-10, 13, 15, 17-25, 27-31 and 42-46) Power Piping

ASTM INTERNATIONAL (ASTM)

ASTM A126 (2004; R 2009) Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000 V and Less) AC Power Circuits

IEEE C62.41.2 (2002) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits

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IEEE C62.45 (2002; R 2008) Recommended Practice on Surge Testing for Equipment Connected to Low-Voltage (1000v and less)AC Power Circuits

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 8802-3 (2000) Information Technology - Telecommunications and Information Exchange Between Systems - Local and Metropolitan Area Networks - Specific Requirements - Part 3: Carrier Sense Multiple Access with Collision Detection (CSMA/CD)Access Method and Physical Layer Specifications

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2011; Errata 2 2012) National Electrical Code

NFPA 72 (2013) National Fire Alarm and Signaling Code

NFPA 90A (2012) Standard for the Installation of Air Conditioning and Ventilating Systems

SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)

SMACNA 1966 (2005) HVAC Duct Construction Standards Metal and Flexible, 3rd Edition

UNDERWRITERS LABORATORIES (UL)

UL 1449 (2006; Reprint Jul 2012) Surge Protective Devices

UL 506 (2008; Reprint Oct 2012) Specialty Transformers

UL 508A (2001; Reprint Feb 2010) Industrial Control Panels

UL 916 (2007; Reprint Mar 2012) Standard for Energy Management Equipment

1.2 DEFINITIONS

1.2.1 ANSI/ASHRAE Standard 135

ANSI/ASHRAE Standard 135: BACnet - A Data Communication Protocol for Building Automation and Control Networks, referred to as "BACnet". ASHRAE developed BACnet to provide a method for diverse building automation devices to communicate and share data over a network.

1.2.2 BACnet

Building Automation and Control Network; the common name for the

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communication standard ASHRAE 135. The standard defines methods and protocol for cooperating building automation devices to communicate over a variety of LAN technologies.

1.2.3 BACnet/IP

An extension of BACnet, Annex J, defines this mechanism using a reserved UDP socket to transmit BACnet messages over IP networks. A BACnet/IP network is a collection of one or more IP subnetworks that share the same BACnet network number. See also "BACnet Broadcast Management Device".

1.2.4 BACnet Internetwork

Two or more BACnet networks, possibly using different LAN technologies, connected with routers. In a BACnet internetwork, there exists only one message path between devices.

1.2.5 BACnet Network

One or more BACnet segments that have the same network address and are interconnected by bridges at the physical and data link layers.

1.2.6 BACnet Segment

One or more physical segments of BACnet devices on a BACnet network, connected at the physical layer by repeaters.

1.2.7 BBMD

BACnet Broadcast Management Device (BBMD). A communications device, typically combined with a BACnet router. A BBMD forwards BACnet broadcast messages to BACnet/IP devices and other BBMDs connected to the same BACnet/IP network. Every IP subnetwork that is part of a BACnet/IP network must have only one BBMD. See also "BACnet/IP".

1.2.8 BAS

Building Automation Systems, including DDC (Direct Digital Controls) used for facility automation and energy management.

1.2.9 BIBBs

BACnet Interoperability Building Blocks. A collection of BACnet services used to describe supported tasks. BIBBs are often described in terms of "A" (client) and "B" (server) devices. The “A” device uses data provided by the "B" device, or requests an action from the “B” device.

1.2.10 BI

BACnet International, formerly two organizations: the BACnet Manufacturers Association (BMA) and the BACnet Interest Group - North America (BIG-NA).

1.2.11 BI/BTL

BACnet International/BACnet Testing Laboratories (Formerly BMA/BTL). The organization responsible for testing products for compliance with the BACnet standard, operated under the direction of BACnet International.

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1.2.12 Bridge

Network hardware that connects two or more network (or BACnet internetwork) segments at the physical and data link layers. A bridge may also filter messages.

1.2.13 Broadcast

A message sent to all devices on a network segment.

1.2.14 DADMS

DON Application and Database Management System, (DADMS) is a listing of digital applications approved for purchase and use.

1.2.15 Device

Any control system component, usually a digital controller, that contains a BACnet Device Object and uses BACnet to communicate with other devices. See also "Digital Controller".

1.2.16 Device Object

Every BACnet device requires one Device Object, whose properties represent the network visible properties of that device. Every Device Object requires a unique Object Identifier number on the BACnet internetwork. This number is often referred to as the device instance.

1.2.17 Device Profile

A collection of BIBBs determining minimum BACnet capabilities of a device, defined in ASHRAE 135, Annex L. Standard device profiles include BACnet Operator Workstations (B-OWS), BACnet Building Controllers (B-BC), BACnet Advanced Application Controllers (B-AAC), BACnet Application Specific Controllers (B-ASC), BACnet Smart Actuator (B-SA), andBACnet Smart Sensor (B-SS). Each device used in new construction is required to have a PICS statement listing BIBBs supported and must be tested and listed by BACnet Testing Laboratory (BTL).

1.2.18 Digital Controller

An electronic controller, usually with internal programming logic and digital and analog input/output capability, which performs control functions. In most cases, synonymous with a BACnet device described in this specification. See also "Device". There are different levels of controllers, with varying levels or complexity and flexibility.

1.2.18.1 Terminal Device Controllers

Terminal device controllers typically are controllers with less control features, may have integrated actuators, and may be mounted directly on equipment (with enclosures).

1.2.18.2 Field Controllers

Field controllers typically have a greater capability for input/output and customization, do not have integral actuators, are mounted in an enclosure not on the equipment and are used for equipment such as VAV air handlers.

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1.2.18.3 Plant Controllers

Plant Controllers are typically used to control various equipment in mechanical rooms such as pumps, heat exchangers, and chillers.

1.2.18.4 Supervisory Controllers

Supervisory Controller is used to coordinate all equipment in a building, input scheduling, and is often used as a connection point for transferring configuration files to the other controllers.

1.2.18.5 Supervisory Building Controller (SBC)

Supervisory Building Controller (SBC) is used to connect the building's DDC system (MS/TP) to Camp Lejeune's EMCS (TC/IP). Depending on approvals and capabilities, the SBC and supervisory controller may be combined into the same piece of hardware.

1.2.19 Direct Digital Control (DDC)

Digital controllers performing control logic. Usually the controller directly senses physical values, makes control decisions with internal programs, and outputs control signals to directly operate switches, valves, dampers, and motor controllers.

1.2.20 DDC System

A distribution network of digital controllers, communication architecture, and user interfaces. A DDC system may include programming, sensors, actuators, switches, relays, factory controls, operator workstations, and various other devices, components, and attributes.

1.2.21 DITSCAP

Department of Defense Information Technology Security Certification and Accreditation Process (DITSCAP). DISCAP and DIACAP are processes that approve IP base equipment that is connected and communicates on the base Ethernet network. All devices using TCP/IP or Ethernet connectivity require prior approval to be listed in the DITSCAP and SSA document.

1.2.22 EMCS

Energy Management & Control System. The EMCS at Camp Lejeune is an enterprise system that actively receives energy and building condition information from multiple sources and provides load shedding, electric metering, alarming, trending, scheduling, set point adjustment and device status of all supervisory building controllers for maintenance personnel. The EMCS receives real time electrical utility pricing data and automatically manages to Camp Lejeune's energy target. The existing Camp Lejeune EMCS is manufactured by Johnson Controls and incorporates the Metasys extended architecture system that communicates over the MRAN.

1.2.23 EMCS Owner

The regional or local user responsible for managing all aspects of the BAS operation, including: network connections, workstation management, submittal review, technical support, control parameters, and daily operation. The BAS Owner for this project is Utility Monitoring & Control (UMAC) Director

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1.2.24 Ethernet

A family of local-area-network technologies providing high-speed networking features over various media. Base Telephone manages all Ethernet connections to the IP networks.

1.2.25 Firmware

Software programmed into read only memory (ROM), flash memory, electrically erasable programmable read only memory (EEPROM), or erasable programmable read only memory (EPROM) chips.

1.2.26 Gateway

Communication hardware connecting two or more different protocols, similar to human language translators. The Gateway translates one protocol into equivalent concepts for the other protocol. In BACnet applications, a gateway has BACnet on one side and non-BACnet (usually proprietary) protocols on the other side.

1.2.27 Half Router

A device that participates as one partner in a BACnet point-to-point (PTP) connection. Two half-routers in an active PTP connection combine to form a single router.

1.2.28 Hub

A common connection point for devices on a network.

1.2.29 Internet Protocol (IP, TCP/IP, UDP/IP)

A communication method, the most common use is the World Wide Web. At the lowest level, it is based on Internet Protocol (IP), a method for conveying and routing packets of information over various LAN media. Two common protocols using IP are User Datagram Protocol (UDP) and Transmission Control Protocol (TCP). UDP conveys information to well-known "sockets" without confirmation of receipt. TCP establishes "sessions", which have end-to-end confirmation and guaranteed sequence of delivery.

1.2.30 Input/Output (I/O)

Physical inputs and outputs to and from a device, although the term sometimes describes software, or "virtual" I/O. See also "Points".

1.2.31 I/O Expansion Unit

An I/O expansion unit provides additional point capacity to a digital controller.

1.2.32 IP subnet

Internet protocol (IP) identifies individual devices with a 32-bit number divided into four groups from 0 to 255. Devices are often grouped and share some portion of this number. For example, one device has IP address 209.185.47.68 and another device has IP address 209.185.47.82. These two devices share Class C subnet 209.185.47.00

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1.2.33 Local-Area Network (LAN)

A communication network that spans a limited geographic area and uses the same basic communication technology throughout.

1.2.34 MAC Address

Media Access Control address. The physical node address that identifies a device on a Local Area Network.

1.2.35 Master-Slave/Token-Passing (MS/TP)

ISO 8802-3. The standard LAN for BACnet. MSTP uses twisted-pair wiring for relatively low speed and low cost communication (up to 4,000 ft at 76.8K bps).

1.2.36 Native BACnet Device

A device that uses BACnet as its primary, if not only, method of communication with other BACnet devices without intermediary gateways. A system that uses native BACnet devices at all levels is a native BACnet system.

1.2.37 Network

Communication technology for building network data communications. BACnet approved network types are Point to Point (PTP) Ethernet, and MS/TP. BACnet over Internet Protocol is not an approved method for building level controls.

1.2.38 Network Number

A site-specific number assigned to each network segment to identify for routing. This network number must be unique throughout the BACnet internetwork.

1.2.39 Object

The concept of organizing BACnet information into standard components with various associated properties. Examples include analog input objects and binary output objects.

1.2.40 Object Identifier

An object property used to identify the object, including object type and instance. Object Identifiers must be unique within a device.

1.2.41 Object Properties

Attributes of an object. Examples include present value and high limit properties of an analog input object. Properties are defined in ASHRAE 135; some are optional and some are required. Objects are controlled by reading from and writing to object properties.

1.2.42 Peer-to-Peer

Peer-to-peer refers to devices where any device can initiate and respond to communication with other devices.

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1.2.43 Performance Verification Test (PVT)

The procedure for determining if the installed BAS meets design criteria prior to final acceptance. The PVT is performed after installation, testing, and balancing of mechanical systems. Typically the PVT is performed by the Contractor in the presence of the Government.

1.2.44 PID

Proportional, integral, and derivative control; three parameters used to control modulating equipment to maintain a setpoint. Derivative control is often not required for HVAC systems (leaving "PI" control).

1.2.45 PICS

Protocol Implementation Conformance Statement (PICS), describing the BACnet capabilities of a device. See BACnet, Annex A for the standard format and content of a PICS statement.

1.2.46 Points

Physical and virtual inputs and outputs. See also "Input/Output".

1.2.47 PTP

Point-to-Point protocol connects individual BACnet devices or networks using serial connections.

1.2.48 Repeater

A network component that connects two or more physical segments at the physical layer.

1.2.49 Router

A BACnet router is a component that joins together two or more networks using different LAN technologies. Examples include joining a BACnet Ethernet LAN to a BACnet MS/TP LAN.

1.2.50 Stand-Alone Control

Refers to devices performing equipment-specific and small system control without communication to other devices or computers for physical I/O, excluding outside air and other common shared conditions. Devices are located near controlled equipment, with physical input and output points limited to 64 or less per device, except for complex individual equipment or systems. Failure of any single device will not cause other network devices to fail. BACnet "Smart" actuators (B-SA profile) and sensors (B-SS profile) communicating on a network with a parent device are exempt from stand-alone requirements.

1.2.51 SSAA

System Security Authorization Agreement. The SSAA is a local document authorizing the use of the IP networks on Camp Lejeune.

1.2.52 Supervisory Controller

Supervisory Controller is the upper level controller on the building's

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MS/TP bus. It provides building wide points, scheduling, and interface with programming tools.

1.2.53 Supervisory Building Controller (SBC)

The Supervisory Building Controller is the point of connection between the Camp Lejeune EMCS network (IP) and the building level control network (MS/TP). The hardware at this location, that provides the connection is referred to as the SBC. Since the EMCS network uses the Marine Air-Ground Task Force Regional Area Network (MRAM) Ethernet network using TCP/IP, any equipment connecting to the Camp Lejeune EMCS must be listed in the approved DITSCAP or DIACAP equipment list and must be Marine Corps DADMS listed and approved.

1.3 SUBCONTRACTOR SPECIAL REQUIREMENTS

Perform all work in this section in accordance with the paragraph entitled "Subcontractor Special Requirements" in Section 01 30 00 ADMINISTRATIVE REQUIREMENTS. The paragraph specifies that all contract requirements of this section shall be accomplished directly by a first tier subcontractor. No work required shall be accomplished by a second tier subcontractor.

a. The controls sub-contractor for this project shall be regularlyengaged in the design and installation of BACnet DDC systems (forbuilding HVAC systems) similar to the size and scope of thisproject, shall have been a representative of the proposed controlsystem manufacturer for a minimum of two years, have a staffedoffice within a 50-mile radius of the project location, and shallhave performed design and installation of DDC systems for aminimum of 5 years.

b. The controls sub-contractor shall ensure that their installing electricians have a copy of, read, and understand the mechanical sheets of the contract's design construction drawings, in addition to the control drawings prepared by the sub-contractor. Provide the DDC programming and graphics using Standard English units of measure, not metric.

1.4 BACnet DIRECT DIGITAL CONTROL SYSTEMS FOR HVAC DESCRIPTION

a. Provide new BACnet DDC systems including associated equipment and accessories. The existing basewide DDC system is manufactured by JCI.

b. Provide a networked DDC system for stand alone control in compliance with the latest revision of the ASHRAE 135 BACnet standard. Include all programming, objects, and service required to meet the sequence of control. Provide BACnet communication between the DDC system and the native BACnet devices furnished with HVAC equipment, and plant equipment including boilers, chillers, and variable frequency drives. Devices provided shall be BACnet Testing Laboratories (BTL) product listing certified. Interface the new DDC system with Camp Lejeune's existing EMCS. Provide a Supervisory Building Controller (SBC) that shall communicate with the field DDC controllers via the MS/TP bus using BACnet, and with the EMCS via the Marine Air-Ground Task Force Regional Area Network (MRAM) Ethernet network using TCP/IP. Provide interface with the existing EMCS including graphic creation, scheduling, alarming, load management scheduling and trending.

c. Authority to Operate/Authority to Connect: Prior approval to

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communicate on the base MRAN is a requirement on this project. Supervisory Building Controllers (SBC) and any other device communicating on the MRAN without being DADMS listed and approved and approval from the Designated Approving Authority based on DITSCAP or DIACAP efforts will not be permitted.

d. Only technicians authorized by the Camp Lejeune utilities department and factory trained on Metasys extended architecture are approved to add, manage or revise data in the EMCS. Authorization shall require a unique username and password managed by the Utilities Department. All equipment listed as being part of the DDC system shall have a defined energy load value and be entered into the base load rolling program. Graphics, naming, trending and overall user views shall be added to the EMCS. All points added shall be consistent with previously installed buildings.

1.4.1 Design Requirements

1.4.1.1 Control System Drawings Title Sheet

Provide a title sheet for the control system drawing set. Include the project title, project location, contract number, the controls contractor preparing the drawings, an index of the control drawings in the set, and a legend of the symbols and abbreviations used throughout the control system drawings.

1.4.1.2 List of I/O Points

Also known as a Point Schedule, provide for each input and output point physically connected to a digital controller: point name, point description, point type (Analog Output (AO), Analog Input (AI), Binary Output (BO), Binary Input (BI)), point sensor range, point actuator range, point address, BACnet object, associated BIBBS (where applicable), and point connection terminal number. Typical schedules for multiple identical equipment are allowed unless otherwise requested in design or contract criteria. All points shall adhere to the Camp Lejeune standard naming conventions.

1.4.1.3 Control System Components List

Provide a complete list of control system components installed on this project. Include for each controller and device: control system schematic name, control system schematic designation, device description, manufacturer, and manufacturer part number. For sensors, include point name, sensor range, and operating limits. For valves, include body style, Cv, design flow rate, pressure drop, valve characteristic (linear or equal percentage), and pipe connection size. For actuators, include point name, spring or non-spring return, modulating or two-position action, normal (power fail) position, nominal control signal operating range (0-10 volts DC or 4-20 milliamps), and operating limits.

1.4.1.4 Control System Schematics

Provide control system schematics. Typical schematics for multiple identical equipment are allowed unless otherwise requested in design or contract criteria. Include the following:

a. Location of each input and output device

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b. Flow diagram for each piece of HVAC equipment

c. Name or symbol for each control system component, such as V-1 for a valve

d. Setpoints, with differential or proportional band values

e. Written sequence of operation for the HVAC equipment

f. Valve and Damper Schedules, with normal (power fail) position

1.4.1.5 HVAC Equipment Electrical Ladder Diagrams

Provide HVAC equipment electrical ladder diagrams. Indicate required electrical interlocks.

1.4.1.6 Component Wiring Diagrams

Provide a wiring diagram for each type of input device and output device. Indicate how each device is wired and powered; showing typical connections at the digital controller and power supply. Show for all field connected devices such as control relays, motor starters, actuators, sensors, and transmitters.

1.4.1.7 Terminal Strip Diagrams

Provide a diagram of each terminal strip. Indicate the terminal strip location, termination numbers, and associated point names.

1.4.1.8 BACnet Communication Architecture Schematic

Provide a schematic showing the project's entire BACnet communication network, including addressing used for LANs, LAN devices including routers and bridges, gateways, controllers, workstations, and field interface devices. If applicable, show connection to existing networks.

1.5 SUBMITTALS

Submit detailed and annotated manufacturer's data, drawings, and specification sheets for each item listed, that clearly show compliance with the project specifications.

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control Approval. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Include the following in the project's control system drawing set:

Control system drawings title sheet; G

List of I/O Points; G

Control System Components List; G

Control system schematics; G

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HVAC Equipment Electrical Ladder diagrams; G

Component wiring diagrams; G

Terminal strip diagrams; G

BACnet communication architecture schematic; G

SD-03 Product Data

Direct Digital Controllers; G

Include BACnet PICS for each controller/device type, including smart sensors (B-SS) and smart actuators (B-SA).

BACnet Gateways; G

Include BACnet and workstation display information; bi-directional communication ability; compliance with interoperability schedule; expansion capacity; handling of alarms, events, scheduling and trend data; and single device capability (not depending on multiple devices for exchanging information from either side of the gateway).

Notebook Computer; G

Sensors and Input Hardware; G

Output Hardware; G

Surge and transient protection; G

Duct smoke detectors; G

SD-05 Design Data

Performance Verification Testing Plan; G

Pre-Performance Verification Testing Checklist; G

SD-06 Test Reports

Performance Verification Testing Report; G

SD-07 Certificates

Contractor's Qualifications; G

SD-09 Manufacturer's Field Reports

Pre-PVT Checklist; G

SD-10 Operation and Maintenance Data

Comply with requirements for data packages in Section 01 78 23OPERATION AND MAINTENANCE DATA and 01 78 24.00 20 FACILITY ELECTRONIC OPERATION AND MAINTENANCE SUPPORT INFORMATION (eOMSI), except as supplemented and modified in this specification.

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BACnet Direct Digital Control Systems, Data Package 4; G

Controls System Operators Manuals, Data Package 4; G

SD-11 Closeout Submittals

DDC Software; G

Training documentation; G

1.6 QUALITY ASSURANCE

1.6.1 Standard Products

Provide material and equipment that are standard manufacturer's products currently in production and supported by a local service organization.

1.6.2 Delivery, Storage, and Handling

Handle, store, and protect equipment and materials to prevent damage before and during installation according to manufacturer's recommendations, and as approved by the Contracting Officer. Replace damaged or defective items.

1.6.3 Operating Environment

Protect components from humidity and temperature variation, dust, and contaminants. If components are stored before installation, keep them within the manufacturer's limits.

1.6.4 Finish of New Equipment

New equipment finishing shall be factory provided. Manufacturer's standard factory finishing shall be proven to withstand 125 hours in a salt-spray fog test. Equipment located outdoors shall be proven to withstand 3000 hours in a salt-spray fog test.

Salt-spray fog test shall be according to ASTM B117, with acceptance criteria as follows: immediately after completion of the test, the finish shall show no signs of degradation or loss of adhesion beyond 0.125 inch on either side of the scratch mark.

1.6.5 Verification of Dimensions

The contractor shall verify all dimensions in the field, and advise the Contracting Officer of any discrepancy before performing work.

1.6.6 Contractor's Qualifications

Submit documentation certifying the controls Contractor performing the work has completed at least three DDC systems installations of a similar design to this project, and programmed similar sequences of operation for at least two years. Submit the name of the technician proposed to make additions/alterations to the EMCS servers. Submit supporting documentation demonstrating their qualifications.

1.6.7 Modification of References

The advisory provisions in ASME B31.1 and NFPA 70 are mandatory. Substitute "shall" for "should" wherever it appears and interpret all

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references to the "authority having jurisdiction" and "owner" to mean the Contracting Officer.

1.6.8 Project Sequence

The control system work for this project shall proceed in the following order:

a. Submit and receive approval on the Shop Drawings, Product Data, and Certificates specified under the paragraph entitled "SUBMITTALS."

b. Perform the control system installation work, including all field check-outs and tuning.

c. Provide support to TAB personnel as specified under the paragraph "TEST AND BALANCE SUPPORT."

d. Submit and receive approval of the Controls System Operators Manual specified under the paragraph "CONTROLS SYSTEM OPERATORS MANUALS."

e. Submit and receive approval of the Performance Verification Testing Plan and the Pre-PVT Checklist specified under the paragraph "PERFORMANCE VERIFICATION TESTING."

f. Perform the Performance Verification Testing.

g. Submit and receive approval on the PVT Report.

h. Submit and receive approval on the Training Documentation specified under the paragraph "INSTRUCTION TO GOVERNMENT PERSONNEL". Submit at least 30 days before training.

i. Deliver the final Controls System Operators Manuals.

j. Conduct the Phase I Training.

k. Conduct the Phase II Training.

l. Submit and receive approval of Closeout Submittals.

PART 2 PRODUCTS

2.1 DDC SYSTEM

Provide a networked DDC system for stand-alone control in compliance with the latest revision of the ASHRAE 135 BACnet standard. Include all programming, objects, and services required to meet the sequence of control. Provide BACnet MSTP communications between the DDC system and native BACnet devices furnished with HVAC equipment, and plant equipment such as boilers, and chillers when provided with BACnet MSTP communications. DDC controllers provided shall be certified in the BACnet Testing Laboratories (BTL) Product Listing. BACnet over IP is not permitted.

2.1.1 Supervisory Building Controller (SBC)

Provide an SBC that communicates between the DDC system and the Camp Lejeune EMCS server. Provide all necessary hardware, drivers, software, material and equipment which shall allow communication and control between

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the SBC and the field DDC controllers using BACnet on the MS/TP bus. The SBC shall be capable of upload/download to and from the EMCS server. All SBC information shall transfer back to the EMCS system via the Ethernet TCP/IP level 1 network. All IP addresses and network drops shall be furnished by base telephone. Supervisory Building Controllers (SBC) must be listed and approved on the Marine Corps DADMS and listed in the sites DITSCAP SSAA documents. When the SBC is disconnected from the enterprise system for maintenance, access to the SBC shall be via a laptop computer with Internet Explorer and not require any proprietary licensed software or license key.

2.1.2 Direct Digital Controllers

Direct digital controllers shall be UL 916 rated.

2.1.2.1 I/O Point Limitation

The total number of I/O hardware points used by a single stand-alone digital controller, including I/O expansion units, shall not exceed 64. Place I/O expansion units in the same cabinet as the digital controller.

2.1.2.2 Environmental Limits

Controllers shall be suitable for, or placed in protective enclosures suitable for the environment (temperature, humidity, dust, and vibration) where they are located.

2.1.2.3 Stand-Alone Control

Provide stand-alone digital controllers capable of meeting the complete sequence of operation with and without network connectivity (being connected to the EMCS).

2.1.2.4 Internal Clock

Provide internal clocks for all BACnet Building Controllers (B-BC) and BACnet Advanced Application Controllers (B-AAC) using BACnet time synchronization services. Automatically synchronize system clocks daily from an operator-designated controller. The system shall automatically adjust for daylight saving time.

2.1.2.5 Memory

Provide sufficient memory for each controller to support the required control, communication, trends, alarms, and messages. Protect programs residing in memory with EEPROM, flash memory, or by an uninterruptible power source (battery or uninterruptible power supply). The backup power source shall have capacity to maintain the memory during a 72-hour continuous power outage. Rechargeable power sources shall be constantly charged while the controller is operating under normal line power. Batteries shall be replaceable without soldering. Trend and alarm history collected during normal operation shall not be lost during power outages less than 72 hours long.

2.1.2.6 Immunity to Power Fluctuations

Controllers shall operate at 90 percent to 110 percent nominal voltage rating.

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2.1.2.7 Transformer

The controller power supply shall be fused or current limiting and rated at 125 percent power consumption.

2.1.2.8 Wiring Terminations

Use screw terminal wiring terminations for all field-installed controllers. Provide field-removable modular terminal strip or a termination card connected by a ribbon cable for all controllers other than terminal units.

2.1.2.9 Input and Output Interface

Provide hard-wired input and output interface for all controllers as follows:

a. Protection: Shorting an input or output point to itself, to another point, or to ground shall cause no controller damage. Input or output point contact with sources up to 24 volts AC or DC for any duration shall cause no controller damage.

b. Binary Inputs: Binary inputs shall monitor two state devices.

c. Pulse Accumulation Inputs: Pulse accumulation inputs shall conform to binary input requirements and accumulate pulses at a resolution suitable to the application.

d. Analog Inputs: Analog inputs shall monitor low-voltage (0-10 VDC), current (4-20 mA), or resistance (thermistor or RTD) signals.

e. Binary Outputs: Binary outputs shall have a toggle switch and send a pulsed 24 VDC low-voltage signal for modulation control, or provide a maintained open-closed position for on-off control. For HVAC equipment and plant controllers, provide for manual overrides, either with three-position (on-off-auto) override switches and status lights, or with an adjacent operator display and interface. Where appropriate, provide a method to select normally open or normally closed operation.

f. Analog Outputs: Analog outputs shall send modulating 0-10 VDC or 4-20 mA signals to control output devices.

g. Tri-State Outputs: Tri-State outputs shall provide three-point floating control of terminal unit electronic actuators.

2.1.2.10 Digital Controller Cabinet

Provide each digital controller as factory mounted or in a factory fabricated cabinet enclosure. Cabinets located indoors shall protect against dust and have a minimum NEMA 1 rating, except where indicated otherwise. Cabinets located outdoors or in damp environments shall protect against all outdoor conditions and have a minimum NEMA 4 rating. Mechanical rooms that contain steam service or equipment are considered damp environments. Outdoor control panels and controllers must be able to withstand extreme ambient conditions, without malfunction or failure, whether or not the controlled equipment is running. If necessary, provide a thermostatically controlled panel heater in freezing locations, and an internal ventilating fan in locations exposed to direct sunlight. Cabinets shall have a hinged lockable door and an offset removable metal back plate,

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except controllers integral with terminal units, like those mounted on VAV boxes. Provide like-keyed locks for all hinged panels provided and a set of two keys at each panel, with one key inserted in the lock.

2.1.2.11 Main Power Switch and Receptacle

Provide each control cabinet with a main external power on/off switch located inside the cabinet. Also provide each cabinet with a separate 120 VAC duplex receptacle.

2.1.2.12 DSL Modems

DSL modems and Rate Adaptive Asymmetric Digital Subscriber Line (RADSL) modems are provided by the government. Telephone modems are not permitted for any other communication with the DDC system.

2.1.2.13 BACnet Gateways

Provide gateways to connect BACnet to legacy systems, existing non-BACnet devices, and existing non-BACnet DDC controlled plant equipment, only when specifically requested and approved by the Government, and shown on the Government approved BACnet Communication Architecture Schematic. Communication shall be MS/TP. Communication using IP is not permitted. Provide with each gateway an interoperability schedule, showing each point or event on the legacy side that the BACnet "client" will read, and each parameter that the BACnet network will write to. Describe this interoperability in terms of BACnet services, or Interoperability Building Blocks (BIBBS), defined in ASHRAE 135 Annex K. Provide two-year minimum warranty for each gateway, including parts and labor.

The following minimum capabilities are required:

a. Gateways shall be able to read and view all readable object properties listed in the interoperability schedule on the non-BACnet network to the BACnet network and vice versa where applicable.

b. Gateways shall be able to write to all writeable object properties listed in the interoperability schedule on the non-BACnet network from the BACnet network and vice versa where applicable.

c. Gateways shall provide single-pass (only one protocol to BACnet without intermediary protocols) translation from the non-BACnet protocol to BACnet and vice versa.

d. Gateways shall meet the requirements of Data Sharing Read Property (DS-RP-B), Data Sharing Write Property (DS-WP-B), Device Management Dynamic Device Binding-B (DM-DDB-B), and Device Management Communication Control (DM-DCC-B) BIBBs, in accordance with ASHRAE 135.

e. Gateways shall include all hardware, software, software licenses, and configuration tools for operator-to-gateway communications. Provide backup programming and parameters on CD media and the ability to modify, download, backup, and restore gateway configuration.

2.1.3 Notebook Computer

Provide a notebook computer, complete with the project's installed DDC software, configuration files and, applications database, to fully troubleshoot and program the project's devices. Provide the notebook

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computer with ballistic nylon carrying case with shoulder strap with all necessary cables and interface hardware needed for setup and communication with the controllers and control system components. At a minimum the notebook computer shall include: Common Access Card reader, a Microsoft XP Professional operating system, processor with capability and speed required by application software, 40 giga-byte hard drive, 512 mega-byte RAM, 2 USB 2.0 ports, 10/100 network interface card, internal V.92 modem, 15-inch display, keyboard, 3-hour battery with charger, 52X internal CD-RW drive with CD creator software, and Microsoft Office bundled software. Provide all original licenses, installation media, documentation, and recovery CDs capable of restoring the original configuration. Provide the manufacturer's 3-year next business day on-site warranty with the Government listed as the warranty owner. Provide a CACcard access port.

2.1.4 DDC Software

2.1.4.1 Programming

Provide programming to execute the sequence of operation indicated. Provide all programming, programming software tools, and programming hardware tools to configure and program all controllers. If the laptop computer provided elsewhere is used as a programming tool, provide all necessary accessories for full functionality. All software shall be licensed to Marine Corps Base, Camp Lejeune Complex for unrestricted use on Camp Lejeune Complex and reproduction for use on Camp Lejeune Complex. Software keys and "dongles" are not permitted. Provide sequence of operation routines in simple, easy-to-follow logic with detailed text comments describing what the logic does and how it corresponds to the project's written sequence of operation.

a. Graphic-based programming shall use a library of function blocks made from pre-programmed code designed for BAS control. Function blocks shall be assembled with interconnecting lines, depicting the control sequence in a flowchart. If providing a computer with device programming tools as part of the project, graphic programs shall be viewable in real time showing present values and logical results from each function block.

b. Menu-based programming shall be done by entering parameters, definitions, conditions, requirements, and constraints.

c. For line-by-line and text-based programming, declare variable types (local, global, real, integer, etc.) at the beginning of the program. Use descriptive comments frequently to describe the programming.

d. If providing a computer with device programming tools as part of the project, provide a means for detecting program errors and testing software strategies with a simulation tool. Simulation may be inherent within the programming software suite, or provided by physical controllers mounted in a NEMA 1 test enclosure. The test enclosure shall contain one dedicated controller of each type provided under this contract, complete with power supply and relevant accessories.

