Souderton Area School District E. Merton Crouthamel Elementary School Addition and Renovations

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1 SECTION BASIC MECHANICAL MATERIALS AND METHODS PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following: 1. Piping materials and installation instructions common to most piping systems. 2. Dielectric fittings. 3. Sleeves. 4. Escutcheons. 1.2 DEFINITIONS A. Finished Spaces: Spaces other than mechanical and electrical equipment rooms, pipe and duct shafts, unheated spaces immediately below roof, and spaces above ceilings. B. Exposed, Interior Installations: Exposed to view indoors. Examples include finished occupied spaces and mechanical equipment rooms. C. Exposed, Exterior Installations: Exposed to view outdoors or subject to outdoor ambient temperatures and weather conditions. Examples include rooftop locations. D. Concealed, Interior Installations: Concealed from view and protected from physical contact by building occupants. Examples include above ceilings and in duct shafts. E. Concealed, Exterior Installations: Concealed from view and protected from weather conditions and physical contact by building occupants but subject to outdoor ambient temperatures. Examples include installations within unheated shelters. PART 2 - PRODUCTS 2.1 PIPE, TUBE, AND FITTINGS A. Refer to individual Division 15 piping Sections for pipe, tube, and fitting materials and joining methods. B. Pipe Threads: ASME B for factory-threaded pipe and pipe fittings. 2.2 JOINING MATERIALS A. Refer to individual Division 15 piping Sections for special joining materials not listed below. B. Pipe-Flange Gasket Materials: ASME B16.21, nonmetallic, flat, asbestos-free, 1/8-inch maximum thickness unless thickness or specific material is indicated. C. Solder Filler Metals: ASTM B 32, lead-free alloys. Include water-flushable flux according to ASTM B DIELECTRIC FITTINGS BASIC MECHANICAL MATERIALS AND METHODS

2 A. Description: Combination fitting of copper alloy and ferrous materials with threaded, solderjoint, plain, or weld-neck end connections that match piping system materials. B. Insulating Material: Suitable for system fluid, pressure, and temperature. C. Dielectric Unions: Factory-fabricated, union assembly, for 250-psig minimum working pressure at 180 deg F. D. Dielectric Flanges: Factory-fabricated, companion-flange assembly, for 150- or 300-psig minimum working pressure as required to suit system pressures. E. Dielectric Couplings: Galvanized-steel coupling with inert and noncorrosive, thermoplastic lining; threaded ends; and 300-psig minimum working pressure at 225 deg F. F. Dielectric Nipples: Electroplated steel nipple with inert and noncorrosive, thermoplastic lining; plain, threaded, or grooved ends; and 300-psig minimum working pressure at 225 deg F. 2.4 SLEEVES A. Galvanized-Steel Sheet: inch minimum thickness; round tube closed with welded longitudinal joint. B. Steel Pipe: ASTM A 53, Type E, Grade B, Schedule 40, galvanized, plain ends. 2.5 ESCUTCHEONS A. Description: Manufactured wall and ceiling escutcheons and floor plates, with an ID to closely fit around pipe, tube, and insulation of insulated piping and an OD that completely covers opening. B. One-Piece, Deep-Pattern Type: Deep-drawn, box-shaped brass with polished chrome-plated finish. PART 3 - EXECUTION 3.1 PIPING SYSTEMS - COMMON REQUIREMENTS A. Install piping according to the following requirements and Division 23 Sections specifying piping systems. All piping that is installed with corroded or rusted exterior surfaces shall be completely cleaned and primed with rust proof paint before exterior pipe insulation is applied and installed. B. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems. Indicated locations and arrangements were used to size pipe and calculate friction loss, expansion, pump sizing, and other design considerations. Install piping as indicated unless deviations to layout are approved on Coordination Drawings. C. Install piping in concealed locations, unless otherwise indicated and except in equipment rooms and service areas. D. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise. BASIC MECHANICAL MATERIALS AND METHODS