2.1.4.2 Parameter Modification

All writeable object properties, and all other programming parameters needed to comply with the project specification shall be adjustable for

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devices at any network level, including those accessible with web-browser communication, and regardless of programming methods used to create the applications.

2.1.4.3 Short Cycling Prevention

Provide setpoint differentials and minimum on/off times to prevent equipment short cycling.

2.1.4.4 Equipment Status Delay

Provide an adjustable delay from when equipment is commanded on or off and when the control program looks to the status input for confirmation.

2.1.4.5 Run Time Accumulation

Use the Elapsed Time Property to provide re-settable run time accumulation for each Binary Output Object connected to mechanical loads greater than 1 HP, electrical loads greater than 10 KW, or wherever else specified.

2.1.4.6 Timed Local Override

Provide a non-cumulative adjustable override time for the push of a local override button.

2.1.4.7 Time Synchronization

Provide time synchronization, including adjustments for leap years, daylight saving time, and operator time adjustments.

2.1.4.8 Scheduling

Provide operating schedules as indicated, with equipment assigned to groups. Changing the schedule of a group shall change the operating schedule of all equipment in the group. Groups shall be capable of operator creation, modification, and deletion. Provide capability to view and modify schedules in a seven-day week format. Provide capability to enter holiday and override schedules one full year at a time.

2.1.4.9 Object Property Override

Allow writeable object property values to accept overrides to any valid value. Where specified or required for the sequence of control, the Out Of Service property of Objects shall be modifiable using BACnet's write property service. When documented, exceptions to these requirement are allowed for life, machine, and process safeties.

2.1.4.10 Alarms and Events

Alarms and events shall be capable of having programmed time delays and high-low limits. All alarms/events shall report to the EMCS server. Alarms/events shall be stored within the Site Building Controller (SBC). Provide alarms/events in agreement with the point schedule, sequence of operation, and the BAS Owner. At a minimum, provide programming to initiate alarms/events any time a piece of equipment fails to operate, a control point is outside normal range or condition shown on schedules, communication to a device is lost, a device has failed, or a controller has lost its memory.

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2.1.4.11 Trending

Provide BACnet trend services capable of trending all object present values set points, and other parameters indicated for trending on project schedules. Trends may be associated into groups, and a trend report may be set up for each group. Trends are stored within a device on the BACnet network, with operator selectable trend intervals from 10 seconds up to 60 minutes. The minimum number of consecutive trend values stored at one time shall be 100 per variable. When trend memory is full, the most recent data shall overwrite the oldest data.

The SBC shall upload trends automatically upon reaching 3/4 of the device buffer limit (via Notification_Threshold property), by operator request, or by time schedule for archiving. Archived and real-time trend data shall be available for viewing numerically and graphically for at the workstation and connected notebook computers.

2.1.4.12 Device Diagnostics

Each controller shall have diagnostic LEDs for power, communication, and device fault condition. The DDC system shall recognize and report a non-responsive controller.

2.1.4.13 Power Loss

Upon restoration of power, the DDC system shall perform an orderly restart and restoration of control.

2.1.4.14 Access Control

Provide at least five levels of password protection for operator interfaces. The lowest level only allowing viewing of graphics. The second level allows viewing graphics and changing space temperature setpoints. The third level allows the previous level's capability, plus changing operating schedules. The fourth level allows access to all functions except passwords. The highest level provides all administrator rights and allows full access to all programming, including setting new passwords and access levels. Provide the BAS Owner with the highest level password access. Provide automatic log out if no keyboard or mouse activity is detected after a user-defined time delay.

2.1.4.15 Configuration Tool

Provide the software with the manufacturer's installation CDs and licenses. Licenses shall allow unrestricted use and reproduction for use at the Camp Lejeune Complex. Software shall not require the use of software keys or "dongles" Configure the software according to the DDC system manufacturer's specifications and in agreement with BACnet standards found in ASHRAE 135, Annex L. The software shall permit complete monitoring, modification, and troubleshooting interface with the DDC system. The operator interface with the software shall be menu-driven with appropriate displays and menu commands to manipulate the DDC system's objects, point data, operating schedules, control routines, system configuration, trends, alarms, messages, graphics, and reports. Trends shall be capable of graphic display in real time, with variables plotted as functions of time. Each alarmed point shall be capable of displaying its alarm history, showing when it went into alarm, if and when it was acknowledged, and when it went

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out of alarm. The modification of DDC system parameters and object properties shall be accomplished with "fill in the blank" and/or "point and drag" methods. Modifications shall download to the appropriate controllers at the operator's request.

2.1.4.16 Graphics Software

Provide web-based system graphics viewable on browsers compatible with MS Internet Explorer 6.X or greater using an industry-standard file format such as HTML, BMP, JPEG, or GIF. Graphics for new projects must be consistent with base standards including layout and device naming. Contractor shall install this graphics package on the EMCS Server, bind all points, and demonstrate operability.

Graphic displays shall have full-screen resolution when viewed on the workstation and notebook computers. Dynamic data on graphics pages shall refresh within 10 seconds using an Internet connection, or 30 seconds using a dial-up modem connection. Graphics viewing shall not require additional "plug-in" software like Java, Shockwave and Flash applications unless the software is readily available for free over the Internet, and certified for use with Government provided personal computers.

The graphics shall show the present value and object name for each of the project's I/O points on at least one graphic page. Arrange point values and names on the graphic displays in their appropriate physical locations with respect to the floor plan or equipment graphic displayed. Graphics shall allow the operator to monitor current status, view zone and equipment summaries, use point-and-click navigation between graphic pages, and edit setpoints and parameters directly from the screens. Items in alarm shall be displayed using a different color or other obvious visual indicator.Provide graphics with the following:

a. Graphic Types: Provide at least one graphic display for each piece of HVAC equipment, building floor, and controlled zone. Indicate dynamic point values, operating statuses, alarm conditions, and control setpoints on each display. Provide summary pages where appropriate.

(1) Building Floor Plans: Provide a floor plan graphic for each of the building's floors and roof with dynamic display of space temperature and other important data. If used, indicate and provide links to sub-plan areas. If possible, use the project's electronic drawing files for the graphic backgrounds. Provide clear names for important areas, such as "Main Conference Room." Include room names and numbers where applicable. Include features such as stairwells, elevators, and main entrances. Where applicable, include the mechanical room, HVAC equipment, and control component locations, with corresponding links to the equipment graphics.

(2) Sub-plan Areas: Where a building's floor plan is too large to adequately display on the screen, sub-divide the plan into distinct areas, and provide a separate graphic display for each area. Provide same level of detail requested in building floor plan section above.

(3) HVAC Equipment: Provide a graphic display for each piece of HVAC equipment, such as a fan coil unit, VAV terminal, or air handling unit. Equipment shall be represented by a two or three-dimensional drawing. Where multiple pieces of equipment

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combine to form a system, such as a central chiller plant or central heating plant, provide one graphic to depict the entire plant. Indicate the equipment, piping, ductwork, dampers, and control valves in the installed location. Include labels for equipment, piping, ductwork, dampers, and control valves. Show the direction of air and water flow. Include dynamic display of applicable object data with clear names in appropriate locations.

(4) Sequence of Operation: Provide a graphic screen displaying the written out full sequence of operation for each piece of HVAC equipment. Provide a link to the sequence of operation displays on their respective equipment graphics.

b. Graphic Title: Provide a prominent, descriptive title on each graphic page.

c. Dynamic Update: When the workstation is on-line, all graphic I/O object values shall update with change-of-value services, or by operator selected discrete intervals.

d. Graphic Linking: Provide forward and backward linking between floor plans, sub-plans, and equipment.

e. Graphic Editing: Provide installed software to create, modify, and delete the DDC graphics. Include the ability to store graphic symbols in a symbol directory and import these symbols into the graphics.

f. Dynamic Point Editing: Provide full editing capability for deleting, adding, and modifying dynamic points on the graphics.

2.2 SENSORS AND INPUT HARDWARE

Coordinate sensor types with the BAS Owner to keep them consistent with existing installations.

2.2.1 Field-Installed Temperature Sensors

Where feasible, provide the same sensor type throughout the project. Avoid using transmitters unless absolutely necessary.

2.2.1.1 Thermistors

Precision thermistors may be used in applications below 200 degrees F. Sensor accuracy over the application range shall be 0.36 degree F or less between 32 to 150 degrees F. Stability error of the thermistor over five years shall not exceed 0.25 degrees F cumulative. A/D conversion resolution error shall be kept to 0.1 degrees F. Total error for a thermistor circuit shall not exceed 0.5 degrees F.

2.2.1.2 Resistance Temperature Detectors (RTDs)

Provide RTD sensors with platinum elements compatible with the digital controllers. Encapsulate sensors in epoxy, series 300 stainless steel, anodized aluminum, or copper. Temperature sensor accuracy shall be 0.1 percent (1 ohm) of expected ohms (1000 ohms) at 32 degrees F. Temperature sensor stability error over five years shall not exceed 0.25 degrees F cumulative. Direct connection of RTDs to digital controllers without transmitters is preferred. When RTDs are connected directly, lead resistance error shall be less than 0.25 degrees F. The total error for a

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RTD circuit shall not exceed 0.5 degrees F. Allow an additional 0.5 percent accuracy for averaging sensors.

2.2.1.3 Temperature Sensor Details

a. Room Type: Provide the sensing element components within a decorative protective cover suitable for surrounding decor. Provide room temperature sensors with timed override button, setpoint adjustment lever, digital temperature display. Provide a communication port for a portable operator interface like a notebook computer or PDA.

b. Duct Probe Type: Ensure the probe is long enough to properly sense the air stream temperature.

c. Duct Averaging Type: Continuous averaging sensors shall be one foot in length for each 4 square feet of duct cross-sectional area, and a minimum length of 6 feet.

d. Pipe Immersion Type: Provide minimum three-inch immersion. Provide each sensor with a corresponding pipe-mounted sensor well, unless indicated otherwise. Sensor wells shall be stainless steel when used in steel piping, and brass when used in copper piping. Provide the sensor well with a heat-sensitive transfer agent between the sensor and the well interior.

e. Outside Air Type: Provide the sensing element on the building's north side with a protective weather shade that positions the sensor approximately 3 inches off the wall surface, does not inhibit free air flow across the sensing element, and protects the sensor from snow, ice, and rain.

2.2.2 Transmitters

Provide transmitters with 4 to 20 mA or 0 to 10 VDC linear output scaled to the sensed input. Transmitters shall be matched to the respective sensor, factory calibrated, and sealed. Size transmitters for an output near 50 percent of its full-scale range at normal operating conditions. The total transmitter error shall not exceed 0.1 percent at any point across the measured span. Supply voltage shall be 12 to 24 volts AC or DC. Transmitters shall have non-interactive offset and span adjustments. For temperature sensing, transmitter drift shall not exceed 0.03 degrees F a year.

2.2.2.1 Relative Humidity Transmitters

Provide transmitters with an accuracy equal to plus or minus 5 percent from 0 to 90 percent scale, and less than one percent drift per year. Sensing elements shall be the polymer type.

2.2.2.2 Pressure Transmitters

Provide transmitters integral with the pressure transducer.

2.2.3 Current Transducers

Provide current transducers to monitor motor amperage. Current switches may be used to indicate on/off status.

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2.2.4 Air Quality Sensors

Provide power supply for each sensor.

2.2.4.1 CO2 Sensors

Provide photo-acoustic type CO2 sensors with integral transducers and linear output. The devices shall read CO2 concentrations between 0 and 2000 ppm with full scale accuracy of at least plus or minus 100 ppm.

2.2.4.2 Air Quality Sensors

Provide full spectrum air quality sensors using a hot wire element based on the Taguchi principle. The sensor shall monitor a wide range of gaseous volatile organic components common in indoor air contaminants like paint fumes, solvents, cigarette smoke, and vehicle exhaust. The sensor shall automatically compensate for temperature and humidity, have span and calibration potentiometers, operate on 24 VDC power with output of 0-10 VDC, and have a service rating of 32 to 140 degrees F and 5 to 95 percent relative humidity.

2.2.5 Input Switches

2.2.5.1 Timed Local Overrides

Provide buttons or switches to override the DDC occupancy schedule programming for each major building zone during unoccupied periods, and to return HVAC equipment to the occupied mode. This requirement is waived for zones clearly intended for 24 hour continuous operation.

2.2.6 Freeze Protection Thermostats

Provide special purpose thermostats with flexible capillary elements 20 feet in length for coil face areas up to 40 square feet. Provide additional thermostats for larger coils. Provide switch contacts rated for the respective motor starter's control circuit voltage. Include auxiliary contacts for the switch's status condition. A freezing condition at any 18-inch increment along the sensing element's length shall activate the switch. The thermostat shall be equipped with a manual push-button reset switch so that when tripped, the thermostat requires manual resetting before the HVAC equipment can restart.

2.2.7 Air Flow Measurement Stations

Air flow measurement stations shall have an array of velocity sensing elements and straightening vanes inside a flanged sheet metal casing. The velocity sensing elements shall be the RTD or thermistor type, traversing the ducted air in at least two directions. The air flow pressure drop across the station shall not exceed 0.1 inch water gage at a velocity of 2,000 fpm. The station shall be suitable for air flows up to 2500 fpm, and a temperature range of 0 to 140 degrees F. The station's measurement accuracy over the range of 125 to 2,500 fpm shall be plus or minus 3 percent of the measured velocity. Station transmitters shall provide a linear, temperature-compensated 4 to 20 mA or 0 to 10 VDC output. The output shall be capable of being accurately converted to a corresponding air flow rate in cubic feet per minute. Transmitters shall be a 2-wire, loop powered device. The output error of the transmitter shall not exceed 0.5 percent of the measurement.

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2.2.8 Energy Metering

Provide energy meters to collect steam and water consumption, and hot water solar collector generation for the facility and report to the EMCS database.

2.2.8.1 Water meters

Water meters 1" and smaller shall be positive displacement nutating disk. Water meters larger than 1" shall be compound type. Output signal shall be 4-10 ma, pulse, or BACnet(MS/TP).

2.3 OUTPUT HARDWARE

2.3.1 Control Dampers

Provide factory manufactured aluminum blade/galvanized steel frame dampers where indicated. Control dampers shall comply with SMACNA 1966 except as modified or supplemented by this specification. Published damper leakage rates and respective pressure drops shall have been verified by tests in compliance with AMCA 500-D requirements.

Provide damper assembly frames constructed of 13 gauge minimumthickness galvanized steel channels with mitered and welded corners. Damper axles shall be 0.5 inches minimum diameter plated steel rods supported in the damper frame by stainless steel or bronze bearings. Blades mounted vertically shall be supported by thrust bearings.

Dampers shall be rated for not less than 2000 fpm air velocity. The pressure drop through each damper when full-open shall not exceed 0.04 inches water gage at 1000 fpm face velocity. Damper assemblies in ductwork subject to above 3-inch water gauge static air pressure shall be constructed to meet SMACNA Seal Class "A" construction requirements.

Provide the damper operating linkages outside of the air stream, including crank arms, connecting rods, and other hardware that transmits motion from the damper actuators to the dampers, shall be adjustable. Additionally, operating linkages shall be designed and constructed to have a 2 to 1 safety factor when loaded with the maximum required damper operating force. Linkages shall be brass, bronze, galvanized steel, or stainless steel.

Provide access doors or panels in hard ceilings and walls for access to all concealed damper operators and damper locking setscrews.

For field-installed control dampers, a single damper section shall have blades no longer than 48 inches and no higher than 72 inches. The maximum damper blade width shall be 12 inches. Larger sized dampers shall be built using a combination of sections.

Frames shall be at least 2 inches wide. Flat blades shall have edges folded for rigidity. Blades shall be provided with compressible gasket seals along the full length of the blades to prevent air leakage when closed.

The damper frames shall be provided with jamb seals to minimize air leakage. Seals shall be suitable for an operating temperature range of minus 40 degrees F to 200 degrees F.

The leakage rate of each damper when full-closed shall be no morethan 2 cfm per sq. foot of damper face area at 1.0 inches water gage static pressure.

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2.3.2 Control Valves

2.3.2.1 Valve Assembly

Valve bodies shall be designed for 125 psig minimum working pressure or 150 percent of the operating pressure, whichever is greater. Valve stems shall be Type 300 series stainless steel. Valve leakage ratings shall be 0.01 percent of rated Cv value. Class 125 copper alloy valve bodies and Class 150 steel or stainless steel valves shall meet the requirements of ASME B16.5. Cast iron valve components shall meet the requirements of ASTM A126 Class B or C.

2.3.2.2 Butterfly Valves

Butterfly valves shall be the threaded lug type suitable for dead-end service and for modulation to the fully-closed position, with stainless steel shafts supported by bearings, non-corrosive discs geometrically interlocked with or bolted to the shaft (no pins), and EPDM seats suitable for temperatures from minus 20 degrees F to plus 250 degrees F. Valves shall have a means of manual operation independent of the actuator.

2.3.2.3 Two-Way Valves

Two-way modulating valves shall have an equal percentage characteristic.

2.3.2.4 Valves for Glycol Fluid Service

a. Bodies for valves 1-1/2 inches and smaller shall be brass or bronze, with threaded or union ends. Bodies for valves from 2 inches to 3 inches inclusive shall be of brass, bronze, or iron. Bodies for 2 inch valves shall have threaded connections. Bodies for valves from 2-1/2 to 3 inches shall have flanged connections.

b. Internal valve trim shall be brass or bronze, except that valve stems shall be stainless steel.

c. Unless indicated otherwise, provide modulating valves sized for 2 psi minimum and 4 psi maximum differential across the valve at the design flow rate.

d. Valves 4 inches and larger shall be butterfly valves, unless indicated otherwise.

2.3.3 Actuators

Provide direct-drive electric actuators for all control applications, except where indicated otherwise.

2.3.3.1 Electric Actuators

Each actuator shall deliver the torque required for continuous uniform motion and shall have internal end switches to limit the travel, or be capable of withstanding continuous stalling without damage. Actuators shall function properly within 85 to 110 percent of rated line voltage. Provide actuators with hardened steel running shafts and gears of steel or copper alloy. Fiber or reinforced nylon gears may be used for torques less than 16 inch-pounds. Provide two-position actuators of single direction, spring return, or reversing type. Provide modulating actuators capable of

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stopping at any point in the cycle, and starting in either direction from any point. Actuators shall be equipped with a switch for reversing direction, and a button to disengage the clutch to allow manual adjustments. Provide the actuator with a hand crank for manual adjustments, as applicable. Actuators without spring-return may only be used on terminal fan coil units, terminal VAV units, convectors, and unit heaters. Spring return actuators shall be provided on all control dampers and all control valves except terminal fan coil units, terminal VAV units, convectors, and unit heaters; unless indicated otherwise. Each actuator shall have distinct markings indicating the full-open and full-closed position, and the points in-between.

2.3.4 Output Switches

2.3.4.1 Control Relays

Field installed and DDC panel relays shall be double pole, double throw, UL listed, with contacts rated for the intended application, indicator light, and dust proof enclosure. The indicator light shall be lit when the coil is energized and off when coil is not energized. Relays shall be the socket type, plug into a fixed base, and replaceable without tools or removing wiring. Encapsulated "PAM" type relays may be used for terminal control applications.

2.4 ELECTRICAL POWER AND DISTRIBUTION

2.4.1 Transformers

Transformers shall conform to UL 506. For control power other than terminal level equipment, provide a fuse or circuit breaker on the secondary side of each transformer.

2.4.2 Surge and Transient Protection

Provide each digital controller with surge and transient power protection. Surge and transient protection shall consist of the following devices, installed externally to the controllers.

2.4.2.1 Power Line Surge Protection

Provide surge suppressors on the incoming power at each controller or grouped terminal controllers. Surge suppressors shall be rated in accordance with UL 1449, have a fault indicating light, and conform to the following:

a. The device shall be a transient voltage surge suppressor, hard-wire type individual equipment protector for 120 VAC/1 phase/2 wire plus ground.

b. The device shall react within 5 nanoseconds and automatically reset.

c. The voltage protection threshold, line to neutral, shall be no more than 211 volts.

d. The device shall have an independent secondary stage equal to or greater than the primary stage joule rating.

e. The primary suppression system components shall be pure silicon avalanche diodes.

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f. The secondary suppression system components shall be silicon avalanche diodes or metal oxide varistors.

g. The device shall have an indication light to indicate the protection components are functioning.

h. All system functions of the transient suppression system shall be individually fused and not short circuit the AC power line at any time.

i. The device shall have an EMI/RFI noise filter with a minimum attenuation of 13 dB at 10 kHz to 300 MHz.

j. The device shall comply with IEEE C62.41.1 and IEEE C62.41.2, Class "B" requirements and be tested according to IEEE C62.45.

k. The device shall be capable of operating between minus 20 degrees F and plus 122 degrees F.

2.4.3 Wiring

Provide complete electrical wiring for the DDC System, including wiring to transformer primaries. Unless indicated otherwise, provide all normally visible or otherwise exposed wiring in conduit. Where conduit is required, control circuit wiring shall not run in the same conduit as power wiring over 100 volts. Circuits operating at more than 100 volts shall be in accordance with Section 26 20 00, INTERIOR DISTRIBUTION SYSTEM. Run all circuits over 100 volts in conduit, metallic tubing, covered metal raceways, or armored cable. Use plenum-rated cable for circuits under 100 volts in concealed accessible spaces. Examples of these spaces include HVAC plenums, within walls, above suspended ceilings, in attics, and within ductwork. All wiring in mechanical rooms and mezzanines shall be run in conduit.

2.4.3.1 Power Wiring

The following requirements are for field-installed wiring:

a. Wiring for 24 V circuits shall be insulated copper 18 AWG minimum and rated for 300 VAC service.

b. Wiring for 120 V circuits shall be insulated copper 14 AWG minimum and rated for 600 VAC service.

2.4.3.2 Analog Signal Wiring

Field-installed analog signal wiring shall be in accordance with manufacturer's installation instructions. Each cable shall be 100 percent shielded and have a 20 AWG drain wire. Each wire shall have insulation rated for 300 VAC service. Cables shall have an overall aluminum-polyester or tinned-copper cable-shield tape.

2.5 FIRE PROTECTION DEVICES

2.5.1 Duct Smoke Detectors

Provide duct smoke detectors in HVAC ducts in accordance with NFPA 72 and NFPA 90A, except as indicated otherwise. Provide UL listed or FM approved detectors, designed specifically for duct installation.

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Furnish detectors under Section 28 31 76 INTERIOR FIRE ALARM AND MASS NOTIFICATION SYSTEM and install under this section. Connect new detectors to the building fire alarm panel.

PART 3 EXECUTION

3.1 INSTALLATION

Perform the installation under the supervision of competent technicians regularly employed in the installation of DDC systems.

3.1.1 BACnet Naming and Addressing

Coordinate with the EMCS Owner and provide naming and addressing consistent with existing buildings already loaded on the EMCS server. All DDC controllers shall have a Camp Lejeune unique instance number and all Site Building Controllers shall have a Camp Lejeune unique name.

a. MAC Address

Every BACnet device shall have an assigned and documented MAC Address unique to its network. For Ethernet networks, document the MAC Address assigned at its creation. For ARCNET or MS/TP, assign from 4 to 128.

b. Network Numbering

Assign unique numbers to each new network installed on the BACnet internetwork. Provide ability for changing the network number; either by device switches, network computer, or field operator interface. The BACnet internetwork (all possible connected networks) can contain up to 65,534 possible unique networks.

c. Device Object Identifier Property Number

Assign unique Device "Object_Identifier" property numbers or device instances for each device on the BACnet internetwork. Provide for future modification of the device instance number; either by device switches, network computer, or field interface. BACnet allows up to 4,194,302 possible unique devices per internetwork.

d. Device Object Name Property Text

The Device Object Name property field shall support 32 minimum printable characters. Assign unique Device "Object_Name" property names with plain-English descriptive names for each deviceFor example, the Device Object Name for the device controlling the first floor air handler unit at Building AS4035 would be:

Name=Air Station.AS4035.First Floor.Air Handling Unit.AHU-1-A

e. Object Name Property Text (Other than Device Objects)

The Object Name property field shall support 32 minimum printable characters. Assign Object Name properties with plain-English names descriptive of the application. Examples include "Zone 1 Temperature" and "Fan Start/Stop".

f. Object Identifier Property Number (Other than Device Objects)

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Assign Object Identifier property numbers according to design drawings or tables if provided. If not provided, Object Identifier property numbers may be assigned at the Contractor's discretion but must be approved by the Government. In this case they must be documented and unique for like object types within the device.

3.1.2 Minimum BACnet Object Requirements

a. Use of Standard BACnet Objects in accordance with existing Camp Lejeune standards

For the following points and parameters, use standard BACnet objects, where all relevant object properties can be read using BACnet's Read Property Service, and all relevant object properties can be modified using BACnet's Write Property Service:all device physical inputs and outputs, all set points, all PID tuning parameters, all calculated pressures, flow rates, and consumption values, all alarms, all trends, all schedules, and all equipment and lighting circuit operating status.

b. BACnet Object Description Property

The Object Description property shall support 32 minimum printable characters. For each object, complete the description property field using a brief, narrative, plain English description specific to the object and project application. For example: "HW Pump 1 Proof." Document compliance, length restrictions, and whether the description is writeable in the device PICS.

c. Analog Input, Output, and Value Objects

Support and provide Description and/or Device_Type text strings matching signal type and engineering units shown on the points list.

d. Binary Input, Output, and Value Objects

Support and provide Inactive_Text and Active_Text property descriptions matching conditions shown on the points list.

e. Calendar Object

For devices with scheduling capability, provide at least one Calendar Object with ten-entry capacity. All operators may view Calendar Objects; authorized operators may make modifications from a workstation. Enable the writeable Date List property and support all calendar entry data types.

f. Schedule Object

Use Schedule Objects for all building system scheduling. All operators may view schedule entries; authorized operators may modify schedules from a workstation.

g. Loop Object or Equal

Use Loop Objects or equivalent BACnet objects in each applicable field device for PID control. Regardless of program method or object used, allow authorized operators to adjust the Update Interval, Setpoint,

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Proportional Constant, Integral Constant, and Derivative Constant using BACnet read/write services.

3.1.3 Minimum BACnet Service Requirements

a. Command Priorities

Use commandable BACnet objects to control machinery and systems, providing the priority levels listed below. If the sequence of operation requires a different priority, obtain approval from the Contracting Officer.

Priority Level Application 1 Manual-Life Safety 2 Automatic-Life Safety 3 (User Defined) 4 (User Defined) 5 Critical Equipment Control 6 Minimum On/Off 7 (User Defined) 8 Manual Operator 9 (User Defined) 10 (User Defined) 11 Load Shedding 12 (User Defined) 13 (User Defined) 14 (User Defined) 15 (User Defined) 16 (User Defined)

b. Alarming

(1) Alarm Priorities - Coordinate alarm and event notification with the BAS Owner.

(2) Notification Class - Enable writeable Priority, Ack Required, and Recipient List properties of Notification Class objects.

(3) Event Notification Message Texts - Use condition specific narrative text and numerical references for alarm and event notification.

c. Updating Displayed Property Values

Allow workstations to display property values at discrete polled intervals, or based on receipt of confirmed and unconfirmed Change of Value notifications. The COV increment shall be adjustable by an operator using BACnet services, and polled intervals shall be adjustable at the operator workstation.

3.1.4 Local Area Networks

Obtain Government approval before connecting new networks with existing networks. Network numbers and device instance numbers shall remain unique when joining networks. Do not change existing network addressing without Government approval. See also "BACnet Naming and Addressing".

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3.1.5 BACnet Routers, Bridges, and Switches

Provide the quantity of BACnet routers, bridges, and switches necessary for communications shown on the BACnet Communication Architecture schematic. Provide BACnet routers with BACnet Broadcast Message Device (BBMD) capability on each BACnet internetwork communicating across an MS/TP network. Configure each BACnet device and bridge, router, or switch to communicate on its network segment. All switches provided by the contractor shall be approved by base telephone.

3.1.6 Wiring Criteria

a. Run circuits operating at more than 100 volts in rigid or flexible conduit, metallic tubing, covered metal raceways, or armored cable.

b. Do not run binary control circuit wiring in the same conduit as power wiring over 100 volts. Where analog signal wiring requires conduit, do not run in the same conduit with AC power circuits or control circuits operating at more than 100 volts.

c. Provide circuit and wiring protection required by NFPA 70.

d. Run all wiring located inside mechanical rooms in conduit.

e. Do not bury aluminum-sheathed cable or aluminum conduit in concrete.

f. Input/output identification: Permanently label each field-installed wire, cable, and pneumatic tube at each end with descriptive text using a commercial wire marking system that fully encircles the wire, cable, or tube. Locate the markers within 2 inches of each termination. Match the names and I/O number to the project's point list. Similarly label all power wiring serving control devices, including the word "power" in the label. Number each pneumatic tube every six feet. Label all terminal blocks with alpha/numeric labels. All wiring and the wiring methods shall be in accordance with UL 508A.

g. For controller power, provide new 120 VAC circuits, with ground, if not defined on the electrical drawings. Provide each circuit with a dedicated breaker, and run wiring in its own conduit, separate from any control wiring. Connect the controller's ground wire to the electrical panel ground; conduit grounds are not acceptable.

h. Surge Protection: Install surge protection according to manufacturer's instructions. Multiple controllers fed from a common power supply may be protected by a common surge protector, properly sized for the total connected devices.

i. Grounding: Ground controllers and cabinets to a good earth ground as specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Conduit grounding is not acceptable; all grounding shall have a direct path to the building earth ground. Ground sensor drain wire shields at the controller end.

j. The Contractor shall be responsible for correcting all associated ground loop problems.

k. Run wiring in panel enclosures in covered wire track.

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3.1.7 Accessibility

Install all equipment so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install digital controllers, data ports, and concealed actuators, valves, dampers, and like equipment in locations freely accessible through access doors.

3.1.8 Digital Controllers

a. Install as stand alone control devices (see definitions).

b. Locate control cabinets at the locations shown on the drawings. If not shown on the drawings, install in the most accessible space, close to the controlled equipment.

3.1.9 Hand-Off-Auto Switches

Wire safety controls such as smoke detectors and freeze protection thermostats to protect the equipment during both hand and auto operation.

3.1.10 Temperature Sensors

Install temperature sensors in locations that are accessible and provide a good representation of sensed media. Installations in dead spaces are not acceptable. Calibrate sensors according to manufacturer's instructions. Do not use sensors designed for one application in a different application.

3.1.10.1 Room Temperature Sensors

Mount the sensors on interior walls to sense the average room temperature at the locations indicated. Avoid locations near heat sources such as copy machines or locations by supply air outlet drafts. Mount the center of the sensor 54 inches above the floor to meet ADA requirements.

3.1.10.2 Duct Temperature Sensors

a. Probe Type: Provide a gasket between the sensor housing and the duct wall. Seal the duct penetration air tight. Seal the duct insulation penetration vapor tight.

b. Averaging Type (and coil freeze protection thermostats): Weave the capillary tube sensing element in a serpentine fashion perpendicular to the flow, across the duct or air handler cross-section, using durable non-metal supports. Prevent contact between the capillary and the duct or air handler internals. Provide a duct access door at the sensor location. The access door shall be hinged on the side, factory insulated, have cam type locks, and be as large as the duct will permit, maximum 18 by 18 inches. For sensors inside air handlers, the sensors shall be fully accessible through the air handler's access doors without removing any of the air handler's internals.

3.1.10.3 Immersion Temperature Sensors

Provide thermowells for sensors measuring piping, tank, or pressure vessel temperatures. Locate wells to sense continuous flow conditions. Do not install wells using extension couplings. Where piping diameters are smaller than the length of the wells, provide wells in piping at elbows to sense flow across entire area of well. Wells shall not restrict flow area to less than 70 percent of pipe area. Increase piping size as required to

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avoid restriction. Provide thermal conductivity material within the well to fully coat the inserted sensor.

3.1.10.4 Outside Air Temperature Sensors

Provide outside air temperature sensors in weatherproof enclosures on the north side of the building, away from exhaust hoods and other areas that may affect the reading. Provide a shield to shade the sensor from direct sunlight.

3.1.11 Energy Meters

Locate energy meters as indicated. Connect each meter output to the DDC system, to measure both instantaneous and accumulated energy usage.

3.1.12 Damper Actuators

Where possible, mount actuators outside the air stream in accessible areas.

3.1.13 Thermometers and Gages

Mount devices to allow reading while standing on the floor or ground, as applicable.

3.1.14 Pressure Sensors

Locate pressure sensors as indicated.

3.1.15 Component Identification Labeling

Using an electronic hand-held label maker with white tape and bold black block lettering, provide an identification label on the exterior of each new control panel, control device, actuator, and sensor. Also provide labels on the exterior of each new control actuator indicating the (full) open and (full) closed positions. For labels located outdoors, use exterior grade label tape, and provide labels on both the inside and outside of the panel door or device cover. Acceptable alternatives are white plastic labels with engraved bold black block lettering permanently attached to the control panel, control device, actuator, and sensor. Have the labels and wording approved by the BAS Owner prior to installation.

3.1.16 Network and Telephone Communication Lines

When telephone lines or network connections by the Government are required, provide the Contracting Officer at least 60 days advance notice of need. Provide 1 inch conduit and Cat 5 cable from the Supervisory Building controller (SBC) to the network connection (most likely in the telephone equipment room).

3.2 INTERFACE WITH EXISTING EMCS

Interface the new DDC system with Camp Lejeune's existing EMCS. Obtain Government approval before connecting new DDC system to the EMCS. Any device connected directly to the EMCS must be approved by the Designated Approving Authority by following procedures listed in the DIACAP instruction. Complete installation and programming includes graphic creation, scheduling, alarming, lard management scheduling and trending. The server is located in Building 24: workstations are located at Buildings 1005, 1023, and 1202. Only Johnson Controls factory trained technicians,

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approved by the EMCS Engineer will be allowed to program the EMCS.

3.3 TEST AND BALANCE SUPPORT

The controls contractor shall coordinate with and provide on-site support to the test and balance (TAB) personnel specified under Section 23 05 93 TESTING, ADJUSTING AND BALANCING FOR HVAC. This support shall include:

a. On-site operation and manipulation of control systems during the testing and balancing.

b. Control setpoint adjustments for balancing all relevant mechanical systems.

c. Tuning control loops with setpoints and adjustments determined by TAB personnel.

3.4 CONTROLS SYSTEM OPERATORS MANUALS

Provide five electronic and three printed copies of a Controls System Operators Manual. The manual shall be specific to the project, written to actual project conditions, and provide a complete and concise depiction of the installed work. Provide information in detail to clearly explain all operation requirements for the control system.

Provide with each manual: CDs of the project's control system drawings, control programs, data bases, graphics, and all items listed below. Include gateway back-up data and configuration tools where applicable. Provide CDs in jewel case with printed and dated project-specific labels on both the CD and the case. For text and drawings, use Adobe Acrobat or MS Office file types. When approved by the Government, AutoCAD and Visio files are allowed. Give files descriptive English names and organize in folders.

Provide printed manuals in sturdy 3-ring binders with a title sheet on the outside of each binder indicating the project title, project location, contract number, and the controls contractor name, address, and telephone number. Each binder shall include a table of contents and tabbed dividers, with all material neatly organized. Manuals shall include the following:

a. A copy of the as-built control system (shop) drawings set, with all items specified under the paragraph "Submittals." Indicate all field changes and modifications.

b. A copy of the project's mechanical design drawings, including any official modifications and revisions.

c. A copy of the project's approved Product Data submittals provided under the paragraph "Submittals."

d. A copy of the project's approved Performance Verification Testing Plan and Report. Test report shall be a 48 hour trend report verifying all temperature setpoints listed in the sequence of operation. The trend report should be printed from the EMCS server. All systems (AHU's, ERV's, CHWS, HWS) should be part of this section.

e. A copy of the project's approved final TAB Report. (Added by the Mechanical Contractor (Division 23)).

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f. Printouts of all control system programs, including controller setup pages if used. Include plain-English narratives of application programs, flowcharts, and source code.

g. Printouts of all physical input and output object properties, including tuning values, alarm limits, calibration factors, and set points.

h. A table entitled "AC Power Table" listing the electrical power source for each controller. Include the building electrical panel number, panel location, and circuit breaker number.

i. The DDC manufacturer's hardware and software manuals in both print and CD format with printed project-specific labels. Include installation and technical manuals for all controller hardware, operator manuals for all controllers, programming manuals for all controllers, operator manuals for all workstation software, installation and technical manuals for the workstation and notebook, and programming manuals for the workstation and notebook software.

j. A list of qualified control system service organizations for the work provided under this contract. Include their addresses and telephone numbers.

k. A written statement entitled "Technical Support" stating the control system manufacturer or authorized representative will provide toll-free telephone technical support at no additional cost to the Government for a minimum of two years from project acceptance, will be furnished by experienced service technicians, and will be available during normal weekday working hours. Include the toll-free technical support telephone number.

l. A written statement entitled "Software Upgrades" stating software and firmware patches and updates will be provided upon request at no additional cost to the Government for a minimum of two years from contract acceptance. Include a table of all DDC system software and firmware provided under this contract, listing the original release dates, version numbers, part numbers, and serial numbers.

3.4.1 Storage Cabinets

In one project mechanical room, provide a wall-mounted metal storage cabinet with hinged doors. Provide cabinets large enough to hold the entire set of Controls System Operators Manuals, and the HVAC operation and maintenance manuals provided under Division 23 HVAC. Locate cabinets adjacent to DDC control panels where applicable. Have each cabinet's proposed installation site approved in advance by the Contracting Officer and the BAS Owner. Prominently label each cabinet with the wording "OPERATION AND MAINTENANCE MANUALS." Place one of the three hard copies of the Operators Manual in this cabinet. Prominently label each binder with the wording "MECHANICAL ROOM COPY - DO NOT REMOVE."

3.5 PERFORMANCE VERIFICATION TESTING (PVT)

3.5.1 General

The PVT shall demonstrate compliance of the control system work with the contract requirements. The PVT shall be performed by the Contractor and witnessed and approved by the Government. If the project is phased, provide separate testing for each phase. A Pre-PVT meeting to review the

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Pre-PVT Checklist is required to coordinate all aspects of the PVT and shall include the Contractor's QA representative, the Contractor's PVT administrator, the Contracting Officer's representative, and the EMCS Owner.

3.5.2 Performance Verification Testing Plan

Submit a detailed PVT Plan of the proposed testing for Government approval. Develop the PVT Plan specifically for the control system in this contract. The PVT Plan shall be a clear list of test items arranged in a logical sequence. Include the intended test procedure, the expected response, and the pass/fail criteria for every component tested.

The plan shall clearly describe how each item is tested, indicate where assisting personnel are required (like the mechanical contractor), and include what procedures are used to simulate conditions. Include a separate column for each checked item and extra space for comments. Where sequences of operations are checked, insert each corresponding routine from the project’s sequence of operation. For each test area, include signature and date lines for the Contractor's PVT administrator, the Contractor's QA representative, the Contracting Officer's representative, and the EMCS Owner to acknowledge successful completion.

3.5.3 PVT Sample Size

Test all central plant equipment, primary air handling unit controllers, and fan coil unit controllers unless otherwise directed. Use the DDC system to verify all VAV boxes are controlling as specified. The Government may require testing of like controllers beyond a statistical sample if sample controllers require retesting or do not have consistent results.

The Government may witness all testing, or random samples of PVT items. When only random samples are witnessed, the Government may choose which ones.

3.5.4 Pre-Performance Verification Testing Checklist

Submit the following as a list with items checked off once verified. Provide a detailed explanation for any items that are not completed or verified.

a. Verify all required mechanical installation work is successfully completed, and all HVAC equipment is working correctly (or will be by the time the PVT is conducted).

b. Verify HVAC motors operate below full-load amperage ratings.

c. Verify all required control system components, wiring, and accessories are installed.

d. Verify the installed control system architecture matches approved drawings.

e. Verify all control circuits operate at the proper voltage and are free from grounds or faults.

f. Verify all required surge protection is installed.

g. Verify the A/C Power Table specified in "CONTROLS SYSTEM OPERATORS

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MANUALS" is accurate.

h. Verify all DDC network communications with the EMCS function properly, including commanding set points, and load shedding.

i. Verify air handling unit and VAV box coil performance by commanding all valves 100 percent open in both heating and cooling. Record the entering and leaving air temperatures. Record the entering water temperature. This data shall be printed, stored, and saved for future reference.

j. Verify each digital controller’s programming is backed up.

k. Verify all wiring, components, and panels are properly labeled.

l. Verify all required points are programmed into devices.

m. Verify all TAB work affecting controls is complete.

n. Verify all valve and actuator zero and span adjustments are set properly.

o. Verify all sensor readings are accurate and calibrated.

p. Verify each control valve and actuator goes to normal position upon loss of power.

q. Provide 48 hours of trend data to verify all systems are functioning as specified. Trend reports will verify control set point adjustment per the temperature re-set schedules (as required by sequence of operation).

Provide the following Trends:

(1) Air Handling Unit: discharge air temperature set point, return air temperature set point, discharge air temperature (actual), return air temperature (actual), valve command position.

(2) Make Up Air Unit: Unit discharge air temperature set point, unit discharge air temperature (actual).

(3) VRF Fan Coil Unit: valve command position, room temperature set point, room temperature (actual).

r. Verify each controller works properly in stand-alone mode.

s. Verify all safety controls and devices function properly, including freeze protection and interfaces with building fire alarm systems.

t. Verify all electrical interlocks work properly.

u. Verify all workstations, notebooks and maintenance personnel interface tools are delivered, all system and database software is installed, and graphic pages are created for each device controlled by the DDC system.

v. Verify the as-built (shop) control drawings are completed.

w. Verify all required alarms are identified at the EMCS server and proper notification is setup for each alarm condition.

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3.5.5 Conducting Performance Verification Testing

a. Provide trend report for each HVAC system that is part of the buildings DDC system. The trend report shall include a value for each set point listed in the sequence of operation.

b. Identify any values that do not meet the sequence of operation requirements, make repairs (re-program) and run a new trend for the system. Document each deficiency and corrective action taken.

c. If re-testing is required, follow the procedures for the initial PVT. The Government may require re-testing of any control system components affected by the original failed test.

3.5.6 Controller Capability and Labeling

Test the following for each controller:

a. Memory: Demonstrate that programmed data, parameters, and trend/ alarm history collected during normal operation is not lost during power failure.

b. Direct Connect Interface: Demonstrate the ability to connect directly to each type of digital controller with a portable electronic device like a notebook computer or PDA. Show that maintenance personnel interface tools perform as specified in the manufacturer's technical literature.

c. Stand Alone Ability: Demonstrate controllers provide stable and reliable stand-alone operation using default values or other method for values normally read over the network. Building DDC system shall function to the project's specifications if connection to the EMCS server is lost.

d. Wiring and AC Power: Demonstrate the ability to disconnect any controller safely from its power source using the AC Power Table. Demonstrate the ability to match wiring labels easily with the control drawings. Demonstrate the ability to locate a controller's location using the BACnet Communication Architecture Schematic and floor plans.

e. Nameplates and Tags: Show the nameplates and tags are accurate and permanently attached to control panel doors, devices, sensors, and actuators.

3.5.7 EMCS Server Operation

a. Show points lists agree with naming conventions.

b. Show that graphics are complete.

c. Show the UPS operates as specified.

3.5.8 BACnet Communications and Interoperability at the EMCS Server

Demonstrate proper interoperability of data sharing, alarm and event management, trending, scheduling, and device and network management. If available or required in this specification, use a BACnet protocol analyzer to assist with identifying devices, viewing network traffic, and verifying interoperability. These requirements must be met even if there is only one

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manufacturer of equipment installed. Testing includes the following:

a. Data Presentation: On each BACnet Operator Workstation, demonstrate graphic display capabilities.

b. Reading of Any Property: Demonstrate the ability to read and display any used readable object property of any device on the network.

c. Setpoint and Parameter Modifications: Show the ability to modify all setpoints and tuning parameters in the sequence of control or listed on project schedules. Modifications are made with BACnet messages and write services initiated by an operator using workstation graphics, or by completing a field in a menu with instructional text.

d. Peer-to-Peer Data Exchange: Show all BACnet devices are installed and configured to perform BACnet read/write services directly (without the need for operator or workstation intervention), to implement the project sequence of operation, and to share global data.

e. Alarm and Event Management: Show that alarms/events are installed and prioritized according to the BAS Owner. Demonstrate time delays and other logic is set up to avoid nuisance tripping, e.g., no status alarms during unoccupied times or high supply air during cold morning start-up. Show that operators with sufficient privilege can read and write alarm/event parameters for all standard BACnet event types. Show that operators with sufficient privilege can change routing (BACnet notification classes) for each alarm/event including the destination, priority, day of week, time of day, and the type of transition involved (TO-OFF NORMAL, TO-NORMAL, etc.).

f. Schedule Lists: Show that schedules are configured for start/stop, mode change, occupant overrides, and night setback as defined in the sequence of operations.

g. Schedule Display and Modification: Show the ability to display any schedule with start and stop times for the calendar year. Show that all calendar entries and schedules are modifiable from any connected workstation by an operator with sufficient privilege.

h. Archival Storage of Data: Show that data archiving is handled by the operator workstation/server, and local trend archiving and display is accomplished with BACnet Trend Log objects.

i. Modification of Trend Log Object Parameters: Show that an operator with sufficient privilege can change the logged data points, sampling rate, and trend duration.

j. Device and Network Management: Show the following capabilities:

(1) Display of Device Status Information

(2) Display of BACnet Object Information

(3) Silencing Devices that are Transmitting Erroneous Data

(4) Time Synchronization

(5) Remote Device Reinitialization

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(6) Backup and Restore Device Programming and Master Database(s)

(7) Configuration Management of Half-Routers, Routers and BBMDs

(8) Demonstrate load shed operations if commanded by the EMCS.

3.5.9 Execution of Sequence of Operation

Demonstrate that the HVAC system operates properly through the complete sequence of operation. Use read/write property services to globally read and modify parameters over the internetwork.

3.5.10 Control Loop Stability and Accuracy

For all control loops tested, give the Government trend graphs of the control variable over time, demonstrating that the control loop responds to a 20 percent sudden change of the control variable set point without excessive overshoot and undershoot. If the process does not allow a 20 percent set point change, use the largest change possible. Show that once the new set point is reached, it is stable and maintained. Control loop trend data shall be in real-time with the time between data points 30 seconds or less.

3.5.11 Performance Verification Testing Report

Upon successful completion of the PVT, submit a PVT Report to the Government and prior to the Government taking use and possession of the facility. Do not submit the report until all problems are corrected and successfully re-tested. The report shall include the annotated PVT Plan used during the PVT. Where problems were identified, explain each problem and the corrective action taken. Include a written certification that the installation and testing of the control system is complete and meets all of the contract's requirements.

3.6 TRAINING REQUIREMENTS

Provide a qualified instructor (or instructors) with two years minimum field experience with the installation and programming of similar BACnet DDC systems. Orient training to the specific systems installed. Coordinate training times with the Contracting Officer and BAS Owner after receiving approval of the training course documentation. Training shall take place at the job site and/or a nearby Government-furnished location. A training day shall occur during normal working hours, last no longer than 8 hours and include a one-hour break for lunch and two additional 15-minute breaks. The project's approved Controls System Operators Manual shall be used as the training text. The Contractor shall ensure the manuals are submitted, approved, and available to hand out to the trainees before the start of training.

3.6.1 Training Documentation

Submit training documentation for review 30 days minimum before training. Documentation shall include an agenda for each training day, objectives, a synopses of each lesson, and the instructor's background and qualifications. The training documentation can be submitted at the same time as the project's Controls System Operators Manual.

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3.6.2 Phase I Training - Fundamentals

The Phase I training session shall last one day and be conducted in a classroom environment with complete audio-visual aids provided by the contractor. Provide each trainee a printed 8.5 by 11 inch hard-copy of all visual aids used. Upon completion of the Phase I Training, each trainee should fully understand the project's DDC system fundamentals. The training session shall include the following:

a. Review of O&M Manual

1. Network Drawing 2. Equipment 3. Flow Diagram 4. Sequence of Operation 5. Wiring 6. Valve Schedule 7. Damper Schedule 8. Bill of Material

b. Network

1. Communication Equipment 2. Configuration Setup of Program 3. Backup Procedures

c. Mechanical Equipment

1. Flow Diagram 2. Wiring & Terminations 3. Hardware Interlocks 4. Sequence of Operation 5. Program Decisions and Illustrations of How Program Meets the Sequence of Operation 6. Global Programming Affecting Each Piece of Equipment

d. Building Data Base

1. Alarm Management 2. Trend Management 3. Building Global Interlocks 4. System Load Shedding & Demand Limiting 5. Utility Data (Water, Steam, Solar)

e. System Tools

1. Network Equipment 2. Supervisory Controllers 3. Equipment Controllers 4. Archives

3.6.3 Phase II Training - Operation

Provide Phase II Training shortly after completing Phase I Training. The Phase II training session shall last one day and be conducted at the DDC system workstation, at a notebook computer connected to the DDC system in the field, and at other site locations as necessary. Upon completion of the Phase II Training, each trainee should fully understand the project's DDC system operation. The training session shall include the following:

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a. A walk-through tour of the mechanical system and the installed DDC components (controllers, valves, dampers, surge protection, switches, thermostats, sensors, etc.)

b. Adding and removing network devices

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No. Nomenclature Description

1 AHU Air Handling Unit2 B Heating Water Boiler3 B Steam Boiler4 C Chiller5 CCC Closed Circuit Cooler6 CCT Closed Circuit Tower7 COM RM Communication Room8 CP Condenser Water Pump9 CRAC Computer Room Air Conditioner

10 CT Cooling Tower11 CTP Cooling Tower Pump12 CTRL PNL Control Panel13 CU Air Cooled Condensing Unit14 CWP Chilled Water Supply Pump15 DECAHP Defense Commissary Agency HP16 DHW Domestic Hot Water17 DPR Damper18 DTS Dual Temperature System19 DWP Domestic Hot Water Pump20 ECT Evaporative Cooling Tower21 EF Exhaust Fan22 EST Elevated Storage Tank23 FCU Fan Coil Unit24 FLTR Filter25 GLBT Ground Level Booster Tank26 HP Heat Pump (On Ground)27 HWP Hot Water Pump28 HWT Hot Water Tank29 HV Heating and Ventilating Unit30 HX Steam to Hot Water Converter31 LS Lift Station32 LP-PMP Loop Pump33 MAD Mixed Air Damper34 MAU Make-up Air Unit35 MZ Multizone Unit36 OA Outside Air37 OAT Outside Air Temperature38 PACU Package Unit39 PHP Packaged Heat Pump (On Ground)40 PX Plate Exchanger41 RA Return Air42 RAF Return Air Fan43 RTHP (RTU) Packaged Rooftop Heat Pump Unit44 RTMZ Rooftop Multizone Unit45 RTU Rooftop Unit (Packaged DX)46 RVS-VLV Reversing Valve47 SA Supply Air

EMCS Equipment and Points Nomenclature for Camp Lejeune

EQUIPMENT

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No. Nomenclature Description

EMCS Equipment and Points Nomenclature for Camp Lejeune

EQUIPMENT48 STP Secondary Treatment Plant49 SV Solenoid Valve/Steam Valve50 TS Temperature Sensor51 TWAC Thru-Wall Air Conditioner52 TWHP Thru-Wall Heat Pump53 UH Unit Heater54 VAV Variable Air Volume55 WAC Window Air Conditioner56 WS Work Station57 WSHP Water Source Heat Pump58 WTP Water Treatment Plant59 WP Well Pump60 ZD Zone Mixing Damper

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No. Nomenclature Description

61 AHU-DHUM Air Handling Unit Dehumidifier62 AHU-OVRRD Air Handling Unit Override63 ALM-CMD Alarm Command64 ALM-HORN Alarm Horn65 ALM-RST Alarm Reset66 ALM-SIL Alarm Silence67 BLR-A Boiler Alarm68 BLR-C Boiler Command69 BLR-S Boiler Start70 BOILER-EN Boiler Enable71 BYPD-C Bypass Damper Command72 C-? Chiller Status73 CD-T Cold Deck Temperature74 CH-CMD Chiller Command75 CH-OVR Chiller Override76 CH-ALM Chiller Alarm77 CH-DP Chiller Differential Pressure78 CH-FLO-S Chiller Flow Switch79 CHILLER-EN Chiller Enable80 CHS-T Chiller Supply Temperature81 CHW-DP Chilled Water Differential Pressure82 CHW-FLOW Chilled Water Flow83 CHW-SYS ENABLE Chilled Water System Enable84 CLG-C Cooling Command85 CLGMAX Cooling Maximum86 CLG-NITE Cooling Night Set Point87 CLG-SP Cooling Set Point88 CLG-VLV Chilled Water Valve Status89 CLG-VLV Chilled Water Valve Operation90 COND1-S Condenser 1 Status91 COND2-S Condenser 2 Status92 COOL1-C Cooling Stage 1 Command93 COOL2-C Cooling Stage 2 Command94 CTFAN-C Cooling Tower Fan Command95 CTFAN-S Cooling Tower Fan Status96 CWR-T Chilled Water Return Temperature97 CWS-GPM Chilled Water Supply GPM98 CWS-T Chilled Water Supply Temperature99 DHW-SET Domestic Hot Water Set Point100 DHWS-T Domestic Hot Water Supply Temperature101 DHW-TANK Domestic Hot Water Tank Temperature102 DHW-VLV Domestic Hot Water Steam Valve103 ELEC-HEAT Electric Heat104 FLTR-DP Filter Differential Pressure105 FLTR-S Air Filter Differential106 HD-T Hot Deck Temperature107 HTG1-C Heating Stage 1 Command

POINTS

EMCS Equipment and Points Nomenclature for Camp Lejeune

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No. Nomenclature Description

POINTS

EMCS Equipment and Points Nomenclature for Camp Lejeune

108 HTG2-C Heating Stage 2 Command109 HTGMAX Heating Maximum Set Point110 HTG-NITE Heating Night Set Point111 HTG-SP Heating Set Point112 HTGV-CMD Heating Command113 HTG-VLV Heating Valve114 HUM-SPT Humidity Set Point115 HW-ENA Hot Water Enable116 HWP-1-C Hot Water Pump 1 Command117 HWP-SPT Hot Water Pump Set Point118 HWP-SS Hot Water Pump Status119 HWR-T Hot Water Return Temperature120 HW-SET Hot Water Reset Set Point121 HWS-FL Hot Water Supply Flow122 HWS-P Hot Water Supply Pressure123 HWS-SPT Hot Water Supply Set Point124 HWS-T Hot Water Supply Temperature125 HW-SYS ENABLE Hot Water System Enable126 HWVLV-C Hot Water Valve Command127 HX-VLV Heat Exchanger Valve128 IA-H Indoor Humidity Sensor129 INST-DMD Instantaneous Demand130 INTV-DMD Interval Demand131 LOOPR-T Loop Return Temperature132 LOOPS-T Loop Supply Temperature133 LPMP-1-C Loop Pump 1 Command134 MAD-CMD Mixed Air Damper Command135 MA-T Mixed Air Temperature136 MAX-CLG Maximum Cooling Set Point137 MAX-HTG Maximum Heating Set Point138 MIN-HTG Minimum Heating Set Point139 MIN-OAD Minimum Outside Air Damper140 OA-CFM Outside Air Cubic Feet Per Minute141 OAD-C Outside Air Damper Position142 OAD-SET Outside Air Damper Set Point143 OAF-C Outside Air Fan Command144 OAF-S Outside Air Fan Status145 OA-H Outside Humidity Sensor146 OA-RH Outside Air Relative Humidity147 OA-T Outside Air Temperature148 OCC-CLG Occupied Cooling149 OCC-HTG Occupied Heating150 OCCTIME Occupied Time (Schedule)151 OCCTIMER Occupied Timer (Schedule)152 OCLG-SP Occupied Cooling Set Point153 OHTG-SP] Occupied Heating Set Point154 OHWP-SPT Occupied Hot Water Sump Set Point

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No. Nomenclature Description

POINTS

EMCS Equipment and Points Nomenclature for Camp Lejeune

155 PH-LEV PH Level156 PH-SET PH Set Point157 PWR-FAIL Power Fail158 PWR-MTR Power Meter159 RAD-C Return Air Damper Position160 RAF-C Return Air Fan Command161 RAF-S Return Air Fan Status162 RA-T Return Air Temperature163 REV-VLV Reversing Valve164 RM-T Room Temperature165 SA-SMKD-C Smoke Detector Command166 SA-SMK-S Smoke Detector Status167 SA-SP Supply Air Set Point168 SA-T Supply Air Temperature169 SETPNT1 Set Point 1170 SETPNT2 Set Point 2171 SF-C Supply Fan Command172 SF-S Supply Fan Status173 SF-VFD Supply Fan Variable Frequency Drive174 SHDN-CMD Shutdown Command175 SMK-S Duct Smoke Detector176 STM-C Steam Command177 STM-S Steam Pressure178 STM-T Steam Temperature179 STM-VLV Steam Valve Operation180 STM-VLV Steam Valve Status181 SUMMER Summer Mode182 SUMWIN-C Summer/Winter Command183 TANK-L-A Tank Level184 TOTAL-KW Total Kilowatt (kW)185 TOTLFLOW Total Flow186 TRIPLOCK Trip Lock Out187 TWR-CMD Tower Command188 UH-ENA Unit Heater Enable189 UH-SPT Unit Heater Set Point190 UNOCC-CLG Unoccupied Cooling191 UNOCC-HTG Unoccupied Heating192 VFD-S Variable Frequency Drive Status193 WINDO-AC Window Air Conditioner194 WINTER Winter Mode195 WSHP-SPT Water Source Heat Pump Set Point196 ZNHTG-SP Zone Heating Set Point197 ZN-T Space/Zone Temperature

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SECTION 23 11 25

FACILITY GAS PIPING11/08

PART 1 GENERAL

1.1 SUMMARY

This specification section applies to incidental underground piping under building, above ground steel piping and corrugated stainless steel tubing (CSST) both outside (up to 5 feet beyond exterior walls) and within buildings in compliance with NFPA 54/AGA Z223.1, "Fuel Gas Piping".

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN GAS ASSOCIATION (AGA)

AGA XR0603 (2006; 8th Ed) AGA Plastic Pipe Manual for Gas Service

AGA Z223.1 (2012) National Fuel Gas Code

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI Z21.1 (2010; Addenda A 2011; Addenda B 2012) Household Cooking Gas Appliances

ANSI Z21.15/CSA 9.1 (2009; Addenda A 2012) Manually Operated Gas Valves for Appliances, Appliance Connector Valves and Hose End Valves

ANSI Z21.18/CSA 6.3 (2007; Addenda A 2010) Gas Appliance Pressure Regulators

ANSI Z21.21/CSA 6.5 (2005; Addenda A 2010; Addenda B 2011) Automatic Valves for Gas Appliances

ANSI Z21.78/CSA 6.20 (2010) Standard Specification for Combination Gas Controls for Gas Appliances

ANSI Z21.80/CSA 6.22 (2011) Line Pressure Regulators

AMERICAN PETROLEUM INSTITUTE (API)

API RP 2009 (2002; R 2007; 7th Ed) Safe Welding, Cutting, and Hot Work Practices in Refineries, Gasoline Plants, and Petrochemical Plants

API Spec 6D (2008; Errata 1 2008; Errata 2 2008; Errata 3 2009; Addendum 1 2009; Errata 4 2010; Errata 5 2010; Errata 6 2011;

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Addendum 2 2011; Addendum 3 2012 ) Specification for Pipeline Valves

API Std 598 (2009) Valve Inspecting and Testing

API Std 607 (2010) Testing of Valves: Fire Test for Soft-Seated Quarter-Turn Valves

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

ASCE 25-06 (2008) Earthquake-Activated Automatic Gas Shutoff Devices

ASME INTERNATIONAL (ASME)

ASME A13.1 (2007; R 2013) Scheme for the Identification of Piping Systems

ASME B1.1 (2003; R 2008) Unified Inch Screw Threads (UN and UNR Thread Form)

ASME B1.20.1 (1983; R 2006) Pipe Threads, General Purpose (Inch)

ASME B16.11 (2011) Forged Fittings, Socket-Welding and Threaded

ASME B16.21 (2011) Nonmetallic Flat Gaskets for Pipe Flanges

ASME B16.3 (2011) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.33 (2012) Manually Operated Metallic Gas Valves for Use in Gas Piping Systems Up to 125 psi, Sizes NPS 1/2 - NPS 2

ASME B16.39 (2009) Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300

ASME B16.5 (2013) Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B16.9 (2012) Standard for Factory-Made Wrought Steel Buttwelding Fittings

ASME B18.2.1 (2012) Square and Hex Bolts and Screws (Inch Series)

ASME B18.2.2 (2010) Standard for Square and Hex Nuts

ASME B31.9 (2011) Building Services Piping

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASME BPVC SEC VIII D1 (2010) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

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ASTM INTERNATIONAL (ASTM)

ASTM 01.01 (2013) Steel - Piping, Tubing, Fittings

ASTM A193/A193M (2012a) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2012a) Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A513/A513M (2012) Standard Specification for Electric-Resistance-Welded Carbon and Alloy Steel Mechanical Tubing

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM F2015 (2000; R 2006) Standard Specification for Lap Joint Flange Pipe End Applications

CSA AMERICA, INC (CSA/AM)

CSA/AM CSA/ANSI LC 1 (2005; Addenda 1B 2011) Fuel Gas Piping Systems Using Corrugated Stainless Steel Tubing (CSST)

FM GLOBAL (FM)

FM APP GUIDE (updated on-line) Approval Guide http://www.approvalguide.com/

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)

MSS SP-25 (2008) Standard Marking System for Valves, Fittings, Flanges and Unions

MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-69 (2003; Notice 2012) Pipe Hangers and Supports - Selection and Application (ANSI Approved American National Standard)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 54 (2012) National Fuel Gas Code

NFPA 70 (2011; Errata 2 2012) National Electrical Code

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SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)

SMACNA 1981 (2008) Seismic Restraint Manual Guidelines for Mechanical Systems, 3rd Edition

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 6/NACE No.3 (2007) Commercial Blast Cleaning

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-310-04 (2012) Seismic Design for Buildings

UNDERWRITERS LABORATORIES (UL)

UL FLAMMABLE & COMBUSTIBLE (2012) Flammable and Combustible Liquids and Gases Equipment Directory

1.3 SYSTEM DESCRIPTION

The gas piping system includes natural gas or propane and piping and appurtenances from point of connection with supply system, as indicated, to gas operated equipment within the facility. Submit operation and maintenance data in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA and 01 78 24.00 20 FACILITY ELECTRONIC OPERATION AND MAINTENANCE SUPPORT INFORMATION (eOMSI), in three separate packages. Section 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS applies to this section, with additions and modifications specified herein.

1.3.1 Gas Facility System and Equipment Operation

Include shop drawings showing piping layout, locations of system valves, gas line markers; step-by-step procedures for system start up, operation and shutdown (index system components and equipment to the system drawings); isolation procedures including valve operation to shutdown or isolate each section of the system (index valves to the system maps and provide separate procedures for normal operation and emergency shutdown if required to be different). Submit Data package No. 4.

1.3.2 Gas Facility System Maintenance

Include maintenance procedures and frequency for system and equipment; identification of pipe materials and manufacturer by locations, pipe repair procedures, and jointing procedures at transitions to other piping material or material from a different manufacturer. Submit Data Package No.4.