3 E. Install piping above accessible ceilings to allow sufficient space for ceiling panel removal. F. Install piping to permit valve servicing. G. Install piping at indicated slopes. H. Install piping free of sags and bends. I. Install fittings for changes in direction and branch connections. J. Install piping to allow application of insulation. K. Select system components with pressure rating equal to or greater than system operating pressure. L. Install escutcheons for penetrations of walls, ceilings, and floors. M. Install sleeves for all pipes passing through concrete and masonry walls, gypsum-board partitions, and concrete floor and roof slabs. N. Refer to equipment specifications in other Sections of these Specifications for roughing-in requirements. 3.2 PIPING JOINT CONSTRUCTION A. Join pipe and fittings according to the following requirements and Division 23 Sections specifying piping systems. B. Ream ends of pipes and tubes and remove burrs. Bevel plain ends of steel pipe. C. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly. D. Soldered Joints: Apply ASTM B 813, water-flushable flux, unless otherwise indicated, to tube end. Construct joints according to ASTM B 828 or CDA's "Copper Tube Handbook," using leadfree solder alloy complying with ASTM B 32. E. Threaded Joints: Thread pipe with tapered pipe threads according to ASME B Cut threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and restore full ID. Join pipe fittings and valves as follows: 1. Apply appropriate tape or thread compound to external pipe threads unless dry seal threading is specified. 2. Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or damaged. Do not use pipe sections that have cracked or open welds. F. Flanged Joints: Select appropriate gasket material, size, type, and thickness for service application. Install gasket concentrically positioned. Use suitable lubricants on bolt threads. 3.3 PIPING CONNECTIONS A. Make connections according to the following, unless otherwise indicated: 1. Install unions, in piping NPS 2 and smaller, adjacent to each valve and at final connection to each piece of equipment. BASIC MECHANICAL MATERIALS AND METHODS

4 2. Install flanges, in piping NPS 2-1/2 and larger, adjacent to flanged valves and at final connection to each piece of equipment. 3. Dry Piping Systems: Install dielectric unions and flanges to connect piping materials of dissimilar metals. 4. Wet Piping Systems: Install dielectric coupling and nipple fittings to connect piping materials of dissimilar metals. 3.4 EQUIPMENT INSTALLATION - COMMON REQUIREMENTS A. Install equipment to allow maximum possible headroom unless specific mounting heights are not indicated. B. Install equipment level and plumb, parallel and perpendicular to other building systems and components in exposed interior spaces, unless otherwise indicated. C. Install mechanical equipment to facilitate service, maintenance, and repair or replacement of components. Connect equipment for ease of disconnecting, with minimum interference to other installations. Extend grease fittings to accessible locations. D. Install equipment to allow right of way for piping installed at required slope. END OF SECTION BASIC MECHANICAL MATERIALS AND METHODS

5 SECTION VALVES PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following general-duty valves: 1. Copper-alloy ball valves. 2. High performance butterfly valves. 3. Bronze check valves. B. See Division 23 Section "Instrumentation and Controls for HVAC for control valves and actuators. C. See Division 23 piping Sections for specialty valves applicable to those Sections only. 1.2 SUBMITTALS A. Product Data: For each type of valve indicated. Include body, seating, and trim materials; valve design; pressure and temperature classifications; end connections; arrangement; dimensions; and required clearances. Include list indicating valve and its application. Include rated capacities; furnished specialties; and accessories. 1.3 QUALITY ASSURANCE A. ASME Compliance: ASME B31.9 for building services piping valves. B. ASME Compliance for Ferrous Valves: ASME B16.10 and ASME B16.34 for dimension and design criteria. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. In other Part 2 articles where subparagraph titles below introduce lists, the following requirements apply for product selection: 1. Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified. 2.2 VALVES, GENERAL A. Refer to Part 3 "Valve Applications" Article for applications of valves. B. Bronze Valves: NPS 2 (DN 50) and Smaller: Threaded ends, unless otherwise indicated. C. Ferrous Valves NPS 2-1/2 (DN 65) and Larger: Flanged ends, unless otherwise indicated. VALVES

6 D. Valve Pressure and Temperature Ratings: Not less than indicated and as required for system pressures and temperatures. E. Valve Sizes: Same as upstream pipe, unless otherwise indicated. F. Valve Actuators: 1. Handwheel: For valves other than quarter-turn types. 2. Lever Handle: For quarter-turn valves NPS 6 (DN 150) and smaller. G. Extended Valve Stems: On insulated valves. H. Valve Flanges: ASME B16.1 for cast-iron valves, ASME B16.5 for steel valves, and ASME B16.24 for bronze valves. I. Valve Grooved Ends: AWWA C Solder Joint: With sockets according to ASME B a. Caution: Use solder with melting point below 840 deg F (454 deg C) for angle, check, gate, and globe valves; below 421 deg F (216 deg C) for ball valves. 2. Threaded: With threads according to ASME B J. Valve Bypass and Drain Connections: MSS SP COPPER-ALLOY BALL VALVES A. Manufacturers: 1. Copper-Alloy Ball Valves: a. American Valve, Inc. b. Conbraco Industries, Inc.; Apollo Div. c. Hammond Valve. d. Milwaukee Valve Company. B. Copper-Alloy Ball Valves, General: MSS SP-110. C. Copper-Alloy Ball Valves: Bronze body with full-port, chrome-plated bronze ball; PTFE seats; and 600-psig (4140-kPa) minimum CWP rating and blowout-proof stem. 2.4 HIGH PERFORMANCE BUTTERFLY VALVES A. Manufacturers: 1. Single-Flange, Ferrous-Alloy Butterfly Valves: a. Victaulic Co. - MasterSeal b. Crane Co.; Crane Valve Group; Stockham Div. c. Hammond Valve. d. Milwaukee Valve Company. B. Ferrous-Alloy Butterfly Valves, General: Pressure rated from full vacuum to 300 psi and for bidirectional, dead end service to full working pressure; seat design that assures full 360 sealing; ductile iron disc conforming to ASTM A-536, grade , with electroless nickel coating VALVES