1.3.3 Gas Facility Equipment Maintenance

Include identification of valves, shut-offs, disconnects, and other equipment by materials, manufacturer, vendor identification and location; maintenance procedures and recommended tool kits for valves and equipment; recommended repair methods (i.e., field repair, factory repair, or replacement) for each valve and piece of equipment; and preventive maintenance procedures, possible failure modes and troubleshooting guide. Submit Data Package No. 3.

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1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Gas Piping System; G,

SD-03 Product Data

Gas equipment connectors; G, Gas Piping System; G, Pipe Coating Materials; G, Pressure regulators; G, Valves; G, Warning and identification tape; G,

SD-06 Test Reports

Testing; G, Pressure Tests; G,

Test With Gas; G,

SD-07 Certificates

Welders procedures and qualifications; G, assigned number, letter, or symbol; G,

SD-08 Manufacturer's Instructions

pipe coating materials; G,

SD-10 Operation and Maintenance Data

Gas facility system and equipment operation; G, Gas facility system maintenance; G, Gas facility equipment maintenance; G,

1.5 QUALITY ASSURANCE

Submit manufacturer's descriptive data and installation instructions for approval for compression-type mechanical joints used in joining dissimilar materials and for insulating joints. Mark all valves, flanges and fittings in accordance with MSS SP-25.

1.5.1 Welding Qualifications

a. Weld piping in accordance with qualified procedures using performance qualified welders and welding operators in accordance with API RP 2009, ASME BPVC SEC IX, and ASME B31.9. Welding procedures qualified by others, and welders and welding operators qualified by another employer may be accepted as permitted by ASME B31.9. Notify the Contracting Officer at least 24 hours in advance of tests, and perform at the work site if practicable.

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b. Submit a certified copy of welders procedures and qualifications metal and PE in conformance with ASME B31.9 for each welder and welding operator. Submit the assigned number, letter, or symbol that will be used in identifying the work of each welder to the Contracting Officer.

1.5.2 Shop Drawings

Submit drawings for complete Gas Piping System, within 30 days of contract award, showing location, size and all branches of pipeline; location of all required shutoff valves; and instructions necessary for the installation of gas equipment connectors and supports.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture of the products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Asbestos or products containing asbestos are not allowed. Submit catalog data and installation instructions for pipe, valves, all related system components, pipe coating materials and application procedures. Conform to NFPA 54 and with requirements specified herein. Provide supply piping to appliances or equipment at least as large as the inlets thereof.

2.2 GAS PIPING SYSTEM AND FITTINGS

2.2.1 Steel Pipe, Joints, and Fittings

a. Pipe: Black carbon steel in accordance with ASTM A53/A53M, Schedule 40, threaded ends for sizes 2 inches and smaller; otherwise, plain end beveled for butt welding.

b. Threaded Fittings: ASME B16.3, black malleable iron.

c. Socket-Welding Fittings: ASME B16.11, forged steel.

d. Butt-Welding Fittings: ASME B16.9, with backing rings of compatible material.

e. Unions: ASME B16.39, black malleable iron.

f. Flanges and Flanged Fittings: ASME B16.5 steel flanges or convoluted steel flanges conforming to ASME BPVC SEC VIII D1, with flange faces having integral grooves of rectangular cross sections which afford containment for self-energizing gasket material.

2.2.2 Steel Tubing, Joints and Fittings

Provide steel tubing conforming to ASTM 01.01, and ASTM A513/A513M, with tubing joints made up with gas tubing fittings recommended by the tubing manufacturer.

2.2.3 Sealants for Steel Pipe Threaded Joints

Provide joint sealing compound as listed in UL FLAMMABLE & COMBUSTIBLE, Class 20 or less. For taping, use tetrafluoroethylene tape conforming to UL FLAMMABLE & COMBUSTIBLE.

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2.2.4 Warning and Identification

Provide pipe flow markings, warning and identification tape, and metal tags as required.

2.2.5 Flange Gaskets

Provide gaskets of nonasbestos compressed material in accordance with ASME B16.21, 1/16 inch thickness, full face or self-centering flat ring type, containing aramid fibers bonded with styrene butadiene rubber (SBR) or nitrile butadiene rubber (NBR) suitable for a maximum 600 degree F service, to be used for hydrocarbon service.

2.2.6 Pipe Threads

Provide pipe threads conforming to ASME B1.20.1.

2.2.7 Escutcheons

Provide chromium-plated steel or chromium-plated brass escutcheons, either one piece or split pattern, held in place by internal spring tension or set screw.

2.2.8 Insulating Pipe Joints

2.2.8.1 Insulating Joint Material

Provide insulating joint material between flanged or threaded metallic pipe systems where shown to control galvanic or electrical action.

2.2.8.2 Threaded Pipe Joints

Provide threaded pipe joints of steel body nut type dielectric unions with insulating gaskets.

2.2.8.3 Flanged Pipe Joints

Provide joints for flanged pipe consisting of full face sandwich-type flange insulating gasket of the dielectric type, insulating sleeves for flange bolts, and insulating washers for flange nuts. Provide lap joint flange pipe ends conforming to ASTM F2015.

2.3 VALVES

Provide lockable shutoff or service isolation valves and bypass valves as indicated in the drawings conforming to the following:

2.3.1 Valves 2 Inches and Smaller

Provide valves 2 inches and smaller conforming to ASME B16.33 of materials and manufacture compatible with system materials used. Provide manually operated household cooking gas appliance valves conforming to ANSI Z21.1 and ANSI Z21.15/CSA 9.1.

2.3.2 Valves 2-1/2 Inches and Larger

Provide valves 2-1/2 inches and larger of carbon steel conforming to API Spec 6D, Class 150.

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2.4 PIPE HANGERS AND SUPPORTS

Provide pipe hangers and supports conforming to MSS SP-58 and MSS SP-69.

2.5 REGULATORS AND SHUTOFF VALVES

Provide regulators conforming to ANSI Z21.18/CSA 6.3 for appliances ANSI Z21.78/CSA 6.20 for combination gas controls for gas appliances, and ANSI Z21.80/CSA 6.22 for line pressure regulators. Provide shutoff valves conforming to ANSI Z21.15/CSA 9.1 for manually controlled gas shutoff valves and ANSI Z21.21/CSA 6.5 for automatic shutoff valves for gas appliances.

2.6 SEISMIC PROVISIONS

Provide earthquake automatic gas shutoff valve conforming to ASCE 25-06, SMACNA 1981 or excess flow valve (EFV) conforming with CSA US 3-92 IAS U.S. Requirements 3-92 for Excess Flow Valves and UL listed or AGA listed or International Association of Plumbing and Mechanical Officials (IAPMO) listed. The earthquake valve may be either pendulum or ball construction with remote, pneumatic electronic or electric actuator. The EFV may be either a bypass (automatic reset) or a non-bypass type (manual reset).

2.7 BOLTING (BOLTS AND NUTS)

Stainless steel bolting; ASTM A193/A193M, Grade B8M or B8MA, Type 316, for bolts; and ASTM A194/A194M, Grade 8M, Type 316, for nuts. Dimensions of bolts, studs, and nuts shall conform with ASME B18.2.1 and ASME B18.2.2 with coarse threads conforming to ASME B1.1, with Class 2A fit for bolts and studs and Class 2B fit for nuts. Bolts or bolt-studs shall extend through the nuts and may have reduced shanks of a diameter not less than the diameter at root of threads. Bolts shall have American Standard regular square or heavy hexagon heads; nuts shall be American Standard heavy semifinished hexagonal.

2.8 GASKETS

Fluorinated elastomer, compatible with flange faces.

2.9 IDENTIFICATION FOR ABOVEGROUND PIPING

ASME A13.1 for legends and type and size of characters. For pipes 3/4 inch od and larger, provide printed legends to identify contents of pipes and arrows to show direction of flow. Color code label backgrounds to signify levels of hazard. Make labels of plastic sheet with pressure-sensitive adhesive suitable for the intended application. For pipes smaller than 3/4 inch od, provide brass identification tags 1 1/2 inches in diameter with legends in depressed black-filled characters.

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Contracting Officer of any discrepancy or areas of conflict before performing the work.

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3.2 EXCAVATION AND BACKFILLING

Provide required excavation, backfilling, and compaction as specified in Section 31 23 00.00 20 EXCAVATION AND FILL.

3.3 GAS PIPING SYSTEM

Provide a gas piping system from the point of delivery, defined as the and bypass valve outlet of the meter set assembly, service regulator or shutoff valve.

3.3.1 Protection and Cleaning of Materials and Components

Protect equipment, pipe, and tube openings by closing with caps or plugs during installation. At the completion of all work, thoroughly clean the entire system.

3.3.2 Workmanship and Defects

Piping, tubing and fittings shall be clear and free of cutting burrs and defects in structure or threading and shall be thoroughly brushed and chip-and scale-blown. Repair of defects in piping, tubing or fittings is not allowed; replace defective items when found.

3.4 PROTECTIVE COVERING

3.4.1 Aboveground Metallic Piping Systems

3.4.1.1 Ferrous Surfaces

Touch up shop primed surfaces with ferrous metal primer. Solvent clean surfaces that have not been shop primed . Mechanically clean surfaces that contain loose rust, loose mill scale and other foreign substances by power wire brushing or commercial sand blasted conforming to SSPC SP 6/NACE No.3 and prime with ferrous metal primer or vinyl type wash coat. Finish primed surfaces with two coats of exterior oil paint or vinyl paint.

3.5 INSTALLATION

Install the gas system in conformance with the manufacturer's recommendations and applicable provisions of NFPA 54 and AGA XR0603, and as indicated. Perform all pipe cutting without damage to the pipe, with an approved type of mechanical cutter, unless otherwise authorized. Use wheel cutters where practicable. On steel pipe 6 inches and larger, an approved gas cutting and beveling machine may be used.

3.5.1 Metallic Piping Installation

Bury underground piping a minimum of 18 inches below grade. Make changes in direction of piping with fittings only; mitering or notching pipe to form elbows and tees or other similar type construction is not permitted. Branch connection may be made with either tees or forged branch outlet fittings. Provide branch outlet fittings which are forged, flared for improvement of flow where attached to the run, and reinforced against external strains.

3.5.2 Concealed Piping in Buildings

Do not use combinations of fittings (unions, tubing fittings, running

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threads, right- and left-hand couplings, bushings, and swing joints) to conceal piping within buildings.

3.5.2.1 Piping and Tubing in Partitions

Locate concealed piping and tubing in hollow, rather than solid, partitions. Protect tubing passing through walls or partitions against physical damage both during and after construction, and provide appropriate safety markings and labels. Provide protection of concealed pipe and tubing in accordance with CSA/AM CSA/ANSI LC 1.

3.5.3 Aboveground Piping

Run aboveground piping as straight as practicable along the alignment and elevation indicated, with a minimum of joints, and separately supported from other piping system and equipment. Install exposed horizontal piping no farther than 6 inches from nearest parallel wall and at an elevation which prevents standing, sitting, or placement of objects on the piping.

3.5.4 Final Gas Connections

Unless otherwise specified, make final connections with rigid metallic pipe and fittings. Provide accessible gas shutoff valve and coupling for each gas equipment item.

3.5.5 Seismic Requirements

Support and brace piping and attached valves to resist seismic loads in conformance with ASCE 25-06 and as specified in UFC 3-310-04, and Section 23 05 48.00 40 VIBRATION CONTROLS FOR HVAC PIPING AND EQUIPMENT as indicated. CSST tubing and fittings that are seismically qualified in accordance with the FM APP GUIDE: Flexible Piping Systems for Flammable Gases shall meet the seismic requirements in accordance with the manufacturer's installation instructions.

3.6 PIPE JOINTS

Design and install pipe joints to effectively sustain the longitudinal pull-out forces caused by contraction of the piping or superimposed loads.

3.6.1 Threaded Metallic Joints

Provide threaded joints in metallic pipe with tapered threads evenly cut and made with UL approved graphite joint sealing compound for gas service or tetrafluoroethylene tape applied to the male threads only. Threaded joints up to 1-1/2 inches in diameter may be made with approved tetrafluoroethylene tape. Threaded joints up to 2 inches in diameter may be made with approved joint sealing compound. After cutting and before threading, ream pipe and remove all burrs. Caulking of threaded joints to stop or prevent leaks is not permitted.

3.6.2 Welded Metallic Joints

Conform beveling, alignment, heat treatment, and inspection of welds to NFPA 54. Remove weld defects and make repairs to the weld, or remove the weld joints entirely and reweld. After filler metal has been removed from its original package, protect and store so that its characteristics or welding properties are not affected adversely. Do not use electrodes that have been wetted or have lost any of their coating.

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3.7 PIPE SLEEVES

Provide pipes passing through concrete or masonry walls or concrete floors or roofs with pipe sleeves fitted into place at the time of construction. Do not install sleeves in structural members except where indicated or approved. Make all rectangular and square openings as detailed. Extend each sleeve through its respective wall, floor or roof, and cut flush with each surface, except in mechanical room floors not located on grade where clamping flanges or riser pipe clamps are used. Extend sleeves in mechanical room floors above grade at least 4 inches above finish floor. Unless otherwise indicated, use sleeves large enough to provide a minimum clearance of 1/4 inch all around the pipe. Provide steel pipe for sleeves in bearing walls, waterproofing membrane floors, and wet areas . Provide sleeves in nonbearing walls, floors, or ceilings of steel pipe, galvanized sheet metal with lock-type longitudinal seam, or moisture-resistant fiber or plastic. For penetrations of fire walls, fire partitions and floors which are not on grade, seal the annular space between the pipe and sleeve with fire-stopping material and sealant that meet the requirement of Section 07 84 00 FIRESTOPPINGG.

3.8 PIPES PENETRATING WATERPROOFING MEMBRANES

Install pipes penetrating waterproofing membranes as specified in Section 22 00 00 PLUMBING, GENERAL PURPOSE.

3.9 FIRE SEAL

Fire seal all penetrations of fire rated partitions, walls and floors in accordance with Section 07 84 00 FIRESTOPPING.

3.10 ESCUTCHEONS

Provide escutcheons for all finished surfaces where gas piping passes through floors, walls, or ceilings except in boiler, utility, or equipment rooms.

3.11 SPECIAL REQUIREMENTS

Provide drips, grading of the lines, freeze protection, and branch outlet locations as shown and conforming to the requirements of NFPA 54.

3.12 BUILDING STRUCTURE

Do not weaken any building structure by the installation of any gas piping. Do not cut or notch beams, joists or columns. Attach piping supports to metal decking. Do not attach supports to the underside of concrete filled floors or concrete roof decks unless approved by the Contracting Officer.

3.13 PIPING SYSTEM SUPPORTS

Support gas piping systems in buildings with pipe hooks, metal pipe straps, bands or hangers suitable for the size of piping or tubing. Do not support any gas piping system by other piping. Conform spacing of supports in gas piping and tubing installations to the requirements of NFPA 54. Conform the selection and application of supports in gas piping and tubing installations to the requirements of MSS SP-69. In the support of multiple pipe runs on a common base member, use a clip or clamp where each pipe

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crosses the base support member. Spacing of the base support members is not to exceed the hanger and support spacing required for any of the individual pipes in the multiple pipe run. Rigidly connect the clips or clamps to the common base member. Provide a clearance of 1/8 inch between the pipe and clip or clamp for all piping which may be subjected to thermal expansion.

3.14 ELECTRICAL BONDING AND GROUNDING

Provide a gas piping system within the building which is electrically continuous and bonded to a grounding electrode as required by NFPA 70.

3.15 SHUTOFF VALVE

Install the main gas shutoff valve and bypass valve at meter controlling the gas piping system to be easily accessible for operation, as indicated, protected from physical damage, and marked with a metal tag to clearly identify the piping system controlled. Install valves approximately at locations indicated. Orient stems vertically, with operators on top, or horizontally. Provide stop valve on service branch at connection to main and shut-off valve on riser outside of building.

3.16 PRESSURE REGULATOR

Provide plug cock or ball valve ahead of regulator. Install regulator outside of building and 18 inches aboveground on riser. Install regulator inside building and extend a full-size vent line from relief outlet on regulator to a point outside of building. Install gas meter in conjunction with pressure regulator. On outlet side of regulator meter, provide a union and a 3/8 inch gage tap with plug.

3.17 TESTING

Submit test procedures and reports in booklet form tabulating test and measurements performed; dated after award of this contract, and stating the Contractor's name and address, the project name and location, and a list of the specific requirements which are being certified. Test entire gas piping system to ensure that it is gastight prior to putting into service. Prior to testing, purge the system, clean, and clear all foreign material. Test each joint with an approved gas detector, soap and water, or an equivalent nonflammable solution. Inspect and test each valve in conformance with API Std 598 and API Std 607. Complete testing before any work is covered, enclosed, or concealed, and perform with due regard for the safety of employees and the public during the test. Install bulkheads, anchorage and bracing suitably designed to resist test pressures if necessary, and as directed and or approved by the Contracting Officer. Do not use oxygen as a testing medium.

3.17.1 Pressure Tests

Submit test procedures and reports in booklet form tabulating test and measurements performed; dated after award of this contract, and stating the Contractor's name and address, the project name and location, and a list of the specific requirements which are being certified. Before appliances are connected, test by filling the piping systems with air or an inert gas to withstand a minimum pressure of 3 pounds gauge for a period of not less than 10 minutes as specified in NFPA 54 without showing any drop in pressure. Do not use Oxygen for test. Measure pressure with a mercury manometer, slope gauge, or an equivalent device calibrated to be read in

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increments of not greater than 0.1 pound. Isolate the source of pressure before the pressure tests are made.

3.17.2 Test With Gas

Before turning on gas under pressure into any piping, close all openings from which gas can escape. Immediately after turning on the gas, check the piping system for leakage by using a laboratory-certified gas meter, an appliance orifice, a manometer, or equivalent device. Conform all testing to the requirements of NFPA 54. If leakage is recorded, shut off the gas supply, repair the leak , and repeat the tests until all leaks have been stopped.

3.17.3 Purging

After testing is completed, and before connecting any appliances, fully purge all gas piping. Do not purge piping into the combustion chamber of an appliance. Do not purge the open end of piping systems into confined spaces or areas where there are ignition sources unless the safety precautions recommended in NFPA 54 are followed.

3.17.4 Labor, Materials and Equipment

Furnish all labor, materials and equipment necessary for conducting the testing and purging.

3.18 PIPE COLOR CODE MARKING

Provide color code marking of piping as specified in Section 09 90 00 PAINTS AND COATINGS, conforming to ASME A13.1.

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REFRIGERANT PIPING10/07

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI)

AHRI 710 I-P (2009) Performance Rating of Liquid-Line Driers

AHRI 720 (2002) Refrigerant Access Valves and Hose Connectors

ANSI/AHRI 750 (2007) Thermostatic Refrigerant Expansion Valves

ANSI/AHRI 760 (2007) Performance Rating of Solenoid Valves for Use With Volatile Refrigerants

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)

ANSI/ASHRAE 15 & 34 (2010; Addenda A, B, C, D, E, F, G, H, I, J, K, L, N and O; Errata 2011; INT 1 2012; Errata 2012; Addenda AD, SD, AE and AF 2013) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants

ASHRAE 17 (2008) Method of Testing Capacity of Thermostatic Refrigerant Expansion Valves

AMERICAN WELDING SOCIETY (AWS)

AWS A5.8/A5.8M (2011; Amendment 2012) Specification for Filler Metals for Brazing and Braze Welding

AWS BRH (2007; 5th Ed) Brazing Handbook

AWS Z49.1 (2012) Safety in Welding and Cutting and Allied Processes

ASME INTERNATIONAL (ASME)

ASME B16.22 (2012) Standard for Wrought Copper and Copper Alloy Solder Joint Pressure Fittings

ASME B16.26 (2011) Standard for Cast Copper Alloy

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Fittings for Flared Copper Tubes

ASME B31.1 (2012; INT 2-6, 8-10, 13, 15, 17-25, 27-31 and 42-46) Power Piping

ASME B31.5 (2013) Refrigeration Piping and Heat Transfer Components

ASME B40.100 (2005; R 2010) Pressure Gauges and Gauge Attachments

ASTM INTERNATIONAL (ASTM)

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A653/A653M (2011) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM B280 (2013) Standard Specification for Seamless Copper Tube for Air Conditioning and Refrigeration Field Service

ASTM B32 (2008) Standard Specification for Solder Metal

ASTM B62 (2009) Standard Specification for Composition Bronze or Ounce Metal Castings

ASTM B75/B75M (2011) Standard Specification for Seamless Copper Tube

ASTM B813 (2010) Standard Specification for Liquid and Paste Fluxes for Soldering of Copper and Copper Alloy Tube

ASTM D3308 (2012) PTFE Resin Skived Tape

ASTM D520 (2000; R 2011) Zinc Dust Pigment

ASTM E84 (2012c) Standard Test Method for Surface Burning Characteristics of Building Materials

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)

MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-69 (2003; Notice 2012) Pipe Hangers and Supports - Selection and Application (ANSI

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Approved American National Standard)

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Refrigerant Piping System; G

SD-03 Product Data

Refrigerant Piping SystemQualifications; GRefrigerant Piping Tests; GDemonstrations; GVerification of Dimensions

SD-06 Test Reports

Refrigerant Piping Tests

SD-07 Certificates

Service Organization; G

SD-10 Operation and Maintenance Data

MaintenanceOperation and Maintenance Manuals

1.3 QUALITY ASSURANCE

1.3.1 Qualifications

Structural members shall be welded in accordance with Section 05 12 00 STRUCTURAL STEEL.

1.3.2 Contract Drawings

Because of the small scale of the drawings, it is not possible to indicate all offsets, fittings, and accessories that may be required. Carefully investigate the plumbing, fire protection, electrical, structural and finish conditions that would affect the work to be performed and arrange such work accordingly, furnishing required offsets, fittings, and accessories to meet such conditions.

1.4 DELIVERY, STORAGE, AND HANDLING

Protect stored items from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Proper protection and care of all material both before and during installation is the Contractor's responsibility. Replace any materials found to be damaged at the Contractor's expense. During installation, cap piping and similar openings to keep out dirt and other foreign matter.

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1.5 MAINTENANCE

1.5.1 General

Submit Data Package 2 plus operation and maintenance data complying with the requirements of Section 01 78 23 OPERATION AND MAINTENANCE DATA and as specified herein.

PART 2 PRODUCTS

2.1 STANDARD COMMERCIAL PRODUCTS

a. Provide materials and equipment which are standard products of a manufacturer regularly engaged in the manufacturing of such products, that are of a similar material, design and workmanship and that have been in satisfactory commercial or industrial use for 2 years prior to bid opening.

b. The 2 year use shall include applications of equipment and materials under similar circumstances and of similar size. The 2 years experience shall be satisfactorily completed by a product which has been sold or is offered for sale on the commercial market through advertisements, manufacturer's catalogs, or brochures. Products having less than a 2 year field service record will be acceptable if a certified record of satisfactory field operation, for not less than 6000 hours exclusive of the manufacturer's factory tests, can be shown.

c. Products shall be supported by a service organization. System components shall be environmentally suitable for the indicated locations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. The service organizations shall be reasonably convenient to the equipment installation and be able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.

d. Exposed equipment moving parts, parts that produce high operating temperature, parts which may be electrically energized, and parts that may be a hazard to operating personnel shall be insulated, fully enclosed, guarded, or fitted with other types of safety devices. Install safety devices so that proper operation of equipment is not impaired. Welding and cutting safety requirements shall be in accordance with AWS Z49.1.

e. Manufacturer's standard catalog data, at least 5 weeks prior to the purchase or installation of a particular component, highlighted to show material, size, options, performance charts and curves, etc. in adequate detail to demonstrate compliance with contract requirements. Include in the data manufacturer's recommended installation instructions and procedures. Provide data for the following components as a minimum:

a. Piping and Fittingsb. Valvesc. Piping Accessoriesd. Pipe Hangers, Inserts, and Supports

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2.2 ELECTRICAL WORK

Manual or automatic control and protective or signal devices required for the operation specified and any control wiring required for controls and devices specified, but not shown, shall be provided.

2.3 REFRIGERANT PIPING SYSTEM

Refrigerant piping, valves, fittings, and accessories shall be in accordance with ANSI/ASHRAE 15 & 34 and ASME B31.5, except as specified herein. Refrigerant piping, valves, fittings, and accessories shall be compatible with the fluids used and capable of withstanding the pressures and temperatures of the service. Refrigerant piping, valves, and accessories used for refrigerant service shall be cleaned, dehydrated, and sealed (capped or plugged) prior to shipment from the manufacturer's plant. Submit drawings, at least 5 weeks prior to beginning construction, provided in adequate detail to demonstrate compliance with contract requirements. Drawings shall consist of:

a. Piping layouts which identify all valves and fittings.

b. Plans and elevations which identify clearances required for maintenance and operation.

2.4 PIPE, FITTINGS AND END CONNECTIONS (JOINTS)

2.4.1 Copper Tubing

Copper tubing shall conform to ASTM B280 annealed or hard drawn as required. Copper tubing shall be soft annealed where bending is required and hard drawn where no bending is required. Soft annealed copper tubing shall not be used in sizes larger than 1-3/8 inches. Joints shall be brazed except that joints on lines 7/8 inchand smaller may be flared. Cast copper alloy fittings for flared copper tube shall conform to ASME B16.26 and ASTM B62. Wrought copper and bronze solder-joint pressure fittings shall conform to ASME B16.22 and ASTM B75/B75M. Joints and fittings for brazed joint shall be wrought-copper or forged-brass sweat fittings. Cast sweat-type joints and fittings shall not be allowed for brazed joints. Brass or bronze adapters for brazed tubing may be used for connecting tubing to flanges and to threaded ends of valves and equipment.

2.4.2 Solder

Solder shall conform to ASTM B32, grade Sb5, tin-antimony alloy for service pressures up to 150 psig. Solder flux shall be liquid or paste form, non-corrosive and conform to ASTM B813.

2.4.3 Brazing Filler Metal

Filler metal shall conform to AWS A5.8/A5.8M, Type BAg-5 with AWS Type 3 flux, except Type BCuP-5 or BCuP-6 may be used for brazing copper-to-copper joints.

2.5 VALVES

Valves shall be designed, manufactured, and tested specifically for refrigerant service. Valve bodies shall be of brass, bronze, steel, or ductile iron construction. Valves 1 inch and smaller shall have brazed connections. Valves larger than 1 inch shall have tongue-and-groove flanged

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end connections. Threaded end connections shall not be used, except in pilot pressure or gauge lines where maintenance disassembly is required. Internal parts shall be removable for inspection or replacement without applying heat or breaking pipe connections. Valve stems exposed to the atmosphere shall be stainless steel or corrosion resistant metal plated carbon steel. Direction of flow shall be legibly and permanently indicated on the valve body. Control valve inlets shall be fitted with integral or adapted strainer or filter where recommended or required by the manufacturer. Purge, charge and receiver valves shall be of manufacturer's standard configuration.

2.5.1 Refrigerant Stop Valves

Valve shall be the globe or full-port ball type with a back-seating stem especially packed for refrigerant service. Valve packing shall be replaceable under line pressure. Valve shall be provided with a handwheel or wrench operator and a seal cap. Valve shall be the straight or angle pattern design as indicated.

2.5.2 Check Valves

Valve shall be the swing or lift type as required to provide positive shutoff at the differential pressure indicated. Valve shall be provide with resilient seat.

2.5.3 Liquid Solenoid Valves

Valves shall comply with ANSI/AHRI 760 and be suitable for continuous duty with applied voltages 15 percent under and 5 percent over nominal rated voltage at maximum and minimum encountered pressure and temperature service conditions. Valves shall be direct-acting or pilot-operating type, packless, except that packed stem, seal capped, manual lifting provisions shall be furnished. Solenoid coils shall be moisture-proof, UL approved, totally encapsulated or encapsulated and metal jacketed as required. Valves shall have safe working pressure of 400 psi and a maximum operating pressure differential of at least 200 psi at 85 percent rated voltage. Valves shall have an operating pressure differential suitable for the refrigerant used.

2.5.4 Expansion Valves

Valve shall conform to ANSI/AHRI 750 and ASHRAE 17. Valve shall be the diaphragm and spring-loaded type with internal or external equalizers, and bulb and capillary tubing. Valve shall be provided with an external superheat adjustment along with a seal cap. Internal equalizers may be utilized where flowing refrigerant pressure drop between outlet of the valve and inlet to the evaporator coil is negligible and pressure drop across the evaporator is less than the pressure difference corresponding to 2 degrees F of saturated suction temperature at evaporator conditions. Bulb charge shall be determined by the manufacturer for the application and such that liquid will remain in the bulb at all operating conditions. Gas limited liquid charged valves and other valve devices for limiting evaporator pressure shall not be used without a distributor or discharge tube or effective means to prevent loss of control when bulb becomes warmer than valve body. Pilot-operated valves shall have a characterized plug to provide required modulating control. A de-energized solenoid valve may be used in the pilot line to close the main valve in lieu of a solenoid valve in the main liquid line. An isolatable pressure gauge shall be provided in the pilot line, at the main valve. Automatic pressure reducing or constant

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pressure regulating expansion valves may be used only where indicted or for constant evaporator loads.

2.5.5 Safety Relief Valves

Valve shall be the two-way type, unless indicated otherwise. Valve shall bear the ASME code symbol. Valve capacity shall be certified by the National Board of Boiler and Pressure Vessel Inspectors. Valve shall be of an automatically reseating design after activation.

2.5.6 Evaporator Pressure Regulators, Direct-Acting

Valve shall include a diaphragm/spring assembly, external pressure adjustment with seal cap, and pressure gauge port. Valve shall maintain a constant inlet pressure by balancing inlet pressure on diaphragm against an adjustable spring load. Pressure drop at system design load shall not exceed the pressure difference corresponding to a 2 degrees F change in saturated refrigerant temperature at evaporator operating suction temperature. Spring shall be selected for indicated maximum allowable suction pressure range.

2.5.7 Refrigerant Access Valves

Refrigerant access valves and hose connections shall be in accordance with AHRI 720.

2.6 PIPING ACCESSORIES

2.6.1 Filter Driers

Driers shall conform to AHRI 710 I-P. Sizes 5/8 inch and larger shall be the full flow, replaceable core type. Sizes 1/2 inch and smaller shall be the sealed type. Cores shall be of suitable desiccant that will not plug, cake, dust, channel, or break down, and shall remove water, acid, and foreign material from the refrigerant. Filter driers shall be constructed so that none of the desiccant will pass into the refrigerant lines. Minimum bursting pressure shall be 1,500 psi.

2.6.2 Sight Glass and Liquid Level Indicator

2.6.2.1 Assembly and Components

Assembly shall be pressure- and temperature-rated and constructed of materials suitable for the service. Glass shall be borosilicate type. Ferrous components subject to condensation shall be electro-galvanized.

2.6.2.2 Gauge Glass

Gauge glass shall include top and bottom isolation valves fitted with automatic checks, and packing followers; red-line or green-line gauge glass; elastomer or polymer packing to suit the service; and gauge glass guard.

2.6.2.3 Bull's-Eye and Inline Sight Glass Reflex Lens

Bull's-eye and inline sight glass reflex lens shall be provided for dead-end liquid service. For pipe line mounting, two plain lenses in one body suitable for backlighted viewing shall be provided.

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2.6.2.4 Moisture Indicator

Indicator shall be a self-reversible action, moisture reactive, color changing media. Indicator shall be furnished with full-color-printing tag containing color, moisture and temperature criteria. Unless otherwise indicated, the moisture indicator shall be an integral part of each corresponding sight glass.

2.6.3 Vibration Dampeners

Dampeners shall be of the all-metallic bellows and woven-wire type.

2.6.4 Flexible Pipe Connectors

Connector shall be a composite of interior corrugated phosphor bronze or Type 300 Series stainless steel, as required for fluid service, with exterior reinforcement of bronze, stainless steel or monel wire braid. Assembly shall be constructed with a safety factor of not less than 4 at300 degrees F. Unless otherwise indicated, the length of a flexible connector shall be as recommended by the manufacturer for the service intended.

2.6.5 Strainers

Strainers used in refrigerant service shall have brass or cast iron body, Y-or angle-pattern, cleanable, not less than 60-mesh noncorroding screen of an area to provide net free area not less than ten times the pipe diameter with pressure rating compatible with the refrigerant service. Screens shall be stainless steel or monel and reinforced spring-loaded where necessary for bypass-proof construction.

2.6.6 Pressure and Vacuum Gauges

Gauges shall conform to ASME B40.100 and shall be provided with throttling type needle valve or a pulsation dampener and shut-off valve. Gauge shall be a minimum of 3-1/2 inches in diameter with a range from 0 psig to approximately 1.5 times the maximum system working pressure. Each gauge range shall be selected so that at normal operating pressure, the needle is within the middle-third of the range.

2.6.7 Temperature Gauges

Temperature gauges shall be the industrial duty type and be provided for the required temperature range. Gauges shall have Fahrenheit scale in 2 degrees graduations scale (black numbers) on a white face. The pointer shall be adjustable. Rigid stem type temperature gauges shall be provided in thermal wells located within 5 feet of the finished floor. Universal adjustable angle type or remote element type temperature gauges shall be provided in thermal wells located 5 to 7 feet above the finished floor. Remote element type temperature gauges shall be provided in thermal wells located 7 feet above the finished floor.

2.6.7.1 Stem Cased-Glass

Stem cased-glass case shall be polished stainless steel or cast aluminum, 9 inches long, with clear acrylic lens, and non-mercury filled glass tube with indicating-fluid column.

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2.6.7.2 Bimetallic Dial

Bimetallic dial type case shall be not less than 3-1/2 inches, stainless steel, and shall be hermetically sealed with clear acrylic lens. Bimetallic element shall be silicone dampened and unit fitted with external calibrator adjustment. Accuracy shall be one percent of dial range.

2.6.7.3 Liquid-, Solid-, and Vapor-Filled Dial

Liquid-, solid-, and vapor-filled dial type cases shall be not less than 3-1/2 inches, stainless steel or cast aluminum with clear acrylic lens. Fill shall be nonmercury, suitable for encountered cross-ambients, and connecting capillary tubing shall be double-braided bronze.

2.6.7.4 Thermal Well

Thermal well shall be identical size, 1/2 or 3/4 inch NPT connection, brass or stainless steel. Where test wells are indicated, provide captive plug-fitted type 1/2 inch NPT connection suitable for use with either engraved stem or standard separable socket thermometer or thermostat. Mercury shall not be used in thermometers. Extended neck thermal wells shall be of sufficient length to clear insulation thickness by 1 inch.

2.6.8 Pipe Hangers, Inserts, and Supports

Pipe hangers, inserts, guides, and supports shall conform to MSS SP-58 and MSS SP-69.

2.6.9 Escutcheons

Escutcheons shall be chromium-plated iron or chromium-plated brass, either one piece or split pattern, held in place by internal spring tension or set screws.

2.7 FABRICATION

2.7.1 Factory Coating

Unless otherwise specified, equipment and component items, when fabricated from ferrous metal, shall be factory finished with the manufacturer's standard finish, except that items located outside of buildings shall have weather resistant finishes that will withstand 3000 hours exposure to the salt spray test specified in ASTM B117 using a 5 percent sodium chloride solution. Immediately after completion of the test, the specimen shall show no signs of blistering, wrinkling, cracking, or loss of adhesion and no sign of rust creepage beyond 1/8 inch on either side of the scratch mark. Cut edges of galvanized surfaces where hot-dip galvanized sheet steel is used shall be coated with a zinc-rich coating conforming to ASTM D520, Type I.

2.7.2 Factory Applied Insulation

Refrigerant suction lines between the cooler and each compressor shall be insulated with not less than 3/4 inch thick unicellular plastic foam. Factory insulated items installed outdoors are not required to be fire-rated. As a minimum, factory insulated items installed indoors shall have a flame spread index no higher than 75 and a smoke developed index no higher than 150. Factory insulated items (no jacket) installed indoors and which are located in air plenums, in ceiling spaces, and in attic spaces

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shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50. Flame spread and smoke developed indexes shall be determined by ASTM E84. Insulation shall be tested in the same density and installed thickness as the material to be used in the actual construction. Material supplied by a manufacturer with a jacket shall be tested as a composite material. Jackets, facings, and adhesives shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50 when tested in accordance with ASTM E84.

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with all details of the work, perform a verification of dimensions in the field. Submit a letter, at least 2 weeks prior to beginning construction, including the date the site was visited, conformation of existing conditions, and any discrepancies found before performing any work.

3.2 INSTALLATION

Pipe and fitting installation shall conform to the requirements of ASME B31.1. Pipe shall be cut accurately to measurements established at the jobsite, and worked into place without springing or forcing, completely clearing all windows, doors, and other openings. Cutting or other weakening of the building structure to facilitate piping installation will not be permitted without written approval. Pipe or tubing shall be cut square, shall have burrs removed by reaming, and shall permit free expansion and contraction without causing damage to the building structure, pipe, joints, or hangers.

3.2.1 Directional Changes

Changes in direction shall be made with fittings, except that bending of pipe 4 inches and smaller will be permitted, provided a pipe bender is used and wide weep bends are formed. Mitering or notching pipe or other similar construction to form elbows or tees will not be permitted. The centerline radius of bends shall not be less than 6 diameters of the pipe. Bent pipe showing kinks, wrinkles, flattening, or other malformations will not be accepted.

3.2.2 Functional Requirements

Piping shall be sloped 1/2 inch/10 feet of pipe in the direction of flow to ensure adequate oil drainage. Open ends of refrigerant lines or equipment shall be properly capped or plugged during installation to keep moisture, dirt, or other foreign material out of the system. Piping shall remain capped until installation. Equipment piping shall be in accordance with the equipment manufacturer's recommendations and the contract drawings. Equipment and piping arrangements shall fit into space allotted and allow adequate acceptable clearances for installation, replacement, entry, servicing, and maintenance.

3.2.3 Fittings and End Connections

3.2.3.1 Threaded Connections

Threaded connections shall be made with tapered threads and made tight with PTFE tape complying with ASTM D3308 or equivalent thread-joint compound

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applied to the male threads only. Not more than three threads shall show after the joint is made.

3.2.3.2 Brazed Connections

Brazing shall be performed in accordance with AWS BRH, except as modified herein. During brazing, the pipe and fittings shall be filled with a pressure regulated inert gas, such as nitrogen, to prevent the formation of scale. Before brazing copper joints, both the outside of the tube and the inside of the fitting shall be cleaned with a wire fitting brush until the entire joint surface is bright and clean. Brazing flux shall not be used. Surplus brazing material shall be removed at all joints. Steel tubing joints shall be made in accordance with the manufacturer's recommendations. Joints in steel tubing shall be painted with the same material as the baked-on coating within 8 hours after joints are made. Tubing shall be protected against oxidation during brazing by continuous purging of the inside of the piping using nitrogen. Piping shall be supported prior to brazing and not be sprung or forced.

3.2.3.3 Flared Connections

When flared connections are used, a suitable lubricant shall be used between the back of the flare and the nut in order to avoid tearing the flare while tightening the nut.

3.2.4 Valves

3.2.4.1 General

Refrigerant stop valves shall be installed on each side of each piece of equipment such as compressors condensers, evaporators, receivers, and other similar items in multiple-unit installation, to provide partial system isolation as required for maintenance or repair. Stop valves shall be installed with stems horizontal unless otherwise indicated. Ball valves shall be installed with stems positioned to facilitate operation and maintenance. Isolating valves for pressure gauges and switches shall be external to thermal insulation. Safety switches shall not be fitted with isolation valves. Filter dryers having access ports may be considered a point of isolation. Purge valves shall be provided at all points of systems where accumulated noncondensable gases would prevent proper system operation. Valves shall be furnished to match line size, unless otherwise indicated or approved.

3.2.4.2 Expansion Valves

Expansion valves shall be installed with the thermostatic expansion valve bulb located on top of the suction line when the suction line is less than 2-1/8 inches in diameter and at the 4 o'clock or 8 o'clock position on lines larger than 2-1/8 inches. The bulb shall be securely fastened with two clamps. The bulb shall be insulated. The bulb shall installed in a horizontal portion of the suction line, if possible, with the pigtail on the bottom. If the bulb must be installed in a vertical line, the bulb tubing shall be facing up.

3.2.4.3 Valve Identification

Each system valve, including those which are part of a factory assembly, shall be tagged. Tags shall be in alphanumeric sequence, progressing in direction of fluid flow. Tags shall be embossed, engraved, or stamped

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plastic or nonferrous metal of various shapes, sized approximately 1-3/8 inch diameter, or equivalent dimension, substantially attached to a component or immediately adjacent thereto. Tags shall be attached with nonferrous, heavy duty, bead or link chain, 14 gauge annealed wire, nylon cable bands or as approved. Tag numbers shall be referenced in Operation and Maintenance Manuals and system diagrams.

3.2.5 Vibration Dampers

Vibration damper shall be provided in the suction and discharge lines on spring mounted compressors. Vibration dampers shall be installed parallel with the shaft of the compressor and shall be anchored firmly at the upstream end on the suction line and the downstream end in the discharge line.

3.2.6 Strainers

Strainers shall be provided immediately ahead of solenoid valves and expansion devices. Strainers may be an integral part of an expansion valve.

3.2.7 Filter Dryer

A liquid line filter dryer shall be provided on each refrigerant circuit located such that all liquid refrigerant passes through a filter dryer. Dryers shall be sized in accordance with the manufacturer's recommendations for the system in which it is installed. Dryers shall be installed such that it can be isolated from the system, the isolated portion of the system evacuated, and the filter dryer replaced. Dryers shall be installed in the horizontal position except replaceable core filter dryers may be installed in the vertical position with the access flange on the bottom.

3.2.8 Sight Glass

A moisture indicating sight glass shall be installed in all refrigerant circuits down stream of all filter dryers and where indicated. Site glasses shall be full line size.

3.2.9 Discharge Line Oil Separator

Discharge line oil separator shall be provided in the discharge line from each compressor. Oil return line shall be connected to the compressor as recommended by the compressor manufacturer.

3.2.10 Accumulator

Accumulators shall be provided in the suction line to each compressor as recommended by the equipment manufacturer.

3.2.11 Flexible Pipe Connectors

Connectors shall be installed perpendicular to line of motion being isolated. Piping for equipment with bidirectional motion shall be fitted with two flexible connectors, in perpendicular planes. Reinforced elastomer flexible connectors shall be installed in accordance with manufacturer's instructions. Piping guides and restraints related to flexible connectors shall be provided as required.

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3.2.12 Temperature Gauges

Temperature gauges shall be located specifically on, but not limited to the following: the sensing element of each automatic temperature control device where a thermometer is not an integral part thereof. Thermal wells for insertion thermometers and thermostats shall extend beyond thermal insulation surface not less than 1 inch.

3.2.13 Pipe Hangers, Inserts, and Supports

Pipe hangers, inserts, and supports shall conform to MSS SP-58 and MSS SP-69, except as modified herein. Pipe hanger types 5, 12, and 26 shall not be used. Hangers used to support piping 2 inches and larger shall be fabricated to permit adequate adjustment after erection while still supporting the load. Piping subjected to vertical movement, when operating temperatures exceed ambient temperatures, shall be supported by variable spring hangers and supports or by constant support hangers.

3.2.13.1 Hangers

Type 3 shall not be used on insulated piping. Type 24 may be used only on trapeze hanger systems or on fabricated frames.

3.2.13.2 Inserts

Type 18 inserts shall be secured to concrete forms before concrete is placed. Continuous inserts which allow more adjustments may be used if they otherwise meet the requirements for Type 18 inserts.

3.2.13.3 C-Clamps

Type 19 and 23 C-clamps shall be torqued in accordance with MSS SP-69 and have both locknuts and retaining devices, furnished by the manufacturer. Field-fabricated C-clamp bodies or retaining devices are not acceptable.

3.2.13.4 Angle Attachments

Type 20 attachments used on angles and channels shall be furnished with an added malleable-iron heel plate or adapter.

3.2.13.5 Saddles and Shields

Where Type 39 saddle or Type 40 shield are permitted for a particular pipe attachment application, the Type 39 saddle, connected to the pipe, shall be used on all pipe 4 inches and larger when the temperature of the medium is 60 degrees F or higher. Type 40 shields shall be used on all piping less than 4 inches and all piping 4 inches and larger carrying medium less than 60 degrees F. A high density insulation insert of cellular glass shall be used under the Type 40 shield for piping 2 inches and larger.

3.2.13.6 Horizontal Pipe Supports

Horizontal pipe supports shall be spaced as specified in MSS SP-69 and a support shall be installed not over 1 foot from the pipe fitting joint at each change in direction of the piping. Pipe supports shall be spaced not over 5 feet apart at valves.

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3.2.13.7 Multiple Pipe Runs

In the support of multiple pipe runs on a common base member, a clip or clamp shall be used where each pipe crosses the base support member. Spacing of the base support members shall not exceed the hanger and support spacing required for an individual pipe in the multiple pipe run.

3.2.13.8 Structural Attachments

Attachment to building structure concrete and masonry shall be by cast-in concrete inserts, built-in anchors, or masonry anchor devices. Inserts and anchors shall be applied with a safety factor not less than 5. Supports shall not be attached to metal decking. Masonry anchors for overhead applications shall be constructed of ferrous materials only. Structural steel brackets required to support piping, headers, and equipment, but not shown, shall be provided under this section. Material used for support shall be as specified under Section 05 12 00 STRUCTURAL STEEL.

3.2.14 Pipe Alignment Guides

Pipe alignment guides shall be provided where indicated for expansion loops, offsets, and bends and as recommended by the manufacturer for expansion joints, not to exceed 5 feet on each side of each expansion joint, and in lines 4 inches or smaller not more than 2 feet on each side of the joint.

3.2.15 Pipe Anchors

Anchors shall be provided wherever necessary or indicated to localize expansion or to prevent undue strain on piping. Anchors shall consist of heavy steel collars with lugs and bolts for clamping and attaching anchor braces, unless otherwise indicated. Anchor braces shall be installed in the most effective manner to secure the desired results using turnbuckles where required. Supports, anchors, or stays shall not be attached where they will injure the structure or adjacent construction during installation or by the weight of expansion of the pipeline. Where pipe and conduit penetrations of vapor barrier sealed surfaces occur, these items shall be anchored immediately adjacent to each penetrated surface, to provide essentially zero movement within penetration seal. Detailed drawings of pipe anchors shall be submitted for approval before installation.

3.2.16 Building Surface Penetrations

Sleeves shall not be installed in structural members except where indicated or approved. Sleeves in nonload bearing surfaces shall be galvanized sheet metal, conforming to ASTM A653/A653M, Coating Class G-90, 20 gauge. Sleeves in load bearing surfaces shall be uncoated carbon steel pipe, conforming to ASTM A53/A53M, Standard weight. Sealants shall be applied to moisture and oil-free surfaces and elastomers to not less than 1/2 inch depth. Sleeves shall not be installed in structural members.

3.2.16.1 General Service Areas

Each sleeve shall extend through its respective wall, floor, or roof, and shall be cut flush with each surface. Pipes passing through concrete or masonry wall or concrete floors or roofs shall be provided with pipe sleeves fitted into place at the time of construction. Sleeves shall be of such size as to provide a minimum of 1/4 inch all-around clearance between bare pipe and sleeves or between jacketed-insulation and sleeves. Except

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in pipe chases or interior walls, the annular space between pipe and sleeve or between jacket over-insulation and sleeve shall be sealed in accordance with Section 07 92 00 JOINT SEALANTS.

3.2.16.2 Waterproof Penetrations

Pipes passing through roof or floor waterproofing membrane shall be installed through a 17 ounce copper sleeve, or a 0.032 inch thick aluminum sleeve, each within an integral skirt or flange. Flashing sleeve shall be suitably formed, and skirt or flange shall extend not less than 8 inches from the pipe and be set over the roof or floor membrane in a troweled coating of bituminous cement. The flashing sleeve shall extend up the pipe a minimum of 2 inches above the roof or floor penetration. The annular space between the flashing sleeve and the bare pipe or between the flashing sleeve and the metal-jacket-covered insulation shall be sealed as indicated. Penetrations shall be sealed by either one of the following methods.

a. Waterproofing Clamping Flange: Pipes up to and including 10 inches in diameter passing through roof or floor waterproofing membrane may be installed through a cast iron sleeve with caulking recess, anchor lugs, flashing clamp device, and pressure ring with brass bolts. Waterproofing membrane shall be clamped into place and sealant shall be placed in the caulking recess.

b. Modular Mechanical Type Sealing Assembly: In lieu of a waterproofing clamping flange and caulking and sealing of annular space between pipe and sleeve or conduit and sleeve, a modular mechanical type sealing assembly may be installed. Seals shall consist of interlocking synthetic rubber links shaped to continuously fill the annular space between the pipe/conduit and sleeve with corrosion protected carbon steel bolts, nuts, and pressure plates. Links shall be loosely assembled with bolts to form a continuous rubber belt around the pipe with a pressure plate under each bolt head and each nut. After the seal assembly is properly positioned in the sleeve, tightening of the bolt shall cause the rubber sealing elements to expand and provide a watertight seal rubber sealing elements to expand and provide a watertight seal between the pipe/conduit seal between the pipe/conduit and the sleeve. Each seal assembly shall be sized as recommended by the manufacturer to fit the pipe/conduit and sleeve involved. The Contractor electing to use the modular mechanical type seals shall provide sleeves of the proper diameters.

3.2.16.3 Fire-Rated Penetrations

Penetration of fire-rated walls, partitions, and floors shall be sealed as specified in Section 07 84 00 FIRESTOPPING.

3.2.16.4 Escutcheons

Finished surfaces where exposed piping, bare or insulated, pass through floors, walls, or ceilings, except in boiler, utility, or equipment rooms, shall be provided with escutcheons. Where sleeves project slightly from floors, special deep-type escutcheons shall be used. Escutcheon shall be secured to pipe or pipe covering.

3.2.17 Access Panels

Access panels shall be provided for all concealed valves, vents, controls,

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and items requiring inspection or maintenance. Access panels shall be of sufficient size and located so that the concealed items may be serviced and maintained or completely removed and replaced. Access panels shall be as specified in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.

3.2.18 Field Applied Insulation

Field installed insulation shall be as specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS, except as defined differently herein.

3.2.19 Field Painting

Painting required for surfaces not otherwise specified, and finish painting of items only primed at the factory are specified in Section 09 90 00 PAINTS AND COATINGS.

3.2.19.1 Color Coding

Color coding for piping identification is specified in Section 09 90 00 PAINTS AND COATINGS.

3.2.20 Identification Tags

Provide identification tags made of brass, engraved laminated plastic or engraved anodized aluminum indicating service and item number on all valves and dampers. Tags shall be 1-3/8 inch minimum diameter and marking shall be stamped or engraved. Indentations shall be black for reading clarity. Tags shall be attached to valves with No. 12 AWG copper wire, chrome-plated beaded chain or plastic straps designed for that purpose.

3.3 CLEANING AND ADJUSTING

Clean uncontaminated system(s) by evacuation and purging procedures currently recommended by refrigerant and refrigerant equipment manufacturers, and as specified herein, to remove small amounts of air and moisture. Systems containing moderate amounts of air, moisture, contaminated refrigerant, or any foreign matter shall be considered contaminated systems. Restoring contaminated systems to clean condition including disassembly, component replacement, evacuation, flushing, purging, and re-charging, shall be performed using currently approved refrigerant and refrigeration manufacturer's procedures. Restoring contaminated systems shall be at no additional cost to the Government as determined by the Contracting Officer. Water shall not be used in any procedure or test.

3.4 TRAINING COURSE

a. Submit a schedule, at least 2 weeks prior to the date of the proposed training course, which identifies the date, time, and location for the training. The training period shall consist of a total 8 hours of normal working time and start after the system is functionally completed but prior to final acceptance tests.

b. The field posted instructions shall cover all of the items contained in the approved operation and maintenance manuals as well as demonstrations of routine maintenance operations.

c. Submit 6 complete copies of an operation manual in bound 8 1/2 by

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11 inch booklets listing step-by-step procedures required for system startup, operation, abnormal shutdown, emergency shutdown, and normal shutdown at least 4 weeks prior to the first training course. The booklets shall include the manufacturer's name, model number, and parts list. The manuals shall include the manufacturer's name, model number, service manual, and a brief description of all equipment and their basic operating features.

d. Submit 6 complete copies of maintenance manual in bound 8 1/2 x 11 inch booklets listing routine maintenance procedures, possible breakdowns and repairs, and a trouble shooting guide. The manuals shall include piping layouts and simplified wiring and control diagrams of the system as installed.

3.5 REFRIGERANT PIPING TESTS

After all components of the refrigerant system have been installed and connected, subject the entire refrigeration system to pneumatic, evacuation, and startup tests as described herein. Submit a schedule, at least 2 weeks prior to the start of related testing, for each test. Identify the proposed date, time, and location for each test. Conduct tests in the presence of the Contracting Officer. Water and electricity required for the tests will be furnished by the Government. Provide all material, equipment, instruments, and personnel required for the test. Provide the services of a qualified technician, as required, to perform all tests and procedures indicated herein. Field tests shall be coordinated with Section 23 05 93 TESTING, ADJUSTING, AND BALANCING OF HVAC SYSTEMS. Submit 6 copies of the tests report in bound 8 1/2 by 11 inch booklets documenting all phases of the tests performed. The report shall include initial test summaries, all repairs/adjustments made, and the final test results.

3.5.1 Preliminary Procedures

Prior to pneumatic testing, equipment which has been factory tested and refrigerant charged as well as equipment which could be damaged or cause personnel injury by imposed test pressure, positive or negative, shall be isolated from the test pressure or removed from the system. Safety relief valves and rupture discs, where not part of factory sealed systems, shall be removed and openings capped or plugged.

3.5.2 Pneumatic Test

Pressure control and excess pressure protection shall be provided at the source of test pressure. Valves shall be wide open, except those leading to the atmosphere. Test gas shall be dry nitrogen, with minus 70 degree F dewpoint and less than 5 ppm oil. Test pressure shall be applied in two stages before any refrigerant pipe is insulated or covered. First stage test shall be at 10 psi with every joint being tested with a thick soap or color indicating solution. Second stage tests shall raise the system to the minimum refrigerant leakage test pressure specified in ANSI/ASHRAE 15 & 34 with a maximum test pressure 25 percent greater. Pressure above 100 psig shall be raised in 10 percent increments with a pressure acclimatizing period between increments. The initial test pressure shall be recorded along with the ambient temperature to which the system is exposed. Final test pressures of the second stage shall be maintained on the system for a minimum of 24 hours. At the end of the 24 hour period, the system pressure will be recorded along with the ambient temperature to which the system is exposed. A correction factor of 0.3 psi

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will be allowed for each degree F change between test space initial and final ambient temperature, plus for increase and minus for a decrease. If the corrected system pressure is not exactly equal to the initial system test pressure, then the system shall be investigated for leaking joints. To repair leaks, the joint shall be taken apart, thoroughly cleaned, and reconstructed as a new joint. Joints repaired by caulking, remelting, or back-welding/brazing shall not be acceptable. Following repair, the entire system shall be retested using the pneumatic tests described above. The entire system shall be reassembled once the pneumatic tests are satisfactorily completed.

3.5.3 Evacuation Test

Following satisfactory completion of the pneumatic tests, the pressure shall be relieved and the entire system shall be evacuated to an absolute pressure of 300 micrometers. During evacuation of the system, the ambient temperature shall be higher than 35 degrees F. No more than one system shall be evacuated at one time by one vacuum pump. Once the desired vacuum has been reached, the vacuum line shall be closed and the system shall stand for 1 hour. If the pressure rises over 500 micrometers after the 1 hour period, then the system shall be evacuated again down to 300 micrometers and let set for another 1 hour period. The system shall not be charged until a vacuum of at least 500 micrometers is maintained for a period of 1 hour without the assistance of a vacuum line. If during the testing the pressure continues to rise, check the system for leaks, repair as required, and repeat the evacuation procedure. During evacuation, pressures shall be recorded by a thermocouple-type, electronic-type, or a calibrated-micrometer type gauge.

3.5.4 System Charging and Startup Test

Following satisfactory completion of the evacuation tests, the system shall be charged with the required amount of refrigerant by raising pressure to normal operating pressure and in accordance with manufacturer's procedures. Following charging, the system shall operate with high-side and low-side pressures and corresponding refrigerant temperatures, at design or improved values. The entire system shall be tested for leaks. Fluorocarbon systems shall be tested with halide torch or electronic leak detectors.

3.5.5 Refrigerant Leakage

If a refrigerant leak is discovered after the system has been charged, the leaking portion of the system shall immediately be isolated from the remainder of the system and the refrigerant pumped into the system receiver or other suitable container. Under no circumstances shall the refrigerant be discharged into the atmosphere.

3.5.6 Contractor's Responsibility

At all times during the installation and testing of the refrigeration system, take steps to prevent the release of refrigerants into the atmosphere. The steps shall include, but not be limited to, procedures which will minimize the release of refrigerants to the atmosphere and the use of refrigerant recovery devices to remove refrigerant from the system and store the refrigerant for reuse or reclaim. At no time shall more than 3 ounces of refrigerant be released to the atmosphere in any one occurrence. Any system leaks within the first year shall be repaired in accordance with the requirements herein at no cost to the Government

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including material, labor, and refrigerant if the leak is the result of defective equipment, material, or installation.

-- End of Section --

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SECTION 23 35 19.00 20

INDUSTRIAL VENTILATION AND EXHAUST02/10

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA)

AMCA 201 (2002; R 2011) Fans and Systems

AMCA 210 (2007) Laboratory Methods of Testing Fans for Aerodynamic Performance Rating

AMCA 211 (2005; Rev 6 2012) Certified Ratings Programme - Product Rating Manual for Air Fan Performance

AMCA 300 (2008) Reverberant Room Method for Sound Testing of Fans

AMCA 301 (2006; INT 2007) Methods for Calculating Fan Sound Ratings from Laboratory Test Data

AMCA 99 (2010) Standards Handbook

AMCA Licensed Products (Online) Directory of Products Licensed Under the AMCA International Certified Ratings Program

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 11 (1990; R 2008) Load Ratings and Fatigue Life for Roller Bearings

ABMA 9 (1990; R 2008) Load Ratings and Fatigue Life for Ball Bearings

AMERICAN CONFERENCE OF GOVERNMENTAL INDUSTRIAL HYGIENISTS (ACGIH)

ACGIH-2092S (2004) Industrial Ventilation: A Manual of Recommended Practice

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 360 (2005) Specification for Structural Steel Buildings

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2012; Errata 2011) Structural Welding Code - Steel

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AWS D1.3/D1.3M (2008; Errata 2008) Structural Welding Code - Sheet Steel

AWS Z49.1 (2012) Safety in Welding and Cutting and Allied Processes

ASTM INTERNATIONAL (ASTM)

ASTM A1011/A1011M (2012b) Standard Specification for Steel, Sheet, and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability and Ultra-High Strength

ASTM A123/A123M (2012) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A167 (1999; R 2009) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A36/A36M (2008) Standard Specification for Carbon Structural Steel

ASTM A653/A653M (2011) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM B152/B152M (2013) Standard Specification for Copper Sheet, Strip, Plate, and Rolled Bar

ASTM C920 (2011) Standard Specification for Elastomeric Joint Sealants

ASTM D1330 (2004; R 2010) Rubber Sheet Gaskets

ASTM D1654 (2008) Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments

ASTM D2000 (2012) Standard Classification System for Rubber Products in Automotive Applications

ASTM D2665 (2012) Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Drain, Waste, and Vent Pipe and Fittings

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 1 (2000; R 2008; E 2010) Standard for Industrial Control and Systems: General Requirements

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NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 6 (1993; R 2011) Enclosures

NEMA MG 1 (2011; Errata 2012) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 91 (2010) Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists and Noncombustible Particulate Solids

RUBBER MANUFACTURERS ASSOCIATION (RMA)

RMA IP-20 (2007) Specifications for Drives Using Classical V-Belts and Sheaves. Specifications for A, B, C, and D Cross Sections

RMA IP-22 (2007) Specifications for Drives Using Narrow V-Belts and Sheaves (Joint RMA/MPTA), 4th Edition

SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)

SMACNA 1403 (2008) Accepted Industry Practice for Industrial Duct Construction, 2nd Edition

SMACNA 1520 (1999) Round Industrial Duct Construction Standards, 3rd Edition

SMACNA 1922 (2004) Rectangular Industrial Duct Construction Standards, 2nd Edition

SMACNA 1972 CD (2012) HVAC Air Duct Leakage Test Manual - 2nd Edition

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC Paint 20 (2002; E 2004) Zinc-Rich Primers (Type I, Inorganic, and Type II, Organic)

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-DTL-12276 (2006; Rev E; Notice 1 2011) Varnish, Phenolic, Baking

MIL-DTL-24441 (2009; Rev D) Paint, Epoxy-Polyamide, General Specification for

MIL-P-21035 (1991; Rev B; Notice 2 2003) Paint, High Zinc Dust Content, Galvanizing Repair (Metric)

MIL-PRF-23236 (2009; Rev D) Coating Systems for Ship

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Structures

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

CID A-A-272 (Rev B; Notice 1) Caulking Compounds

FS TT-S-001543 (Rev B; Notice 1) Sealing Compound: Silicone Rubber Base (For Calking, Sealing, and Glazing in Buildings and Other Structures)

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910.219 Mechanical Power Transmission Apparatus

UNDERWRITERS LABORATORIES (UL)

UL 214 (1997; Rev thru Aug 2001) Tests for Flame-Propagation of Fabrics and Films

1.2 GENERAL REQUIREMENTS

1.2.1 SMACNA Duct Construction Manuals

The recommendations in the Sheet Metal and Air Conditioning Contractors' National Association (SMACNA) duct construction manuals shall be considered mandatory requirements. Substitute the word "shall" for "should" in these manuals.

1.2.2 Fan Data

For fans include fan curves or rating tables and derating factors. Provide certified performance curves showing total pressure, power, and mechanical efficiency versus flow rate of the operating density and fan speed. All areas of unstable operation shall be indicated. For fans equipped with adjustable capacity controls such as variable inlet or vaneaxial fans with adjustable blade settings, minimum and maximum performance shall be indicated along with performance for fire intermediate settings.

1.2.3 Natural Ventilation

Evaluate natural ventilation for appropriate spaces, and design air distribution systems to operate in the same direction as natural ventilation to reduce energy cost of pumping outdoor air.

1.2.4 Industrial Ventilation and Exhaust Systems

Submit drawings including fan installation drawings; duct systems; supports and anchor location and load imposed.

1.2.5 Start-Up Tests

Submit start-up tests reports in accordance with the paragraph entitled "Testing, Adjusting and Balancing." Submit final test report for the systems tested, describing all test apparatus, instrumentation calculations, factors, flow coefficients, sound levels, and equipment data based on ACGIH-2092S recommended forms or reasonable facsimiles thereof to suit project conditions. Adjustment and setting data shall be included in test report. Submit sound level test reports for high noise level equipment.

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1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Industrial ventilation and exhaust systems; G

SD-03 Product Data

Fans; G

Dust Collection Units; G

Filter Boxes; G

SD-07 Certificates

Welding test procedures; G

Welders' identification; G

SD-06 Test Reports

Fan tests, including sound power level tests; G

Dust Collection exhaust system start-up tests; G

Sound level tests; G

SD-10 Operation and Maintenance Data

Fans, Data Package 2; G

Dust Collection exhaust system, Data Package 2; G

Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA.

SD-11 Closeout Submittals

Posted operating instructions

Submit text of posted operating instructions for ventilation and exhaust systems.

1.4 QUALITY ASSURANCE

1.4.1 Welders' Identification

Submit a listing of the names and identification symbols to be used to identify the work performed by the welder or welding operator who after completing a welded joint shall identify it as his work by applying his assigned symbol for a permanent record.

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1.4.2 Qualification of Welders

Qualify each welder or welding operator by tests using equipment, welding procedures and a base metal and electrode or filler wire from the same compatible group number that will be encountered in the applicable welding test procedures. Welders or welding operators who make acceptable procedure qualification test welds will be considered performance qualified for the welding procedure used. Determine performance qualification in accordance with AWS D1.1/D1.1M. Notify the Contracting Officer 24 hours in advance as to the time and place of tests and wherever practical perform the tests at the work site.

1.4.3 TAB Requirements

Requirements are specified in Section 23 05 93 TESTING, ADJUSTING AND BALANCING.

1.5 POSTED OPERATING INSTRUCTIONS

Provide for ventilation and exhaust system. In addition, permanently mark, drill, and pin as an integral part of device, final adjustment and settings pursuant to testing, adjusting, and balancing.

1.6 SAFETY PRECAUTIONS

1.6.1 Guards and Screens

Provide metal personnel safety guards for normally accessible unducted fan inlets and discharges and moving power transmission components in accordance with OSHA 29 CFR 1910.219.

1.6.2 Welding

Conform to AWS Z49.1 for safety in welding and cutting.

PART 2 PRODUCTS

2.1 FANS, GENERAL REQUIREMENTS FOR

2.1.1 General Performance, Component, and Other Requirements

Fans shall have certified performance ratings as evidenced by conformance to the requirements of AMCA 211, and shall be listed in AMCA Licensed Products, or shall be currently eligible for such listing. Fans shall generally be in accordance with AMCA 99 unless superseded by other requirements stated elsewhere herein. Determine performance data for fans in accordance with AMCA 210. Select fans to minimize the exposure of personnel working in or occupying the immediate installation area. The total sound power level of the fan tests shall not exceed 90 dBA when tested per AMCA 300 and rated per AMCA 301, or it shall be provided with an appropriate attenuation device or devices. Scheduled fan performance is the performance required under specified or indicated installation conditions with specified or indicated accessories. The net installed air performance of the fan, with accessories/appurtenances in place, shall be sufficient to meet the scheduled performance within the limits of the fan rating certification tolerance. Affix the manufacturer's product identification nameplate to each unit. Apply additional requirements for specific service or generic type or class of fan. If nonuniform air flow conditions are likely to be encountered, contact the fan manufacturer to

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ensure that the fan is rated for the additional fan inlet and outlet effect. Install fans to minimize fan system effect in accordance with AMCA 201. Fans shall be listed in the Directory of Products licensed to use AMCA seal.

2.1.2 Bearings and Lubrication

Precision anti-friction or sleeve type with provisions for self-alignment and for radial and thrust loads imposed by the service. Provide water-cooled bearings where required for the service or recommended by the manufacturer.

2.1.2.1 Anti-friction Bearings

Constructed of steel alloys with a certified L-10 minimum rated life of 40,000 hours under load conditions imposed by the service. Rated and selected in accordance with ABMA 9 and ABMA 11. Provide with dust-tight seals suitable for environment and lubricant pressures encountered; cast ferrous metal housing, bolted-split pillow block type where located within fan casings; grease lubricated with provisions to prevent overheating due to excess lubricant; surface ball check type grease supply fittings. Provide manual or automatic grease pressure relief fittings visible from normal maintenance locations. Include lubrication extension tubes where necessary to facilitate safe maintenance during operation and fill tubes with lubricant prior to equipment operation. Prelubricated, sealed, anti-friction bearings, which conform to above specified materials and L-10 life requirements, may be provided for fans requiring less than 1/2 horsepower.

2.1.2.2 Sleeve Bearings

Premounted, self-aligning, continuous oil supply, single or double ring lubricated, insert type, with suitable provisions for shaft expansion and such thrust as may be imposed by service loads. Provide water cooling for shaft surface speed exceeding 1200 feet per minute. Provide each sleeve bearing with approximately 16 ounce capacity constant level oiler and oil level gage. Include on sleeve bearing submittal data: Bearing manufacturing source, type, lubricant, clearances, "L/D" ratio, antifriction metal, belt angle, shaft speed, shaft critical speed, Brinell hardness at journal, and shaft surface finish at journal in micro-inches.

2.1.3 Motors and Motor Starters

Conform to NEMA MG 1 and NEMA ICS 1 and NEMA ICS 2. Motors less than 1 hp shall meet NEMA High Efficiency requirements. Motors 1 hp and larger shall meet NEMA Premium Efficiency requirements. Motors shall not exceed 1800 rpm, unless otherwise indicated, and shall be variable-speed, totally enclosed fan cooled type. Provide part-winding or wye-delta type motor starters with weather resistant NEMA 3R enclosure in accordance with NEMA ICS 6. Provide single-phase motors with inherent thermal overload protection with manual reset. Provide three-phase motors with thermal overload protection in the control panel. Provide permanently lubricated or grease-lubricated ball or roller bearings; auxiliary lubrication and relief fittings on outside of fan casing; arrange grease lines to minimize pressure on bearing seals. Motor power shall not be less than brake power required with blades set at maximum pitch angle at any air delivery from the indicated amount down to 50 percent thereof.

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2.1.4 Guards and Screens

Construct guards and screens to provide, as applicable: required strength and clearance with minimal reduction in free area at fan inlets and discharges; cooling; access panels for tachometer readings; ease of sectional disassembly for maintenance and inspection functions where guard total weight exceeds 50 pounds; weather protection where components are weather exposed. Installed guards and screens shall not negate noise control and vibration isolation provisions.

2.1.5 Power Transmission Components

2.1.5.1 Fan Drives

Direct or V-belt type as indicated. V-belt drives shall conform to RMA IP-20 and RMA IP-22. Drives shall be applied in accordance with the manufacturer's published recommendations, unless specified otherwise. Base power rating of a V-belt drive on maximum pitch diameter of sheaves. Provide classical belt section adjustable sheave type, with a minimum service factor of 1.5 for drives with motors rated up to and including 30 hp. Provide classical section or narrow section, fixed sheave or adjustable sheave type with a minimum 1.5 service factor for drives with motors rated over 30 hp. Provide at least two belts for drives with motors rated one hp and above.

2.1.5.2 Sheaves

Statically and dynamically balanced, machined cast ferrous metal or machined carbon steel, bushing type, secured by key and keyway. Pitch diameter or fixed sheaves and adjustable sheaves, when adjusted to specified limits, shall not be less than that recommended by NEMA MG 1. Select adjustable sheaves that provide the required operating speed with the sheave set at midpoint of its adjustment range. The adjustment range for various size and type belts shall be: 16 percent, minimum for Classical section belts; 12 percent, minimum for Narrow section belts. Belt deflection in adjustable sheave drives shall not exceed 1 1/2 degrees. Provide companion sheaves for adjustable sheave drives with wide groove spacing to match driving sheaves, except that standard fixed pitch spacing may be used for all two-through-four groove drives whose center-to-center dimensions exceed the following: "A" and "B" Section 16 inches; "C" Section 25 inches; "D" Section 36 inches. Furnish endless, static dissipating, oil-resistant, synthetic cloth or filament reinforced elastomer construction belts.

2.2 CENTRIFUGAL FANS

2.2.1 General Requirements for Centrifugal Fans

Provide fan of backward inclined type blades. Arrange fans for indicated service, and construct for the applicable AMCA 99Class pressure ratings as indicated for system design pressure and temperature. Fan shaft shall be solid steel, ground and finished as required for the service, with first critical speed a minimum 25 percent higher than cataloged fan speed. Select fan for maximum efficiency, minimum noise, and stability during all modes of system operation. Vibration isolation mountings shall be spring type and limit vibration transmissibility to a maximum 5 percent of the unbalanced force at lowest equipment speed, unless otherwise specified or indicated. Arrangement and drives shall be as indicated.

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2.2.2 Industrial Exhausters

Single-width, single-inlet type arranged for indicated service and constructed for duty at indicated system design pressure and temperature not to exceed 200 degrees F. Continuously welded carbon steel scroll with required reinforcement, flanged inlet and outlet connections, inlet bolted to scroll side sheet, threaded and plugged scroll drain, bolted access door with gasket; Carbon steel shaft, shaft seal; continuously welded carbon steel impeller assembly. Provide protective coating on fan surfaces exposed to air stream; Motor shall be totally enclosed type. Mount complete assembly including motor, power transmission components, and guards on a common vibration isolation base with spring mountings conforming to requirements indicated.

2.2.3 Utility Sets

Single-width, single-inlet, nonoverloading scroll type. Scroll shall be continuously welded carbon steel with required reinforcement, flanged inlet and outlet connections, streamline orifice inlet bolted and gasketed to scroll side sheet, threaded and piped scroll drain. Carbon steel shaft finished as required and fitted withshaft seal; welded carbon steel impeller assembly; backward inclined flat or single thickness airfoil type impeller blades. Provide protective coating for fan surfaces exposed to air stream and weather. Motor and power transmission components shall be enclosed in ventilated weathertight hood. Discharge shall be fitted with an automatic gravity shutter. Mount complete assembly from individual points of support on rails and vibration isolated by double-rubber-in-shear mountings.

2.3 Dust Collection Units and Dust Collection Exhaust System

Dust collection unit shall perform as an air filtration system used in conjunction with the total containment bullet trap. Unit shall act as an active lead accumulation system that captures and removes airborne lead particulates from within the deflection aperture and deceleration chamber of the total containment bullet trap.

The dust collection unit system shall employ a containment canister where bullet components are directed and contained. The components can then be removed for disposal or recycling. The canister shall be connected to the dust collection unit with an air-tight seal. The canister shall have a locking lid.

The dust collection unit shall maintain an average airflow rate of at least 150 cfm for every 5 feet of linear bullet trap. The velocity of the air entering each chamber shall be maintained at above 360 fpm through the trap's opening.

The filtration section of the dust collection unit shall process airflow at an efficiency rate exceeding 99.99% on 1 micron particulates and 99.9% on 0.12 micron particulates.

The dust collection unit shall incorporate a self-monitoring, self-cleaning process. All filter elements shall be disposable and have an average life expectancy of 5000 operating hours.

Provide a redundant HEPA grade filtration system integrated with the dust collection unit. The HEPA filter shall exceed 99.99% efficiency on 0.12 micron particulates.

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ACCESSORIES:

a. Backwards Incline Fan Systemb. 55 Gallon Drum (For Deposit)c. Local or Remote Start/Stopd. Duct Manifold Systeme. Air Compressor Systemf. Motor Starter

2.4 BASIC MATERIALS

2.4.1 Coated and Uncoated Carbon Steel Sheets, Plates, and Shapes

2.4.1.1 Mill Galvanized Steel Sheet

ASTM A653/A653M, lock forming quality, Coating G-90.

2.4.1.2 Mill Galvanized Steel Shapes

ASTM A36/A36M galvanized in accordance with ASTM A123/A123M.

2.4.1.3 Uncoated (Black) Carbon Steel Sheet

ASTM A1011/A1011M.

2.4.1.4 Uncoated (Black) Carbon Steel Plates and Shapes

ASTM A36/A36M.

2.4.2 Corrosion Protection

Treat equipment fabricated from ferrous metals that do not have a zinc coating conforming to ASTM A123/A123M for prevention of corrosion with a factory coating or paint system that will withstand 125 hours in a salt-spray fog test except that equipment located outdoors shall withstand 3,000 hours. Perform salt-spray fog test in accordance with ASTM B117. Each specimen shall have a standard scribe mark as defined in ASTM D1654. Upon completion of exposure, evaluate and rate the coating or paint system in accordance with procedures A and B of ASTM D1654. The rating of failure at the scribe mark shall be not less than six (average creepage not greater than 1/8 inch). The rating of the unscribed area shall be less than ten (no failure). Thickness of coating or paint system on the actual equipment shall be identical to that on the test specimens with respect to materials, conditions of application, and dry-film thickness.

2.5 HEAT RECOVERY SYSTEMS

Heat recovery systems are specified in Section 23 00 00 AIR SUPPLY DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS.

2.5.1 Filter Boxes

Provide a side access, galvanized steel duct mounted filter box assembly with integral holding frames suitable for accommodating HEPA filters. Provide filter box constructed of minimum 0.05 inch thick galvanized steel with extruded aluminum tracks and individual universal holding frames with polyurethane foam gaskets and positive sealing clips designed to accommodate various standard size filters in various efficiency ranges.

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Provide access doors with positive sealing, heavy duty quick opening half-twist latches and sponge neoprene gasketing on each side of filter box for removal and replacement of filters. For each filter box provide one magnehelic gauge or inclined manometer with static pressure taps, shut-off and vent cocks, and aluminum tubing with range 0.0073 to 0.21 psi.

2.6 MISCELLANEOUS MATERIALS

2.6.1 Filler Metal, Welding

AWS filler metal specification and grade compatible with base materials to develop full joint strength.

2.6.2 Flashing Materials

Mill galvanized, phosphatized, steel sheet with minimum spangle, conforming to ASTM A653/A653M, Coating G90, 24 gage minimum thickness. Mill No. 1 or 2D finished, stainless steel, fully annealed, soft temper, conforming to ASTM A167, Type 304, 0.015 inch minimum thickness. Mill finished copper, conforming to ASTM B152/B152M, minimum 16 ounces per square foot.

2.6.3 Flexible Connectors

2.6.3.1 General Service

Airtight, fire-retardant, fume and vapor resistant, chloroprene or chlorosulfonated polyethylene impregnated, woven fibrous glass fabric, rated for continuous service at 250 degrees F, conforming to UL 214, with 20 ounce per square yard weight for service at 2 inches water gage and under and 30 ounce per square yardweight for service over 2 inches water gage. Provide with or without integral 24 gage mill galvanized sheet metal connectors.

2.6.3.2 Dust Collection Service

1/8 inch thick, single-ply, synthetic fabric reinforced chloroprene suitable for 225 degrees F.

2.6.4 Gaskets

2.6.4.1 Elastomer Buna N

Sheet, 1/8 inch thick, conforming to ASTM D2000, Type 2BG410B14.

2.6.4.2 Elastomer Chloroprene

Sheet, 1/8 inch thick, conforming to ASTM D2000, Type 2BE410B14.

2.6.4.3 Rubber

Sheet, 1/8 inch thick red or black, natural, reclaimed, synthetic rubber or mixture thereof, conforming to ASTM D1330.

2.6.5 Protective Coating Materials

2.6.5.1 Baked Unmodified Phenolic

MIL-DTL-12276, Type II.

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2.6.5.2 Epoxy Coating

Conform to MIL-PRF-23236, Type I, Class 1 or MIL-DTL-24441 system, Formula 150 green primer 3 mils, Formula 151 haze gray 3 mils, and Formula 152 white 3 mils.

2.6.5.3 Inorganic Zinc Coating

SSPC Paint 20, Type I-C (Self-cure type).

2.6.5.4 Galvanizing Repair Paint

Conform to MIL-P-21035.

2.6.6 Sealants

2.6.6.1 Elastomeric

Sealant specified in these specifications or referenced standards as elastomeric or without further qualification, shall be silicone, polyurethane, polysulfide, polyisobutylene, or acrylic terpolymer suitable for the service. For sealing of nongasketed duct joints during fabrication or assembly, sealant shall be polyurethane, acrylic terpolymer or polysulfide. Sealants shall conform to the following:

a. Silicone: Conforming to FS TT-S-001543, single component type, not requiring primed substrate, with manufacturer published estimated life of 30 years and a maximum 5 percent shrinkage when cured.

b. Polyurethane: Conforming to ASTM C920, Type 2, Class A, single component type, not requiring primed substrate, with manufacturer published estimated life of 20 years and a maximum 10 percent shrinkage when cured.

c. Polysulfide: Conforming to ASTM C920, Type 2, Class A, single component type, not requiring primed substrate, with manufacturer published estimated life of 20 years and a maximum 10 percent shrinkage when cured.

d. Polyisobutylene/Butyl: Conforming to CID A-A-272, Type 1, single component type, not requiring primed substrate, with manufacturer published estimated life of 10 years and a maximum 15 percent shrinkage when cured.

e. Acrylic Terpolymer: Conforming to ASTM C920, single component type, not requiring primed substrate, with manufacturer's published estimated life of 20 years and a maximum 10 percent shrinkage when cured.

2.6.6.2 Caulking of Building Surface Penetration

Foamed silicones, two-component, fire-resistant, low-exotherm, room temperature vulcanizing silicone.

2.7 SPECIALTIES

Steel, cast iron, stainless steel, nonferrous metal, or plastic to match duct construction, or as indicated.

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2.7.1 Access Ports, Test

With gasketed screw cap and flange, to suit exhaust service.

2.7.2 Damper Regulators

Incremental position indicating and locking type, with satin finish chrome plated, flush surface mounting cover and regulator box where concealment is required in finished spaces. For splitter dampers, provide splitter tip mounted trunnion brackets with self-locking screw regulator or rods with external swivel joint brackets.

2.7.3 Cast Iron Access Door

Cast iron frame, hinged and gasketed cast iron door, quick closing clamps for watertight sealing, 6 by 9 inches minimum size.

2.8 SUPPORTS AND HANGERS

2.8.1 General Requirements for Supporting Elements

Provide ducting systems and equipment supporting elements including but not limited to building structure attachments; supplementary steel; hanger rods, stanchions and fixtures; vertical duct attachments; horizontal duct attachments; anchors; supports. Design supporting elements for stresses imposed by systems, with a minimum safety factor of 4.0 based on duct being 50 percent full of particulate conveyed. Supporting elements shall conform to SMACNA 1403, SMACNA 1922, SMACNA 1520, and NFPA 91, as applicable, and modified and supplementary requirements specified herein. Do not use weld studs and powder actuated anchoring devices to support mechanical systems components without prior approval.

2.8.2 Vertical Attachments

Provide in accordance with SMACNA Standards, except mill galvanized iron straps shall be a minimum of one inch wide, 16 gage thick.

2.8.3 Horizontal Attachments

Provide as indicated in accordance with SMACNA Standards.

2.8.4 Supplementary Steel

Provide where required to frame structural members between existing members or where structural members are used in lieu of commercially rated supports. Such supplementary steel shall be fabricated in accordance with the AISC 360.

2.8.5 Vibration Isolators

Conform to Section 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT.

2.9 DUCTWORK, DUST COLLECTION

2.9.1 General Requirements for Dust Collection Ductwork

Fabricate system ductwork from black carbon steel, with welded seams and flanged and gasketed joints, minimum 5 percent post-consumer recycled

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content, or minimum 20 percent post-industrial recycled content. Construct duct to handle lead particulate. Provide ductwork in accordance with best practice recommendations and requirements of SMACNA 1922 and SMACNA 1520.

2.9.2 Fabrication of Dust Collection Ductwork

Provide indicated sizes, lengths and configuration without deviation unless otherwise approved. Assemble ductwork airtight as defined under paragraph entitled "Ductwork Structural Integrity and Leakage Testing," in this section and include necessary reinforcements, bracing, supports, framing, gasketing and fastening to guarantee rigid construction and freedom from vibration, airflow induced motion, and excessive deflection. Welding shall conform to requirements specified herein. Provide flanges at equipment and enclosure connections, where necessary for ease of access to equipment or maintenance disassembly, and where indicated. Provide elbows and fittings a minimum 2 gages heavier than straight ducts of equal diameter.

2.9.3 Radius Elbows

Fabricated from butt welded specified piece gore sections or from formed welded or seamless tubing to a minimum centerline radius of 2.0 diameters. Assemble, weld, and finish ground gore sections to eliminate internal projections. Construct gored elbow in accordance with the following:

400 mm diameter and less 16 inches diameter and less

Over 400 mm diameter Over 16 inches diameter

90 degree - 5 piece minimum 90 degree - 7 piece minimum

60 degree - 4 piece minimum 60 degree - 6 piece minimum

45 degree - 3 piece minimum 45 degree - 5 piece minimum

30 degree - 3 piece minimum 30 degree - 4 piece minimum

15 degree - 2 piece minimum 15 degree - 3 piece minimum

2.9.4 Flanged Joints

Gasketed with full face gaskets 1/8 inch thick red or black rubber as specified under paragraph, "Miscellaneous Materials," in this section.

2.9.5 Access Doors

Provide hinged, gasketed, and fitted with snap-action closures access doors. Equip access door with gaskets of common weather stripping type, foamed, closed-cell, elastomer with pressure sensitive adhesive back. Provide cleanout adjacent to every bend and vertical riser. In horizontal duct runs, locate cleanout door with maximum of spacing of 12 feet for ducts 12 inches or less in diameter and 20 feet for larger ducts.

2.9.6 Flexible Connectors

Provide flange secured flexible connectors, conforming to requirements specified under paragraph entitled "Miscellaneous Materials," in this section, utilizing bellows type metal expansion joint.

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PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Installation Requirements

Install in accordance to NFPA 91, and SMACNA 1922, and SMACNA 1520. Provide mounting and supports for equipment, ductwork, and accessories, including structural supports, hangers, vibration isolators, stands, clamps and brackets, access doors, blast gates, and dampers. Install accessories in accordance with the manufacturer's instructions. Construct positive pressure duct inside buildings airtight.

3.1.1.1 Indoor Shooting Range Facilities

For Indoor Shooting Range facilities, conform to OSHA and NIOSH.

3.1.2 Electrical Ground Continuity

Where electrical ground continuity is required, provide brazed connection insulated, multi-strand, copper wire jumpers across points of discontinuity. Provide connection to ground and continuity testing as part of the work of Division 16.

3.1.3 Special Requirements for Installation of Thermoplastic Ductwork

Requirements for installation of thermoplastic ductwork for nonflammable corrosive fume and vapor exhaust:

3.1.3.1 Slope

Slope horizontal ducts one inch in 40 feet in the direction of airflow or one inch in 10 feet in opposite to the direction of airflow. Where necessary, slope duct to common drainage point.

3.1.3.2 Drains

Provide drains at all low points, at internal to duct drainage restrictions, at base of risers, and where indicated. Provide drain connections of one inch IPS couplings with polytetrafluoroethylene paste lubricated plug where drainage piping is not indicated, and where piping is indicated, provide PVC Type DWV piping conforming to ASTM D2665 to points indicated. Provide trap of one inch greater depth than the positive or negative pressure in the duct but not less than 2 inches.

3.1.3.3 Duct Supports

Isolate duct support contact surfaces from supporting steel by 1/4 inch thick closed-cell foamed cellular elastomer insulation material of a width greater than support. Provide duct support system to include additional weight due to collection of condensate and washing water in nondrainable, deflected surface and other areas.

3.1.4 Miscellaneous Sheet Metal Work

Sheet metal thickness, reinforcement and fabrication, where not indicated, shall conform to SMACNA 1403.

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3.1.5 Building Penetrations

3.1.5.1 General Penetration Requirements

Provide properly sized, fabricated, located, and trade coordinated sleeves and prepared openings, for duct mains, branches, and other item penetrations, during the construction of the surface to be penetrated. Provide sleeves for round duct 15 inches and smaller and prepared openings for round duct larger than 15 inches and square or rectangular duct. Fabricate sleeves, except as otherwise specified or indicated, from 20 gage, 0.0396 inch thick mill galvanized sheet metal. Sleeves penetrating load bearing surfaces shall be standard weight galvanized steel pipe. Provide roof penetrations as shown in SMACNA 1403.

3.1.5.2 Framed Opening

Provide framed openings in accordance with approved shop drawings. Refer to paragraph entitled "Fire Dampers," in this section, for related work.

3.1.5.3 Clearances

Provide a minimum one inch clearance between penetrating and penetrated surfaces. Fill clearance space with bulk fibrous glass, or mineral wood or foamed silicone and seal and close.

3.1.5.4 Tightness

Penetration shall be weathertight, vaportight to prevent vapor transmission to conditioned spaces, sound tight to prevent sound transmission to or between normally occupied or finished spaces and deleterious or hazardous substance-tight where substances or gases could migrate.

3.1.5.5 Sealants

Provide sealant of elastomeric type or foamed silicone type, as specified under paragraph entitled "Sealants," in this section. Apply to oil free surfaces to a minimum 3/8 inch depth.

3.1.5.6 Closure Collars

Provide a minimum 4 inches wide, unless otherwise indicated, for exposed ducts and items on each side of penetrated surface, except where equipment is installed. Install collar tight against the surface and fit snugly around penetrating item without contact. Grind sharp edges smooth to prevent damage to penetrating surface. Fabricate collars for round ducts 15 inches in diameter or less from 20 gage, 0.0396 inch nominal thickness, mill galvanized steel. Attach collars a minimum of 4 fasteners to where the opening is 12 inches in diameter or less, and a minimum of 8 fasteners where the opening is 20 inches in diameter or less. Fabricate collars for square and rectangular ducts with a maximum side of 15 inches or less from 20 gage, 0.0396 inch nominal thickness, mill galvanized steel. Fabricate collars for round, square, and rectangular ducts with minimum dimension over 15 inches from 18 gage, 0.0516 inch in nominal thickness, mill galvanized steel. Install collars with fasteners a maximum of 6 inches on center. Where penetrating items are irregularly shaped and where approved, smoothly finished, fire-retardant, foamed silicone elastomer may be utilized without closure collar.

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3.1.6 Installation of Flexible Connectors

Flexibly connect duct connected and vibration isolated fans , ducts crossing building expansion joints and specified or indicated components , except where direct connections are specified or indicated. When fans are started, stopped, or operating, flexible connector surfaces shall be curvilinear, free of stress induced by misalignment or fan reaction forces, and shall not transmit vibration. Leakage shall not be perceptible to the hand when placed within 6 inches of the flexible connector surface or joint. Provide a minimum of 6 inches and a maximum of 2 feet active length with a minimum of one inch of slack, secured at each end by folding in to 24 gage sheet metal or by metal collar frames.

3.1.7 Installation of Supports

3.1.7.1 Selection

Select duct and equipment support system taking into account the best practice recommendations and requirements of SMACNA 1922, SMACNA 1520, and NFPA 91; location and precedence of work under other sections; interferences of various piping and electrical work; facility equipment; building configuration; structural and safety factor requirements; vibration and imposed loads under normal and abnormal service conditions. Indicated support sizes, configurations, and spacings are the minimal type of supporting component required for normal loads. Where installed loads are excessive for the normal support spacings, provide heavier duty components or reduce the element spacing. After system start-up, replace or correct support elements which vibrate and cause noise or possible fatigue failure. Exercise special care to prevent cascading failure.

3.1.7.2 General Requirement for Supports

Securely attach supporting elements to building structural steel or structural slabs. Where supports are required between building structural members provide supplementary structural steel as specified for work under this section. On submittals show location of supports and anchors and loads imposed on each point of support or anchor. Do not hang ductwork or equipment from piping, or other ducts or equipment. Attach supports to structural framing member and concrete slab. Do not anchor supports to metal decking unless a means is provided and approved for preventing the anchor from puncturing the metal decking. Where supports are required, between structural framing members, provide suitable intermediate metal framing. Where C-clamps are used, provide retainer clips. A maximum span of 10 feet shall exist between any two points, with lesser spans as specified or as required by duct assemblies, interferences, and loads imposed or permitted. Provide a minimum one set of two vertical support elements for each point of support and each length of duct, except as otherwise specified. Install supports on both sides of all duct turns, branch fittings, and transitions. Cross-brace hangers sufficiently to eliminate sway. Perforated strap hangers are prohibited. Where ductwork system contains heavy equipment, hang such equipment independently of the ductwork. Coordinate deflection of duct and equipment mountings and conform to Section 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT.

3.1.7.3 Methods of Attachment

Clamp, or weld when approved, attachment to building structural steel in accordance with AWS D1.1/D1.1M. Construct masonry anchors selected for

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overhead applications of ferrous materials only. Install masonry anchors in rotary, non-percussion, electric drilled holes. Self-drilling anchors may be used provided masonry drilling is performed with electric hammers selected and applied in such a manner as to prevent concrete spalling or cracking. Pneumatic tools are prohibited.

3.1.8 Welding

Welding test agenda shall be done in accordance with the applicable provisions of AWS D1.1/D1.1M and AWS D1.3/D1.3M.

3.1.9 Test Ports

Provide test access ports at points required for work under paragraph entitled "Testing, Adjusting, and Balancing," in this section. Locate test ports in straight duct as far as practical downstream of fans, change of direction fittings, takeoffs, interior to duct accessories, and like turbulent flow areas.

3.1.10 Ductwork Cleaning

Protect duct openings from construction debris using temporary caps, flanges, or other approved means. Clean ductwork in accordance with manufacturer's recommendations. Clean dirty duct interior with high velocity water and oil-free air streams or by vacuum cleaning as required by project conditions. After construction is complete but accessible and prior to acceptance, remove all construction debris from exterior surfaces. Do not close duct inspection ports until inspected by the Contracting Officer.

3.1.11 Factory and Field Painting and Finishing

3.1.11.1 Factory Work

Factory finish interior ferrous metal and other specified metallic equipment and component surfaces with manufacturer's standard surface preparation, primer, and finish coating. Factory finish exterior to building space ferrous metal surfaces and other exterior to building and interior to building metallic or nonmetallic surfaces with specified protective coating system in accordance with the paragraph entitled "Protective Coating Material," in this section and otherwise with manufacturer's standard surface preparation, primer and finish which meet the requirements of paragraph entitled "Corrosion Prevention."

3.1.11.2 Field Work

Touch-up or if necessary, repaint factory applied finishes which are marred, damaged, or degraded during shipping, storage, handling, or installation to match the original finish. Clean and prime field or shop fabricated ferrous metals required for the installation specified under this section in accordance with the applicable provisions of Section 09 90 00 PAINTS AND COATINGS. Painting of surfaces not otherwise specified and finish painting of items only primed at the factory or elsewhere, are specified as part of the work under Section 09 90 00 PAINTS AND COATINGS.

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3.2 TESTING, ADJUSTING, AND BALANCING

3.2.1 Ductwork Structural Integrity and Leakage Testing

Leakage test procedure and apparatus shall be in accordance with SMACNA 1972 CD. Total leakage, prorated to length of duct under test, shall not exceed one percent of system capacity. Confirm that duct leakage is less than three percent of coil airflow for new systems. Do not permit leakage in positive pressure ducts in buildings carrying flammable or toxic materials.

3.2.2 Power Transmission Components Adjustment

Test and adjust V-belts and sheaves for proper alignment and tension preliminary to operation and after 72 hours of operation at final speed, in the presence of the Contracting Officer. Belts on drive side shall be uniformly loaded, not bouncing. Align direct-drive couplings to less than half of manufacturer's allowable range of misalignment.

3.2.3 Preliminary Tests

Conduct an operational test on the entire exhaust duct systems, components, and equipment for a period of not less than 6 hours after power transmission components are adjusted. Replace filters, if any, after preliminary tests and prior to conducting final acceptance tests.

3.2.4 Testing, Adjusting, and Balancing Work

Perform work in accordance with the applicable and recommended procedures of: ACGIH-2092S. Provide apparatus, certified, calibrated, instrumentation including that to measure sound levels, motor current, and power factor. Unless approved otherwise, instruments shall be limited to manometers and approved aneroid type gages (such as a Magnehelic). Velometers may be used for low velocity measurements if approved by the Contracting Officer.

3.2.5 Systems Volume Acceptance Criteria

Systems final volume shall be within the following limits:

Fan: Plus 10 percent, minus zero percent of design volume at design temperature

Equipment: Plus or minus 5 percent of design volume at design temperature

Note: Tolerances shall be taken on clean or dirty conditions as indicated on the drawings.

3.2.6 Perform Start-Up Tests for the following:

a. Dust collection exhaust system start-up test.

3.2.7 Sound Level Tests

Report to the Contracting Officer in writing, sound levels higher than 84 dBA at hoods or at workers' normal operating positions at equipment in addition to being included in the required test reports.

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3.3 SYSTEM OPERATION DEMONSTRATION

After systems and equipment testing, adjusting, and balancing has been completed and accepted, demonstrate the complete and correct functioning of systems equipment and controls by operation through normal ranges and sequences, and by simulation of abnormal conditions. Manually and automatically cause every device to function as intended. Readjust, as necessary, any settings and after sufficient operating time, but not less than 6 hours, verify ability of equipment and controls to establish and maintain stable and accurate operation and required system performance. Note any abnormal deviations, such as excessive vibration, noise, and heat, binding damper mechanisms, and incorrect fan rotation. Make any necessary repairs, replacements or adjustments.

3.4 WASTE MANAGEMENT

Separate waste in accordance with the Waste Management Plan, placing copper materials, ferrous materials, and galvanized sheet metal in designated areas for reuse. Close and seal tightly all partly used adhesives and solvents; store protected in a well-ventilated, fire-safe area at moderate temperature.

-- End of Section --

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SECTION 23 81 00.00 20

UNITARY AIR CONDITIONING EQUIPMENT11/09

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI)

AHRI DCUP (Online) Directory of Certified Unitary Products

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)

ANSI/ASHRAE 15 & 34 (2010; Addenda A, B, C, D, E, F, G, H, I, J, K, L, N and O; Errata 2011; INT 1 2012; Errata 2012; Addenda AD, SD, AE and AF 2013) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants

ASHRAE 52.2 (2012; Errata 2013) Method of Testing General Ventilation Air-Cleaning Devices for Removal Efficiency by Particle Size

ASHRAE 55 (2010; Errata 2011; Addenda A 2011; Addenda B, C, D, E and F 2012; Errata 2012; Addenda H and G 2013) Thermal Environmental Conditions for Human Occupancy

ASHRAE 62.1 (2010; Errata 2011; INT 3 2012; INT 4 2012; INT 5 2013) Ventilation for Acceptable Indoor Air Quality

ASHRAE 90.1 - IP (2010; Errata 1-3 2011; INT 1-12 2011; Addenda A, B, C, G, H, J, K, O, P, S, Y, Z, BZ, CG, CI and DS 2012; Errata 4-8 2012; INT 13-16 2012; Errata 9-12 2013; INT 17 2013) Energy Standard for Buildings Except Low-Rise Residential Buildings

ASME INTERNATIONAL (ASME)

ASME B31.5 (2013) Refrigeration Piping and Heat Transfer Components

ASTM INTERNATIONAL (ASTM)

ASTM A123/A123M (2012) Standard Specification for Zinc

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(Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM D1654 (2008) Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments

ASTM F1040 (1987; R 2007) Standard Specification for Filter Units, Air Conditioning, Viscous - Impingement and Dry Types, Replaceable

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 1 (2000; R 2008; E 2010) Standard for Industrial Control and Systems: General Requirements

NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 6 (1993; R 2011) Enclosures

NEMA MG 1 (2011; Errata 2012) Motors and Generators

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-DTL-5541 (2006; Rev F) Chemical Conversion Coatings on Aluminum and Aluminum Alloys

U.S. ENVIRONMENTAL PROTECTION AGENCY (EPA)

Energy Star (1992; R 2006) Energy Star Energy Efficiency Labeling System

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

CID A-A-50502 (Basic) Air Conditioners, (Unitary Heat Pump), Air to Air (3,000 to 300,000 BTU)

FS OO-A-374 (Rev C; Notice 1) Air Conditioners with Remote Condensing Units or Remote Air-Cooled, and Water-Cooled Condenser Units, Unitary

U.S. GREEN BUILDING COUNCIL (USGBC)

LEED NC (2009) Leadership in Energy and Environmental Design(tm) New Construction Rating System

UNDERWRITERS LABORATORIES (UL)

UL 873 (2007; Reprint Jul 2012) Standard for Temperature-Indicating and -Regulating Equipment

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UL 900 (2004; Reprint Feb 2012) Standard for Air Filter Units

1.2 RELATED REQUIREMENTS

Section 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS, applies to this section with the additions and modifications specified herein.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Control system wiring diagrams

SD-03 Product Data

Heat pumps, air to air

Air conditioners

Submit documentation for Energy Star qualifications or meeting FEMP requirements. Indicate Energy Efficiency Rating.

Filters; (LEED NC)

Thermostats

Coatings for finned tube coils

For packaged terminal units, include indoor noise rating.

SD-06 Test Reports

Salt-spray tests

Start-up and initial operational tests

SD-08 Manufacturer's Instructions

Heat pumps, air to air

Air conditioners

Filters

Thermostats

Refrigerant piping and accessories

SD-10 Operation and Maintenance Data

Heat pumps, air to air, Data Package 3

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Air conditioners, Data Package 3

Filters, Data Package 2

Thermostats, Data Package 2

Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA and Section 01 78 24.00 20 FACILITY ELECTRONIC OPERATION AND MAINTENANCE SUPPORT INFORMATION (eOMSI).

SD-11 Closeout Submittals

Posted operating instructions

1.4 QUALITY ASSURANCE

1.4.1 Modification of References

Accomplish work in accordance with the referenced publications, except as modified by this section. Consider the advisory or recommended provisions to be mandatory, as though the word "shall" had been substituted for the words "should" or "could" or "may," wherever they appear. Interpret reference to "the Authority having jurisdiction," "the Administrative Authority," "the Owner," or "the Design Engineer" to mean the Contracting Officer.

1.4.2 Detail Drawing

For refrigerant piping, submit piping, including pipe sizes. Submit control system wiring diagrams.

1.4.3 Safety

Design, manufacture, and installation of unitary air conditioning equipment shall conform to ANSI/ASHRAE 15 & 34.

1.4.4 Posted Operating Instructions

Submit posted operating instructions for each packaged air conditioning unit.

1.4.5 Sizing

Size equipment based on Design Manual CS from the Air Conditioning Contractors of America; do not oversize.

1.5 REFRIGERANTS

Refrigerants shall have an Ozone Depletion Factor (ODF) of 0.05 or less. The ODF shall be in accordance with the "Montreal Protocol On Substances That Deplete The Ozone Layer," September 1987, sponsored by the United Nations Environment Programme. CFCs and HCFCs and Halons shall not be permitted. Refrigerant shall be an approved alternative refrigerant per EPA's Significant New Alternative Policy (SNAP) listing.

1.6 ENVIRONMENTAL REQUIREMENTS

For proper Indoor Environmental Quality, maintain positive pressure within the building. Ventilation shall meet or exceed ASHRAE 62.1 and all

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published addenda. Meet or exceed filter media efficiency as tested in accordance with ASHRAE 52.2. Thermal comfort shall meet or exceed ASHRAE 55.

PART 2 PRODUCTS

2.1 HEAT PUMPS, AIR TO AIR

CID A-A-50502, except as modified in this article; Type II, Class 1. List units with capacities smaller than 135,000 Btu/hr in the AHRI DCUP; in lieu of listing in the ARI Directory, a letter of certification from ARI that the units have been certified and will be listed in the next Directory will be acceptable. Provide factory assembled units complete with accessories, wiring, piping, and controls. Provide units with air filters as specified in the paragraph entitled "Filters."

2.1.1 Energy Performance

Minimum energy efficiency shall be in accordance with ASHRAE 90.1 - IP.

2.1.2 Air Coils

Extended-surface fin and tube type with seamless copper tubes with copper or aluminum fins securely bonded to the tubes. Provide fins of aluminum alloy 7072. Provide a coating on outdoor air coils as specified in the paragraph entitled "Coatings for Finned Tube Coils." Coils to be coated shall be part of manufacturer's standard product for capacities and ratings indicated and specified. Provide plate type fins.

2.1.3 Supplemental Electric Heaters

Provide electrical resistance heaters integral with the unit where indicated. Heaters shall have a total capacity as indicated. Provide internal fusing for heaters.

2.1.4 Compressors

For compressors above 20 tons, compressor speed shall not exceed 3450 rpm. For equipment over 10 tons, provide automatic capacity reduction of at least 50 percent of rated capacity. Capacity reduction may be accomplished by cylinder unloading, use of multiple, but not more than four compressors, or a combination of the two methods. Units with cylinder unloading shall start with capacity reduction devices in the unloaded position. Units with multiple compressors shall have a means to sequence starting of compressors. Provide compressors with devices to prevent short cycling when shutdown by safety controls. Provide reciprocating compressors with crankcase heaters, and vibration isolators.

2.1.5 Mounting Provisions

Provide units that permit mounting as indicated. Provide suitable lifting attachment plates to enable equipment to be lifted to normal position.

2.1.6 Temperature Controls

Provide controls as specified in CID A-A-50502 and as modified herein. Provide indoor thermostats of the adjustable type that conform to applicable requirements of UL 873. Provide manual means for temperature set-back. Provide thermostats capable of controlling supplemental heat as specified in CID A-A-50502. Provide a manual selector switch or other

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means to permit the supplementary heater to be energized when the heat pump compressor and associated equipment are inoperative. Control supplementary heater with the room thermostat while bypassing the outdoor thermostat. Locate switch adjacent to or as an integral part of the room thermostat. An indicator light on the room thermostat or manual heat switch shall indicate when supplementary heaters are operating.

2.1.7 Accessories

In addition to accessories specified in CID A-A-50502, provide the following accessories for heat pump units.

a. Protective grille around outside unit coils

b. Start capacitor kit

2.2 AIR CONDITIONERS

2.2.1 Split-System Type

FS OO-A-374, except as modified herein; Type SPY, Style A, Class 1. Additional requirements for various system components are specified in this paragraph; however, basic requirements for the system and system components are contained in FS OO-A-374. Provide separate assemblies designed to be used together. Base ratings on the use of matched assemblies. Provide performance diagrams for units with capacities not certified by ARI to verify that components of the air conditioning system furnished will satisfy the capacity requirement specified or indicated. Minimum energy efficiency shall be in accordance with ASHRAE 90.1 - IP, at a minimum. List units with capacities smaller than 135,000 Btu/hr in the AHRI DCUP; in lieu of listing in the ARI Directory, a letter of certification from ARI that units have been certified and will be listed in the next Directory will be acceptable. Provide capacity, electrical characteristics and operating conditions as indicated.

2.2.2 Compressors

For compressors over 20 tons, compressor speed shall not exceed 3450 rpm. For systems over 10 tons provide automatic capacity reduction of at least 50 percent of rated capacity. Capacity reduction may be accomplished by cylinder unloading, use of multi- or variable speed compressors, use of multiple, but not more than four compressors, or a combination of the two methods. Units with cylinder unloading shall start with capacity reduction devices in the unloaded position. Units with multiple compressors shall have means to sequence starting of compressors. Provide compressors with devices to prevent short cycling when shut down by safety controls. Device shall delay operation of compressor motor for at least 3 minutes but not more than 6 minutes. Provide a pumpdown cycle for units 20 tons and over. Provide reciprocating compressors with crankcase heaters in accordance with the manufacturer's recommendations. If compressors are paralleled, provide not less than two independent circuits.

2.2.3 Coils

On coils with all-aluminum construction, provide tubes of aluminum alloy 1100, 1200, or 3102; provide fins of aluminum alloy 7072; and provide tube sheets of aluminum alloy 7072 or 5052. Provide a separate air cooled condenser circuit for each compressor or parallel compressor installation. Provide a coating on condenser coils and fins as specified in the paragraph

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entitled "Coatings for Finned Tube Coils." Coils to be coated shall be part of manufacturer's standard product for capacities and ratings indicated and specified. Provide plate type fins.

2.2.4 Condenser Controls

Provide start-up and head pressure controls to allow for system operation at ambient temperatures down to 14 degrees F.

2.2.5 Fans

Provide belt-driven evaporator fans with adjustable pitch pulleys; except for units less than 5 ton capacity, direct drive with at least two speed taps may be used. Select pulleys at approximately midpoint of the adjustable range.

2.2.6 Filters

Provide filters of the type specified in this section.

2.2.7 Thermostats

Provide adjustable type that conforms to applicable requirements of UL 873. Provide cooling type with contacts hermetically sealed against moisture, corrosion, lint, dust, and foreign material. Design to operate on not more than 1.5 degrees Fdifferential and of suitable range calibrated in degrees F. Provide independent temperature sensing elements electrically connected to control the compressor. Provide system selector switches to provide "COOL" and "OFF" and fan selector switches to provide "AUTOMATIC" and "ON." Provide relays, contactors, and transformers located in a panel or panels for replacement and service.

2.2.7.1 Cooling

a. When thermostat is in "COOL" position with fan selector switch in "AUTO" position, compressor, evaporator fan, and condenser fan shall cycle together.

b. When thermostat is in "COOL" position with fan selector switch in "ON" position, compressor, and condenser fan shall cycle together and evaporator fan shall run continuously.

2.2.7.2 Supply Air Fan

a. When fan selector switch is in "AUTO" position with thermostat in "OFF" position, fan shall not run.

b. When fan selector switch is in "ON" position, fan shall run continuously.

2.3 FILTERS

Provide filters to filter outside air and return air and locate as indicated. Provide replaceable (throw-away) type. Filters shall conform to UL 900, Class 1. Polyurethane filters shall not be used on units with multiframe filters. Filters shall contain a minimum of 85 percent biobased material like cotton.

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2.3.1 Replaceable Type Filters

ASTM F1040 throw-away frames and media, standard dust holding capacity, 350 fpm maximum face velocity, and one inch thick. Filters shall have a minimum efficiency reporting value (MERV) of 8 when tested in accordance with ASHRAE 52.2.

2.4 COATINGS FOR FINNED TUBE COILS

Where stipulated in equipment specifications of this section, coat finned tube coils of the affected equipment as specified below. Apply coating at the premises of a company specializing in such work. Degrease and prepare for coating in accordance with the coating applicator's procedures for the type of metals involved. Completed coating shall show no evidence of softening, blistering, cracking, crazing, flaking, loss of adhesion, or "bridging" between the fins.

2.4.1 Phenolic Coating

Provide a resin base thermosetting phenolic coating. Apply coating by immersion dipping of the entire coil. Provide a minimum of two coats. Bake or heat dry coils following immersions. After final immersion and prior to final baking, spray entire coil with particular emphasis given to building up coating on sheared edges. Total dry film thickness shall be 2.5 to 3.0 mils.

2.4.2 Chemical Conversion Coating with Polyelastomer Finish Coat

Dip coils in a chemical conversion solution to molecularly deposit a corrosion resistant coating by electrolysis action. Chemical conversion coatings shall conform to MIL-DTL-5541, Class 1A. Cure conversion coating at a temperature of 110 to 140 degrees F for a minimum of 3 hours. Coat coil surfaces with a complex polymer primer with a dry film thickness of 1 mil. Cure primer coat for a minimum of 1 hour. Using dip tank method, provide three coats of a complex polyelastomer finish coat. After each of the first two finish coats, cure the coils for 1 hour. Following the third coat, spray a fog coat of an inert sealer on the coil surfaces. Total dry film thickness shall be 2.5 to 3.0 mils. Cure finish coat for a minimum of 3 hours. Coating materials shall have 300 percent flexibility, operate in temperatures of minus 50 to plus 220 degrees F, and protect against atmospheres of a pH range of 1 to 14.

2.5 MOTORS AND STARTERS

NEMA MG 1, NEMA ICS 1, and NEMA ICS 2. Variable speed. Motors less than 1 hp shall meet NEMA High Efficiency requirements. Motors 1 hp and larger shall meet NEMA Premium Efficiency requirements. Determine specific motor characteristics to ensure provision of correctly sized starters and overload heaters. Provide motors to operate at full capacity with a voltage variation of plus or minus 10 percent of the motor voltage rating. Motor size shall be sufficient for the duty to be performed and shall not exceed its full load nameplate current rating when driven equipment is operated at specified capacity under the most severe conditions likely to be encountered. When motor size provided differs from size indicated or specified, the Contractor shall make the necessary adjustments to the wiring, disconnect devices, and branch circuit protection to accommodate equipment actually provided. Provide general-purpose weather-resistant type starter enclosures in accordance with NEMA ICS 6.

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2.6 REFRIGERANT PIPING AND ACCESSORIES

Provide accessories as specified in Section 23 23 00 REFRIGERANT PIPING. Install per that section and the manufacturer's requirements.

2.7 FINISHES

Provide steel surfaces of equipment including packaged terminal units, heat pumps, and air conditioners, that do not have a zinc coating conforming to ASTM A123/A123M, or a duplex coating of zinc and paint, with a factory applied coating or paint system. Provide a coating or paint system on actual equipment identical to that on salt-spray test specimens with respect to materials, conditions of application, and dry-film thickness.

2.8 SOURCE QUALITY CONTROL

2.8.1 Salt-Spray Tests

Salt-spray test the factory-applied coating or paint system of equipment including packaged terminal units, heat pumps, and air conditioners in accordance with ASTM B117. Conduct test for 3000 hours for equipment installed outdoors, or 125 hours for equipment installed indoors. Test specimens shall have a standard scribe mark as defined in ASTM D1654. Upon completion of exposure, evaluate and rate the coating or paint system in accordance with procedures A and B of ASTM D1654. Rating of failure at the scribe mark shall not be less than six, average creepage not greater than 1/8 inch. Rating of the unscribed area shall not be less than 10, no failure.

PART 3 EXECUTION

3.1 EQUIPMENT INSTALLATION

Install equipment and components in a manner to ensure proper and sequential operation of equipment and equipment controls. Install equipment not covered in this section, or in manufacturer's instructions, as recommended by manufacturer's representative. Provide proper foundations for mounting of equipment, accessories, appurtenances, piping and controls including, but not limited to, supports, vibration isolators, stands, guides, anchors, clamps and brackets. Foundations for equipment shall conform to equipment manufacturer's recommendation, unless otherwise indicated. Set anchor bolts and sleeves using templates. Provide anchor bolts of adequate length, and provide with welded-on plates on the head end embedded in the concrete. Level equipment bases, using jacks or steel wedges, and neatly grout-in with a nonshrinking type of grouting mortar. Locate equipment to allow working space for servicing including shaft removal, disassembling compressor cylinders and pistons, replacing or adjusting drives, motors, or shaft seals, access to water heads and valves of shell and tube equipment, tube cleaning or replacement, access to automatic controls, refrigerant charging, lubrication, oil draining and working clearance under overhead lines. Provide electric isolation between dissimilar metals for the purpose of minimizing galvanic corrosion.

3.1.1 Unitary Air Conditioning System

Install as indicated, in accordance with requirements of ANSI/ASHRAE 15 & 34, and the manufacturer's installation and operational instructions.

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3.2 PIPING

Brazing, bending, forming and assembly of refrigerant piping shall conform to ASME B31.5. Refer to Specification Section 23 23 00 REFRIGERANT PIPING for installation requirements. Install per that section and the manufacturer's requirements.

3.3 AUXILIARY DRAIN PANS, DRAIN CONNECTIONS, AND DRAIN LINES

Provide auxiliary drain pans under units located above finished ceilings or over mechanical or electrical equipment where condensate overflow will cause damage to ceilings, piping, and equipment below. Provide separate drain lines for the unit drain and auxiliary drain pans. Trap drain pans from the bottom to ensure complete pan drainage. Provide drain lines full size of drain opening. Traps and piping to drainage disposal points shall conform to Section 22 00 00 PLUMBING, GENERAL PURPOSE.

3.4 ACCESS PANELS

Provide access panels in accordance with specification section 05 50 13 MISCELLANEOUS METAL FABRICATIONS for concealed valves, controls, dampers, and other fittings requiring inspection and maintenance.

3.5 AIR FILTERS

Provide access space for servicing filters. Install filters with suitable sealing to prevent bypassing of air.

3.6 FLASHING AND PIPE PENETRATIONS

Provide flashing for equipment supports and roof penetrations and flashing where piping or ductwork passes through exterior walls in accordance with Section 07 60 00 FLASHING AND SHEET METAL.

3.7 IDENTIFICATION TAGS AND PLATES

Provide equipment, gages, thermometers, valves, and controllers with tags numbered and stamped for their use. Provide plates and tags of brass orsuitable nonferrous material, securely mounted or attached. Provide minimum letter and numeral size of 1/8 inch high.

3.8 FIELD QUALITY CONTROL

3.8.1 Leak Testing

Upon completion of installation of air conditioning equipment, test factory- and field-installed refrigerant piping with an electronic-type leak detector. Use same type of refrigerant to be provided in the system for leak testing. When nitrogen is used to boost system pressure for testing, ensure that it is eliminated from the system before charging. Minimum refrigerant leak field test pressure shall be as specified in ANSI/ASHRAE 15 & 34, except that test pressure shall not exceed 150 psig on hermetic compressors unless otherwise specified as a low side test pressure on the equipment nameplate. If leaks are detected at time of installation or during warranty period, remove the entire refrigerant charge from the system, correct leaks, and retest system.

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3.8.2 Evacuation, Dehydration, and Charging

After field charged refrigerant system is found to be without leaks or after leaks have been repaired on field-charged and factory-charged systems, evacuate the system using a reliable gage and a vacuum pump capable of pulling a vacuum of at least one mm Hg absolute. Evacuate system in accordance with the triple-evacuation and blotter method or in accordance with equipment manufacturer's printed instructions and recharge system.

3.8.3 Start-Up and Initial Operational Tests

Test the air conditioning systems and systems components for proper operation. Adjust safety and automatic control instruments as necessary to ensure proper operation and sequence. Conduct operational tests for not less than 8 hours.

3.8.4 Performance Tests

Upon completion of evacuation, charging, startup, final leak testing, and proper adjustment of controls, test the systems to demonstrate compliance with performance and capacity requirements. Test systems for not less than 8 hours, record readings hourly. At the end of the test period, average the readings, and the average shall be considered to be the system performance. Refer to Specification Section 23 05 93 TESTING, ADJUSTING AND BALANCING for additional requirements.

3.9 WASTE MANAGEMENT

Separate waste in accordance with the Waste Management Plan, placing copper materials in designated areas for reuse. Close and seal tightly all partly used adhesives and solvents; store protected in a well-ventilated, fire-safe area at moderate temperature.

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SECTION 23 81 28.10 22

VARIABLE REFRIGERANT FLOW (VRF) MULTI-SPLIT AIR CONDITIONING AND HEAT PUMPEQUIPMENT07/13

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)

ANSI/ASHRAE 15 & 34 (2010; Addenda A, B, C, D, E, F, G, H, I, J, K, L, N and O; Errata 2011; INT 1 2012; Errata 2012; Addenda AD, SD, AE and AF 2013) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants

ASHRAE 90.1 - IP (2010; Errata 1-3 2011; INT 1-12 2011; Addenda A, B, C, G, H, J, K, O, P, S, Y, Z, BZ, CG, CI and DS 2012; Errata 4-8 2012; INT 13-16 2012; Errata 9-12 2013; INT 17 2013) Energy Standard for Buildings Except Low-Rise Residential Buildings

ETL TESTING LABORATORIES (ETL)

ETL DLP (updated continuously) Directory of ETL Listed Products

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 9001 (2008; Corr 1 2009) Quality Management Systems- Requirements

ISO 14001 (2009; Corr 1) Environmental Management Systems - Requirements With Guidance for Use - TECHNICAL CORRIGENDUM 1 - Second Edition

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2011; Errata 2 2012) National Electrical Code

U.S. ENVIRONMENTAL PROTECTION AGENCY (EPA)

Energy Star (1992; R 2006) Energy Star Energy Efficiency Labeling System

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1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Control system wiring diagrams

Submit Shop Drawings, at least 5 weeks prior to beginning construction, provided in adequate detail to demonstrate compliance with contract requirements.

SD-03 Product Data

Indoor Units; G

Outdoor Units; G

Refrigerant Valves; G

SD-06 Test Reports

Performance Tests; G

SD-08 Manufacturer's Instructions

Manufacturers Installation Instructions

Operation and Maintenance Training

SD-10 Operation and Maintenance Data

Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA and 01 78 24.00 20 FACILITY ELECTRONIC OPERATION AND MAINTENANCE SUPPORT INFORMATION (eOMSI).

Operation and Maintenance Manuals

Indoor Units; G, Data Package 3

Outdoor Units; G, Data Package 3

1.3 GENERAL REQUIREMENTS

Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS applies to work specified in this section.

Section 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT, applies to work specified in this section.

Section 23 23 00 REFRIGERANT PIPING, applies to work specified in this section.

1.4 SYSTEM DESCRIPTION

a. Provide a complete air cooled, multiple evaporator, direct expansion

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heating and cooling system. The system shall consist of multiple evaporators using PID control The outdoor unit shall be a direct expansion (DX), air-cooled heat recovery air-conditioning system, variable speed driven compressor multi zone split system, using R410A refrigerant. The outdoor unit may connect an indoor evaporator capacity up to 200 percent to that of the outdoor condensing unit capacity. All indoor units shall each be capable of operating separately with individual temperature control.

b. The outdoor units shall be interconnected to the indoor units in accordance with the manufacturer's engineering data detailing each available indoor unit. The indoor units shall be connected to the outdoor utilizing the manufacturer's specified piping joints and headers.

1.5 QUALITY ASSURANCE

a. The units shall be listed by ETL DLP and bear the ETL label.

b. All wiring shall be in accordance with NFPA 70, the National Electric Code.

c. The system will bear the Energy Star label.

d. The system will be produced in an ISO 9001 and ISO 14001 facility. The system shall be factory tested for safety and function.

e. The outdoor unit shall be factory charged with R410A.

1.6 DELIVERY, STORAGE, AND HANDLING

Unit shall be stored and handled according to the manufacturer's recommendations.

1.7 WARRANTY

The units shall have a manufacturer's warranty for a period of one (1) year from date of installation. The units shall have a limited labor warranty for a period of one (1) year from date of installation. The compressors shall have a minimum warranty of 5 years parts and labor.

PART 2 PRODUCTS

2.1 OUTDOOR UNITS

2.1.1 General

The outdoor unit shall be designed specifically for use with all other series components.

a. The outdoor unit shall be factory assembled and pre-wired with all necessary electronic and refrigerant controls. The refrigeration circuit of the condensing unit shall consist of a scroll compressor, motors, fans, condenser coil, electronic expansion valve, solenoid valves, 4 way valve, distribution headers, capillaries, filters, shut off valves, oil separators, service parts, liquid receivers and accumulators.

b. Both liquid and suction lines must be individually insulated between

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the outdoor and indoor units.

c. The outdoor unit can be wired and piped with outdoor unit access from left, right or rear.

d. The connection ratio of indoor units must be individually insulated between the outdoor and indoor units.

e. The sound pressure dB(A) at rated conditions shall be a value of 58 decibels at 3 feet from the front of the unit. The outdoor unit shall be capable of operating at further reduced noise during the night time.

f. The system will automatically restart operation after a power failure and will not cause any settings to be lost, thus eliminating the need for re-programming.

g. The outdoor unit shall be modular in design and should allow for a side-by-side installation with minimum spacing.

h. The following safety devices shall be included on the condensing unit: high pressure switch, control circuit fuses, crankcase heaters, fusible plug, high pressure switch, overload relay, inverter overload protector, thermal protectors for compressor and fan motors, overcurrent protection for the inverter and anti-recycling timers. To ensure the liquid refrigerant does not flash when supplying to the various fan coil units, the circuit shall be provided with a sub-cooling feature. Oil recovery cycle shall be automatic occurring 2 hours after start of operation and then every 8 hours of operation.

i. The outdoor unit shall be capable of heating operation at 0 degrees F dry bulb ambient temperature without additional low ambient controls.

2.1.2 Condenser Coil

a. The condenser coil shall be manufactured from copper tubes expanded into aluminum fins to form a mechanical bond.

b. The coil shall be of a waffle louver fin and high heat exchanger, rifled bore tube design to ensure highly efficient performance.

c. The coils shall be complete with corrosion treatment of an acrylic resin type. The thickness of the coating must be between 2.0 to 3.0 microns.

d. Coils shall be tested in accordance with ANSI/ASHRAE 15 & 34 at the factory and be suitable for the working pressure of the installed system.

2.1.3 Compressor

a. The scroll compressor shall be variable speed controlled which is capable of changing the speed to follow the variations in total cooling load as determined by the suction gas pressure as measured in the condensing unit.

b. The inverter driven compressor in each condensing unit shall be of highly efficient reluctance DC, hermetically sealed scroll.

c. The capacity control range shall be 6 to 100 percent, with 29

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individual capacity steps. Each non-inverter compressor shall also be of the hermetically sealed scroll type.

d. Each compressor shall be equipped with a crankcase heater, high pressure safety switch, and internal thermal overload protector.

e. Oil separator shall be standard with equipment together with an oil balancing circuit.

f. The compressor shall be mounted to avoid the transmission of vibration.

g. The control wiring shall be a two-wire multiplex transmission system, making it possible to connect multiple indoor units to one outdoor unit with 2-cable wire, thus simplifying the wiring operation.

h. The VRV system must interface with the BACnet DDC system as described in Section 23 09 23.13 22 BACnet DIRECT DIGITAL CONTROL SYSTEMS FOR HVAC.

i. The control wiring lengths are: outdoor to indoor unit is 6,665 ft, outdoor to central controller is 3,330 ft, outdoor unit to remote controller is 1,665 ft. Wiring type is 16 AWG, 2 wire, non-polarity, non-shielded, stranded.

2.2 BRANCH SELECTOR BOX FOR VRV HEAT RECOVERY SYSTEM

2.2.1 General

The branch selector boxes shall be provided for use with heat recovery system components.

a. These selector boxes shall be factory assembled, wired and piped.

b. The sum of connected capacity of all indoor air handlers shall range up to 200 percent of rated capacity.

c. These branch controllers must be run tested at the factory.

d. These selector boxes must be mounted indoors.

e. When simultaneously heating and cooling, the units in heated mode shall energize their sub cooling solenoid valve.

2.2.2 Unit Cabinet

a. These units shall have a galvanized steel plate casing.

b. Each cabinet shall house multiple refrigeration control valves and a liquid gas separator.

c. The cabinet shall contain a tube in tube heat exchanger.

d. The unit shall have sound absorption thermal insulation material made of flame and heat resistant foamed polyethylene.

2.2.3 Refrigerant Valves

a. The unit shall be furnished with a 3-way refrigerant valve to control the direction of refrigerant flow.

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b. Electronic expansion valves shall be used to control the variable refrigerant flow.

c. The refrigerant connections must be of the solder-joint type.

2.2.4 Drainage

a. The unit shall not require drainage.

b. The control voltage between the indoor and outdoor unit shall be non-shielded 2 conductor cable.

2.3 INDOOR UNITS - CEILING CONCEALED DUCTED UNIT

2.3.1 General

The indoor unit shall be a built-in ceiling concealed fan coil unit, operable with R410A refrigerant, equipped with an electronic expansion valve, for installation into the ceiling cavity. The unit shall be constructed of a galvanized steel casing. It shall be available from 7,500 Btu/h to 48,000 Btu/h capacities and compatible with the outdoor unit heat pump and heat recovery model. It shall be a horizontal discharge air with horizontal return air or bottom return air configuration. Unit shall be a low height (11-7/8") construction. Computerized PID control shall be used to maintain room temperature within 1 degrees F. The unit shall be equipped with a programmed drying mechanism that dehumidifies while inhibiting changes in room temperature. Included as standard equipment, MERV B filters, isolation valves at evaporator, a condensate drain pan and drain pump kit. The indoor units sound pressure shall range from 35 dB(A) to 43 dB(A) at low speed 5 feet below the suction grille.

2.3.2 Indoor Unit

a. The indoor unit shall be completely factory assembled and tested. Included in the unit is factory wiring, piping, electronic proportional expansion valve, control circuit board, fan motor thermal protector, solder-joint connections, condensate drain pan, condensate drain pump, self-diagnostics, auto-restart function, 3-minute fused time delay, and test run switch. The unit shall have an adjustable external static pressure switch.

b. Indoor unit and refrigerant pipes will be charged with dehydrated air prior to shipment from the factory.

c. Both refrigerant lines shall be insulated from the outdoor unit.

d. Return air shall be through a net mold resistant filter.

e. The indoor units shall be equipped with a condensate pan and condensate pump.

f. The indoor units shall be equipped with a return air thermistor.

g. Switch box shall be reached from the side or bottom for ease of service and maintenance.

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2.3.3 Unit Cabinet

The cabinet shall be located into the ceiling and ducted to the supply and return openings. The cabinet shall be constructed with sound absorbing foamed polystyrene and polyethylene insulation. Optional high efficiency air filters shall be available for the unit.

2.3.4 Fan

The fan shall be direct-drive Sirocco type fan, statically and dynamically balanced impeller with high and low fan speeds available. The air flow rate shall be available in high and low settings. The fan motor shall be thermally protected and shall be tested in accordance with ASHRAE 90.1 - IP.

2.3.5 Filter

The return air shall be filtered by means of a washable long-life filter with mildew proof resin.

2.3.6 Coil

a. Coils shall be the direct expansion type constructed from copper tubes expanded into aluminum fins to form a mechanical bond.

b. The coil shall be a waffle louver fin and high heat exchange, rifled bore tube design to ensure highly efficient performance.

c. The coil shall be a 3 row cross fin copper evaporator coil with 14 FPI design completely factory tested.

d. The refrigerant connections shall be solder-joint connections and the condensate will be 1 -1/4 inch outside diameter PVC.

e. A condensate pan shall be located under the coil.

f. A condensate pump shall be located below the coil in the condensate pan with a built in safety arm.

g. A thermistor will be located on the liquid and gas line.

2.3.7 Electrical

Transmission (control) wiring between the indoor and outdoor unit shall be a maximum of 3,280 feet (total 6,560 feet). Transmission (control) wiring between the indoor and remote controller shall be a maximum distance of 1,640 feet.

2.3.8 Control

The unit shall have controls to perform input functions necessary to operate the system. The unit shall be compatible with interfacing with connection to BACnet networks. Submit control system wiring diagrams

2.3.9 Accessories

Provide a wall mounted, hard wired remote sensor kit for ceiling-embedded type fan coils. The temperature sensor shall be located where indicated in the documents, if not indicated, contractor shall request a location from the engineer in writing.

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2.4 INDIVIDUAL ZONE CONTROLLER - WIRED REMOTE CONTROLLER

2.4.1 Physical Characteristics

The control system shall be a neutral color plastic material. Each control may have a Liquid Crystal Display (LCD).

2.4.2 Electrical Characteristics

2.4.2.1 General

From each circuit board to the controls, the electrical voltage shall be 16 volts DC.

2.4.2.2 Wiring

Control wiring shall be installed in a daisy chain configuration from indoor unit to indoor unit then to the branch selector box and outdoor unit. Control wiring shall run from the indoor unit terminal block to the specific. The wire shall be a non-shielded, 2-core sheathed vinyl cord or cable, size AWG18-2.

2.4.3 Controller Characteristics

The wired remote controller shall be able to control 1 group (maximum of 16 fan coil units) and shall be able to function as follows:

a. The controller shall have a maximum wiring length of 1,640 feet.

b. The controller shall have a self diagnosis function that constantly monitors the system for malfunctions (total of 80 components).

c. The controller shall be able to immediately display fault location and condition.

d. An LCD digital display will allow the temperature to be set in 1 degrees F units.

e. The controller shall monitor room temperature and preset temperature by microcomputer and can select cool/heat operation mode automatically.

f. The controller shall allow the user to select cool / heat / fan operation mode with indoor remote controller of choice without using the cool / heat selector.

The wired remote controller shall have the following features:

Operation Start/Stop Operation Mode Temperature Settings 60 Degrees F - 90 Degrees F Set Point Range Fan Speed Airflow Direction

Monitoring Status Malfunction Flashing Malfunction Content

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Filter Sign Operation Mode Temperature Setting Permit/Prohibit Selection Fan Speed Airflow Direction

Control Management Field Setting Mode Group Setting Auto Re-Start

2.5 INTELLIGENT TOUCH CONTROLLER

2.5.1 Physical Characteristics

The control system shall be a neutral color plastic material. The controller has a 5.7" Liquid Crystal Display (LCD, QVGA 320x240, 4096 colors).

2.5.2 Electrical Characteristics

2.5.2.1 General

From each outdoor unit circuit board to the I-touch controller, the daisy chained wiring electrical voltage shall be 16 volts DC.

2.5.2.2 Wiring

For heat recovery the control wiring shall be installed in a daisy chain configuration from outdoor unit to each branch selector box then from the branch selector box to the indoor unit.

2.5.2.3 Control Wiring Size

The wire shall be a non-shielded, stranded, 2 conductor PVC or vinyl clad cable. 18-gauge copper cabling specified. Application of UV stabilized cable should be standard when exposed to outside elements. Plenum rated where applicable. Maximum wiring length between controller and indoor units: 3,280 ft.

2.5.2.4 Power Supply to Controller

24V AC (transformer to be field supplied).

2.5.3 Controller Characteristics

The intelligent controller shall be able to control, via a full color LCD touch screen, up to 10 outdoor units and 64 indoor unit groups (maximum 128 Fan Coil Units) with the following functions:

a. On/Off selection for each fan coil unit or group

b. Temperature set point adjustment for each fan coil unit or group

c. Fan speed adjustment for each fan coil unit or group

d. Heat/cool/automatic changeover mode selection

e. Forced shutdown terminals

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f. Priority settings for restriction of local access for start/stop, heat/cool mode and set point adjustment (at local remote controllers if installed)

g. Temperature limitation in both heating and cooling mode

h. Weekly schedule with start up and shut off times, temperature settings and operation modes, 16 operations/ each day can be set in one schedule, and 8 different schedules are available. In addition a yearly calendar is also available for holidays or periods of non use.

i. Actual time and display setting

j. Reset ability for malfunction codes and filter maintenance warning

k. Maximum 13 months backup power supply to maintain the memory

l. Malfunction reports can be sent via e-mail to a cell phone or a PC

m. Remote monitoring via PC, network and web browser (optional). Available web browser are: Real time status monitoring/Operation/Malfunction history display/User password setting and schedule setting

Manufacturer to provide Web based software for off-site monitoring purposes.

PART 3 EXECUTION

3.1 INSTALLATION

The system must be installed by factory trained and authorized contractor. The contractor shall install the VRF system in accordance with the recommendations of the VRF manufacturer as outlined in the Manufacturers Installation Instructions.

3.2 START-UP

Equipment start-up, performance tests, and commissioning shall be provided by a factory trained and authorized contractor. Control start-up and commissioning shall be provided by the factory.

3.3 PRODUCT SUPPORT

Installation, Operation and Maintenance Manuals are to be provided to the owner once commissioning is complete. Eight hours of Operation and Maintenance training will be provided to the owner and owner's personnel once commissioning is complete.

-- End of Section --

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SECTION 23 82 00.00 20

TERMINAL HEATING AND COOLING UNITS11/08

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM D1654 (2008) Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 6 (1993; R 2011) Enclosures

NEMA MG 1 (2011; Errata 2012) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 211 (2013) Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances

NFPA 54 (2012) National Fuel Gas Code

NFPA 70 (2011; Errata 2 2012) National Electrical Code

NFPA 90A (2012) Standard for the Installation of Air Conditioning and Ventilating Systems

NFPA 90B (2012) Standard for the Installation of Warm Air Heating and Air Conditioning Systems

NFPA 91 (2010) Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists and Noncombustible Particulate Solids

1.2 RELATED REQUIREMENTS

Section 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS, applies to this section with additions and modifications specified herein.

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1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Unit heaters

SD-10 Operation and Maintenance Data

Unit heaters, Data Package 2

Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA.

PART 2 PRODUCTS

2.1 UNIT HEATERS

Self-contained and factory assembled, propeller fan with capacities expressed as Btu per hour output and cubic foot-per-minute air delivery, operating conditions, and mounting arrangements as indicated. Average fan bearing life shall be minimum 200,000 hours at operating conditions. Provide fan motor with direct drive. Construct fan-guard motor mount of steel wire. Equip each heater with individually adjustable package discharge louver. Louvers may be substituted by discharge cones or diffusers. Provide thermostats. Furnish circuit breaker disconnect switch.

2.1.1 Electric Unit Heater

UL listed; wattage, voltage, phase, and number of steps as indicated. Provide control-circuit terminals and single source of power supply. Heater 5 Kw and larger shall be three-phase, with load balanced on each of the three phases. Limit leaving air temperature below 140 degrees F at 60 degrees F entering air.

2.1.1.1 Casing

Minimum 21 gage steel.

2.1.1.2 Heating Element

Nickel-chromium heating wire element, free from expansion noise and 60 Hz hum. Embed element in magnesium-oxide insulating refractory. Seal element in high-mass steel or corrosion-resisting metallic sheath with fins. Enclose element ends in terminal box. Space fins at maximum six fins per inch. Limit fin surface temperature 550 degrees F at any point during normal operation.

2.1.1.3 Controls

Include limit controls for thermal overheat protection of heaters. For remote thermostatic operation, provide contactor rated for 100,000 duty cycles. Provide a control transformer to supply 120-volt thermostat control circuit for each heater. Provide room thermostat for pilot duty.

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2.1.1.4 Wiring

Completely factory-prewired to terminal strips, ready to receive branch circuit and control connections for 140 degrees F copper wiring.

2.2 FAN

Provide steel or aluminum fans with ball or roller bearings for motors over 1/8 horsepower (hp) and sleeve bearings for motors 1/8 hp and under. Provide sleeve bearings with oil reservoir, if not permanently lubricated.

2.3 MOTOR AND STARTER

NEMA MG 1, and NEMA ICS 2, and NEMA ICS 6, respectively. Provide continuous-duty motor with built-in automatic reset thermal overload protection. For motor 1/2 hp and larger, use three-phase. Provide single-phase motor of permanent split capacitor or capacitor start. Limit motor speed at 1800 r/min. Wire motor to heater power supply source.

2.4 SOURCE QUALITY CONTROL

Protect affected equipment items by manufacturers' corrosion-inhibiting coating or paint system that has proved capable of withstanding salt-spray test in accordance with ASTM B117. Test indoor and outdoor equipment for 125 hours; test outdoor equipment used in a marine atmosphere for 3000 hours. For each specimen, perform a scratch test as defined in ASTM D1654.

2.5 NOISE VIBRATION AND SEISMIC CONTROLS

Section 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT.

PART 3 EXECUTION

3.1 INSTALLATION

Install equipment where indicated and as recommended by manufacturer's recommendations, NFPA 54, NFPA 90A, NFPA 90B, NFPA 91 and NFPA 211.

3.1.1 Suspensions of Equipment

Provide equipment supports including beam clamps, turnbuckles and twist links or weld-wire chains, wire ropes with rope clips and rope thimbles, threaded-eye rod hangers with lock nuts and heat-duct hangers, threaded-eye bolts with expansion screws, brackets, platform and mounting frame, and vibration isolators. Locate equipment in such a manner that working space is available for servicing, such as vacuum pump and burner removal, access to automatic controls, and lubrication. Provide electrical isolation of dissimilar metals. Clean interior of casings or cabinets before and after completion of installation.

3.1.2 Electrical Work

NFPA 70 and Division 26 ELECTRICAL. When replacing original control wires, provide No. 16 AWG with minimum 105 degrees C insulation.

3.2 FIELD QUALITY CONTROL

Administer, schedule, and conduct specified tests. Furnish personnel,

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instruments and equipment for such tests. Correct defects and repeat the respective inspections and tests. Conduct inspections and testing in the presence of the Contracting Officer.

3.2.1 Test Instruments and Apparatus

Provide instruments and apparatus currently certified as being accurate to within one percent of their full scale. Use gages with a maximum scale between 1 1/2 and 2 times test pressure.

3.2.2 Field Inspection

Prior to initial operation, inspect equipment installation to ensure that indicated and specified requirements have been met.

3.2.3 Field Tests

3.2.3.1 Insulation-Resistance Tests for Electrical Equipment

At the completion of wiring, test 600 volt wiring to verify that no short circuits exist before or after the attachment of electrical heating equipment to the power source. Make tests with an instrument which applies a voltage of approximately 500 volts for a direct reading of insulation resistance.

3.2.3.2 Operational Tests

After completing fire tests and insulation-resistance tests, operate equipment continuously under varying load conditions to verify functioning of combustion controls, electrical controls, flame safeguard controls, safety interlocks, and specified operating sequence. Run each test for a minimum period of one hour.

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23 82 01

RANGE VENTILATION SYSTEM08/13

PART 1 GENERAL

1.1 DESCRIPTION

Provide Range Ventilation meeting Navy and NIOSH standards using a subcontractor experienced in range ventilation to design and construct a range ventilation system meeting the performance based standards specified herein. This section applies to the shooting area of the range facility. This section does not apply to the CQC/Shoothouse or the Breacher Classroom. The range ventilation system indicated on the drawings is conceptual in design showing approximate location and size of equipment. The design intent of the range ventilation has been provided in the contract documents; however, construction of the range and implementation of the design should be accomplished in accordance with this section and the design drawings. Shall comply with Section 23 00 00 AIR SUPPLY, DISTRIBUTION, AND EXHAUST SYSTEMS".

The Range ventilation subcontractor is responsible for the entire range ventilation system including design, controls, and balancing and shall be on site during acceptance testing.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ACOUSTICAL SOCIETY OF AMERICA (ASA)

ASA S12.51 (2012) Acoustics Determination of Sound Power Levels of Noise Sources using Sound Pressure Precision Method for Reverberation Rooms

AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA)

AMCA 201 (2002; R 2011) Fans and Systems

ASTM INTERNATIONAL (ASTM)

ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2011; Errata 2 2012) National Electrical Code

NFPA 90A (2012) Standard for the Installation of Air Conditioning and Ventilating Systems

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SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)

SMACNA 1403 (2008) Accepted Industry Practice for Industrial Duct Construction, 2nd Edition

SMACNA 1819 (2002) Fire, Smoke and Radiation Damper Installation Guide for HVAC Systems, 5th Edition

SMACNA 1966 (2005) HVAC Duct Construction Standards Metal and Flexible, 3rd Edition

1.3 SYSTEM DESCRIPTION

Provide a "purge" style system with 100% outside air (no recirculation allowed) designed for 75 feet per minute (fpm) at the firing line, negative pressure inside the range, and meeting additional detailed requirements provided herein. System start up from cold start to "green light" (ready to fire) shall be 10 minutes or less. Provide ductwork, piping offsets, fittings, and accessories as required to provide a complete installation. Coordinate the work of the different trades to avoid interference between piping, equipment, structural, and electrical work. Provide complete, in place, all necessary offsets in piping and ductwork, and all fittings, and other components, required to install the work as indicated and specified.

a. This system is provided for the firing range portion of the facility (area where shooting occurs) including the "Get Ready" area behind firing line, the firing line to the bullet trap, but does not include the Range Safety Office or any non-shooting areas of the facility.

b. The range ventilation contractor shall have experience in range ventilation systems as defined herein and shall be responsible for providing the entire system including all range ventilation equipment, controls, and balancing as necessary to meet the requirements specified herein.

c. Provide heat to maintain indoor air conditions specified herein.

Provide Heat recovery system using run around glycol piping.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Range Ventilation System Drawings; G

SD-03 Product Data

Range Ventilation System Controls; G

SD-05 Design Data

Control Logic/Sequence (list/narrative); G

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SD-06 Test Reports

Preliminary Air Flow tests (prior to acceptance testing); GAcceptance Testing Plan; G

SD-07 Certificates

Range Ventilation Experience; G

SD-11 Closeout Submittals

Final Air Flow measurements; GVerification Testing; GTraining Documentation; G

1.4.1 EXPERIENCE CLAUSE

The ventilation contractor providing the range ventilation systems shall have range ventilation experience in both design and construction of ventilation systems meeting NIOSH and NAVY requirements and similar to those included in this project and specifically, providing ventilation for multi-lane ranges having an air flow averaging 70 to 80 fpm when measured at each firing location across the width of the firing line, with no reading less than 50 fpm and maintaining a negative pressure of -0.04 (plus/minus 0.02) inches water gauge, with similar controls to those required for this project. The range ventilation contractor shall submit a list of at least 3 ranges in operation within the continental United States having at least a 24 foot wide firing line and meeting these requirements and that are accessible to the Navy for verification testing. For each range listed, include range location, width, number of lanes, a description of the control system, in-house personnel (including phone number) responsible for the project, and name/address of owner. The contractor is responsible for obtaining the owners permission and arranging access for the Navy to enter these ranges for the purposes of verifying that the ventilation system meets these requirements. If the ranges are not available to the Navy or do not meet these requirements, the range ventilation subcontractor will be deemed unsuitable. The experience pertains to only that work which the range ventilation subcontractor has done with in-house personnel currently employed (i.e. work done through subcontractors does not count.)

1.4.2 Verification Testing

The Navy will measure the air flow at each firing lane at 1 foot, 3 feet, and 5 feet off the floor in each lane. Acceptable readings are 75 fpm (plus or minus 10 percent) over entire range, with no one reading less than 50 fpm. Smoke released at each lane shall move positively downrange. Any smoke moving backwards (up-range) shall constitute failure. The pressure differential on either side of range entrance shall be measured. Acceptable differential readings are between -0.02 and -0.06 inches water gauge. Verify control system operating as designed. NOTE: This paragraph applies only to experience verification of existing ranges for the sole purposes of validating contractor's experience. The system requirements and acceptance tests for the new range ventilation system are more stringent.

1.4.3 Prevention of Corrosion

Protect metallic materials against corrosion.

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Provide additional protective coatings on exterior ductwork and equipment that meets or exceeds the requirements of a 3,000 hour salt spray test in accordance with ASTM B117.

1.4.4 MAINTENANCE

The installing range subcontractor will provide 1 year's maintenance and warranty to the ventilation system as part of this construction contract and shall include the following.

a. Monthly monitoring: The ventilation systems performance shall be monitored at least monthly through a modem provided by the range subcontractor and connected to the telecommunications system. Modem shall be capable of sending information on all control points specified for the DDC system.

b. Quarterly preventative maintenance (4 visits): At approximately 3 month, 6 months, 9 months, and 12 months after range opening) perform routine maintenance and check controls on all ventilation equipment. These visits may be performed by a local contractor trained by the range ventilation subcontractor.

c. Bi-annual air balancing: (2 visits): At approximately 6 months and 12 months, perform a check and rebalancing of the ventilation system. Document critical parameters including control and damper settings, outside and inside air temperatures, filter loadings, etc. These visits shall be done a representative from the range ventilation subcontractor.

1.4.5 COMPLIANCE VERIFICATION

Compliance with the performance based requirements will be determined and accepted by NAVFAC's Small Arms Range Center of Expertise at NAVFAC-MIDLANT in Norfolk, VA.

1.4.6 QUALITY ASSURANCE

Materials and assemblies installed in the work shall be inspected and found to be in compliance with the industry standards and these specifications prior to acceptance of the work. Items found not to be in compliance shall be removed or corrective measures taken, to assure compliance with the referenced standard. Prior to testing and balancing the system, the range ventilation contractor shall verify that range has been properly sealed.

Material Standards

Materials, equipment, fixtures, and other appurtenances shall comply with applicable Underwriters Laboratories, (UL) Inc., American National Standards Institute, Inc., and National Electrical Manufacturer's Association standards including ASA S12.51, AMCA 201, NFPA 70, NFPA 90A, SMACNA 1403, SMACNA 1819, and SMACNA 1966.All materials shall be new, and shall bear the label of Underwriters Laboratories whenever standards have been established and label service is normally and regularly furnished by the agency. All equipment provided shall be listed and labeled suitable for the specified purpose, environment, and application and installed in accordance with manufacturer's recommendations. All insulation shall be asbestos free.

Manufacturer's Nameplate

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Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place, the nameplate of the distributing agent will not be acceptable.

1.4.7 TRAINING

After installation of the equipment and systems, provide a training course for Government personnel covering the items listed below and the Operations and Maintenance manuals. The course will be divided into two parts: a general overview and familiarization with the system and equipment for all attendees, followed by a more in-depth/detailed discussion of the control panel and preventative maintenance for a select group. Provide two copies of the Operations and Maintenance manual for attendees. Provide one DVD disc of the training courses to be used as refresher courses and to train additional personnel. Training shall be conducted by the same individual that supervised the installation of the system. Training shall include classroom discussion as well as hands on maintenance, replacement of typical components and repair type maintenance training for parts typically replaced or repaired in the field. Submit training documentation plan 14 calendar days prior to training sessions. Training plan shall include scheduling, content, outline, and training material handouts. Provide training for:

a. Operation of the systemb. trouble shootingc. preventative maintenanced. Control Systeme. Control panel readings and what they meanf. Filter removal and replacement

Time will vary depending on questions and user interest, but contractor shall assume a full 8 hour day training session for the range ventilation system. Coordinate training schedule with range targeting equipment training since some personnel will be attending both.

PART 2 PRODUCTS

2.1 RANGE VENTILATION SYSTEM

2.1.1 General System Requirements: Design the system to provide an air flow of 75 fpm at the firing line(s) and meeting the acceptance criteria provided herein. Provide a negative pressure inside the range relative to the base building with the exhaust designed to exhaust 110% of the supply volume of air, with actual exhaust volume adjusted during testing and balancing. System shall be a "purge" style system with 100% outside air. Design for positive and even movement of air downrange. Each exhaust fan shall be interlocked with one specific supply air fan.

a. Motor Sizing: Limit AHU motor to 75 hp or less. Provide multiple paired supply/exhaust units where large cams are required.

b. Location: Locate equipment as indicated. Isolate the supply intake from the exhaust outlet and separated a minimum of 30 feet.

c. Negative Pressure: Maintain a negative inches of water pressure in the operating range area of .04 +/- .02 relative to the base building areas. The exhaust fan speed shall modulate through the VFD to steady

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state at a design range differential of -0.50" Static Pressure, and shall maintain design parameters with only minor adjustments after steady state has been reached.

d. Noise: Ventilation System shall not exceed 75 decibels when measured at the firing line and 5 feet back (uprange) from the firing line.

e. Make all ductwork absolutely symmetrical to the extent practical.

f. Variable Frequency Drives: Provide VFD's on both supply and exhaust systems. Connect ventilation system control equipment to telephone/modem communication cable (cable provided under other section).

g. The Design of the system shall be in accordance with Navy Environmental Health Center, Technical Manual NEHC-TM6290.99-10. The drawings indicate a generalized arrangement for the Range Ventilation System. the contractor shall be responsible for the performance of the system and shall make modifications as necessary to ensure that the system meets the Range Ventilation System criteria. Submit Range Ventilation System drawings for approval prior to procurement of equipment, ductwork and piping.

2.12.2 Supply System

Supply air from the air handling unit shall be delivered through a continuous graduated plenum, and then through ductwork into the diffuser system. The ductwork into the diffuser system shall have dampers to allow for adjustment/control of air into the individual diffuser sections. The diffuser system shall consist of a series of adjacent sections from which air enters the range through a double wall radial diffuser.

a. Supply filters: Provide double stage Merv 13 supply filters.

b. Supply diffuser: Provide a double wall radial diffuser with sufficient surface area and free area to provide an even and quiet supply of air behind the shooters, and as a minimum:

8 feet ceiling height or less: 24 inches diameters half round Over 8 feet and up to 10 feet ceiling height: 30 inches diameter half round Over 10': 36 inches diameter half round

Quarter round radial diffusers sized to provide equivalent surface area are acceptable.

d. Alignment of Diffuser section: The radial diffuser sections shall be aligned with the lanes such that one section provides air to one lane: i.e. if the range has 4 feet wide lanes, each radial plenum section shall be in 4 feet sections whose ends match up with the lane dividers. The intent of this alignment is to aide in the adjusting and balancing of the system. The supply diffuser shall not restrict view into the range from the range masters booth.

2.3 Exhaust System

The exhaust fan and filter system should be designed to allow for 350 to 500 fpm velocities across the filter media. Provide a two stage filter system including a pre-filter followed by a high-efficiency particulate

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arrestor (HEPA) filter for final exhaust filter. The exhaust fan should be designed to allow for operational static pressure at least 7 inches wg. at the desired volume of air flow, with a "clean" HEPA filter loss of 1.25 inches wg. and a minimum of 5.0 inches across the "dirty" HEPA filter to allow extended time between filter changes. The final filter media should be that of at least 99.97% (HEPA) @ .03 micron.

a. Exhaust Plenum: Provide a semi-continuous slot to capture the exhaust air, with maximum 5 inch of broken slot at duct connections. The exhaust duct system should be constructed in a fashion that evenly extracts the supply air from the range.

b. Filter access: Provide HEPA rated filter housing for the HEPA filters. Provide easy access, removal, and replacement of supply and exhaust filters. Access doors shall be located with no adjacent equipment, pipes, or other features blocking or hindering access, and shall be easily opened without any special tools or equipment. Access door shall close tightly and evenly around the perimeter. Filters shall be capable of being removed and replaced without any special tools or equipment.

2.4 Range Ventilation System Controls

Submit control logic/sequence. Provide On/Off switch or button along with "Do Not Shoot", "Safe to Shoot", and "Warning" lights. "Safe to Shoot" light will be on only when all systems are within operating parameters. Otherwise, "Do Not Shoot" light will be on. In addition, controls will provide warning indicators as described below. Locate control panel in the RSO. Locate the range ventilation system warning lights on the control panel inside RSO booth such all three of these lights are readily visible at all times.

a. Condition to turn on "Do Not Shoot" light. (if any of these conditions occur, controls will sound alarm and shut down range ventilation system):

Either supply fan or exhaust fan is offRange entrance/exit doors remains open for more than a given set point (adjustable set point, initially use 5 minutes)Door into trap area is openRange pressure is outside the upper limit (0 inches of water, non negotiable) and lower (negative 0.10 inches of water typical, but adjustable) for a given time (2 minutes typical, but adjustable)Exhaust Pre-Filter is past its limit (limit adjustable)HEPA Filter is past its limit (limit adjustable).Supply static pressure is below its limit (limit adjustable)

b. Condition to turn on "Warning" light:

Exhaust Pre-filter is past set point (set point adjustable)Exhaust HEPA filter is past set point (set point adjustable)Supply, Pre-filters on exhaust, or HEPA filters) are greater than a given set point. Range temperature is outside given set points (adjustable)

c. Provide DDC with all points necessary to meet requirements herein and including:

Discharge, outside, and space air temperatureSupply air temperature downstream of heating unit

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Supply air static pressureSupply air filter statusFreezestat (when unit is hot water or steam)Smoke detectorSupply fan start/stop with Variable Frequency Drive (VFD)Supply fan run statusSupply fan fault status Supply fan start/stop with VFDExhaust fan start/stop with VFDExhaust fan run statusExhaust fan fault statusExhaust air static pressureExhaust air pre-filter differentialExhaust air HEPA filter differentialRange to base building space(outside double door vestibule) air pressure differentialDoor into bullet Trap area open/closedRange doors open/closed

d. System Startup

The system shall be manually energized from the switch center console located in the Range Masters Control Booth. The system shall take a maximum of 8 minutes for systems with air conditioning and 5 minutes for systems without air conditioning from cold start to "Safe to Shoot" light.

Energizing the system shall initiate the following sequence:

Supply and Exhaust VFD's initiate fan at low speed

The supply air fan shall ramp up at a predetermined rate (field adjustable) and the exhaust fan shall track the supply air fan and maintain a negative pressure at all times.

The supply fan will pause at every increased level for a predetermined time until the exhaust fan has adjusted to the new position, such that the building static pressure will be maintained at each ramp-up.

This sequence shall continue until the system is running at design capacity, with exhaust fan running at steady state at design range differential. Once steady state has been achieved for the day, the system shall run smoothly and evenly with no excessive modulating or "hunting".

"Safe to Shoot" light energized.

e. Emergency Cut Off Switch

For each range, provide two emergency red "mushroom" cut off switches, wired directly to the supply and exhaust VFDs that will manually and safely shut off the entire ventilation system when pressed without damage to the system. These cut off switches shall be "hard wired" and provide immediate shutdown of the system including all supply and exhaust fans into the range, and shall not rely or be dependent on any control system. Locate one switch inside the range on the back wall behind the shooters, and the other inside the range masters office.

2.5 HEPA Vacuum

For each bay, provide one High Efficiency Particulate Arrestor (HEPA) -

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Nilfisk Model CFM 137 or equal, with HEPA filter placed in system to remove particulates prior to reaching fan/motor assembly. Vacuum shall fit in storage area closet accessible from the range side.

PART 3 EXECUTION

3.1 Range Ventilation System

Do no start construction until all design submittals have been approved. Coordinate Construction with general contractor and ballistic contractor providing Baffles, Overhead Baffles, Targeting system)

3.13.2 Acceptance Testing

Acceptance Testing is required to verify that the range ventilation system fully meets the performance requirements specified herein. Prior to scheduling acceptance testing the contractor shall verify that the range is relatively "air tight" with all doors, door sweeps, sealants, etc in place and that all significant holes and gaps sealed. The range ventilation subcontractor shall perform preliminary air flow tests and shall verify the system passes all tests prior to scheduling acceptance testing by the Government. The Range ventilation subcontractor is responsible for meeting the performance requirements and shall be on site during acceptance testing.

3.3 Acceptance Testing Plan

The contractor shall develop and submit a Testing Plan and "check list" tailored to their system and designed to provide an accurate and efficient sequence of testing for their system, including method to run simulated dirty filter tests. Include a line for each item indicated to be checked and verified. For each item, include a test method to check each system requirement. Test by actual operation of condition: For example, physically open doors and hold open to verify door controls. At the discretion of the Navy, some tests (for example temperature sensing tests) may be run by using the controls to "simulate" changing temperatures.

Submit an Acceptance Test Plan and schedule acceptance test minimum of 4 weeks in advance (8 weeks for overseas projects). The contractor is responsible for assuring the facility is ready for testing (all seals on doors, roof joints, and penetrations in place, etc) and the ventilation system is working properly prior to scheduling of tests.

3.4 Control System

a. Control Conditions: Verify each control condition to turn on the "Do Not Shoot" and "Warning" light.

b. DDC Points: Verify the control panel includes all required points, and record reading of each one.

c. System Startup: Observe system through startup. Record VFD settings at each stage. Record time necessary to achieve final steady state. Verify system runs smoothly without excessive modulating or "hunting" where system is under continual adjustment to stay within parameters. Verify time between cold start and green light meets requirements stated herein.

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3.5 Smoke Tests

Provide either a fog machine or "smoke bombs" in sufficient supply to complete testing. Release smoke in each lane along the entire height (between 1 foot and 5 feet off the floor). All smoke must move downrange. Smoke moving up, down, stagnant, or going backwards will constitute failure of acceptance.

3.6 Air Flow measurements (with Clean HEPA Filters)

Take air flow measurements using a "Velgrid" or similar meter with the system on and running, with the get-ready area empty. Note the time of day and outdoor air temperature.

3.7 Measurement Locations and acceptable readings

Take measurements at the firing line in the center of each lane, take air measurement readings at 1 foot, 3 feet, and 5 feet off the floor.

3.8 Acceptable Readings

a. Individual Readings: No single reading under 50 fpm or over 115 fpm

b. Lane Average: Each lane between 60 fpm and 90 fpm

c. Range Average: Between 72 fpm and 80 fpm

3.9 Final Air Flow Measurements (Simulated "Dirty" filters)

a. HEPA Filters: Simulate loaded HEPA filters to achieve a "yellow" filters warning light and repeat Air Flow Measurements with acceptable readings stated above. Contractor is responsible for determining safe method to simulate loaded filters, but typically done by inserting cardboard to block off a substantial amount of the filters as necessary to create a yellow filter warning light.

b. Prefilter loading - Simulate loaded pre-filters - This test may be run using same method HEPA filters or, if all others tests are successful than an easier/quicker method of temporary manipulation (manual input) of the control system may be used.

3.10 Noise measurements

Measure decibels at the firing line and 5 feet behind (uprange) the firing line with the system on and running. Decibels shall not exceed the level stated herein.

3.11 Final Acceptance

The contractor will be given three full days to run the acceptance tests, make adjustments as necessary, and repeat tests until all requirements are met. Adjustments made to any item will require tests to be repeated on all other items affected by the adjustment. For example, and modification to the airflow at any one location in a range bay will require a complete re-testing of the entire range bay. If the contractor is not able to pass all acceptance test criteria in this time, the tests will be discontinued. The contractor will then make adjustments as necessary, confirm the system is capable of passing the tests, and then re-scheduled acceptance tests at a time mutually agreed upon by the contractor and the Navy, and at no

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additional cost to the Navy.

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