7 conforming to ASTM B-733; 416 stainless steel blowout proof stem conforming to ASTM A- 582; EPDM seat with temperature range 30 F to +250 F; lever lock handle or gear operator handwheel with chainwheel as applicable. 2.5 BRONZE CHECK VALVES A. Manufacturers: 1. Bronze, Swing Check Valves with Nonmetallic Disc: a. Crane Co.; Crane Valve Group; Stockham Div. b. Hammond Valve. c. Milwaukee Valve Company. B. Bronze Check Valves, General: MSS SP-80. C. Class 150, Bronze, Horizontal Lift Check Valves: Bronze body with nonmetallic disc and bronze seat. D. Class 150, Bronze, Swing Check Valves: Bronze body with nonmetallic disc and bronze seat. PART 3 - EXECUTION 3.1 VALVE APPLICATIONS A. Use the following: 1. Shutoff or Throttling Service: a. 2 and smaller: Ball valves. b. 2 to 3 : Ball valves or high performance butterfly valves. c. 4 and larger: High performance butterfly valves. 2. Pump Discharge: Spring-loaded, lift-disc check valves. 3. If valves with specified SWP classes or CWP ratings are not available, the same types of valves with higher SWP class or CWP ratings may be substituted. 3.2 VALVE INSTALLATION A. Piping installation requirements are specified in other Division 23 Sections. Drawings indicate general arrangement of piping, fittings, and specialties. B. Install valves with unions or flanges at each piece of equipment arranged to allow service, maintenance, and equipment removal without system shutdown. C. Locate valves for easy access and provide separate support where necessary. D. Install gear operator handwheel with chainwheel for valves mounted 12 feet or higher above finished floor in mechanical areas. E. Install valves in horizontal piping with stem at or above center of pipe. F. Install valves in position to allow full stem movement. VALVES

8 G. Install valves at all branch take off. H. Install check valves for proper direction of flow and as follows: 1. Swing Check Valves: In horizontal position with hinge pin level. 2. Lift Check Valves: With stem upright and plumb. 3.3 JOINT CONSTRUCTION A. Refer to Division 23 Section "Basic Mechanical Materials and Methods" for basic piping joint construction. B. Grooved Joints: Assemble joints with keyed coupling housing, gasket, lubricant, and bolts according to coupling and fitting manufacturer's written instructions. C. Soldered Joints: Use ASTM B 813, water-flushable, lead-free flux; ASTM B 32, lead-freealloy solder; and ASTM B 828 procedure, unless otherwise indicated. 3.4 ADJUSTING A. Adjust or replace valve packing after piping systems have been tested and put into service but before final adjusting and balancing. Replace valves if persistent leaking occurs. END OF SECTION VALVES

9 SECTION HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT PART 1 - GENERAL 1.1 SUMMARY A. This Section includes hangers and supports for mechanical system piping and equipment. 1.2 PERFORMANCE REQUIREMENTS A. Design channel support systems for piping to support multiple pipes capable of supporting combined weight of supported systems, system contents, and test water. 1.3 QUALITY ASSURANCE A. Welding: Qualify procedures and personnel according to AWS D1.1, "Structural Welding Code--Steel." PART 2 - PRODUCTS 2.1 MANUFACTURERS 1. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the manufacturers specified. 2.2 MANUFACTURED UNITS A. Pipe Hangers, Supports, and Components: MSS SP-58, factory-fabricated components. 1. Manufacturers: a. B-Line Systems, Inc. b. Carpenter & Patterson, Inc. c. Globe Pipe Hanger Products, Inc. d. Grinnell Corp. e. GS Metals Corp. f. National Pipe Hanger Corp. 2. Galvanized, Metallic Coatings: For piping and equipment that will not have field-applied finish. 3. Nonmetallic Coatings: On attachments for electrolytic protection where attachments are in direct contact with copper tubing. 4. Field Painted Coatings: For all pipe hangers that are not coated shall have field applied finish applied. Finish shall be one coat of primer and two coats of approved paint. B. Channel Support Systems: MFMA-2, factory-fabricated components for field assembly. 1. Manufacturers: a. B-Line Systems, Inc. b. Grinnell Corp. c. GS Metals Corp. d. Thomas & Betts Corp. HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT

10 e. Unistrut Corp. 2. Coatings: Manufacturer's standard finish, unless bare metal surfaces are indicated. 3. Nonmetallic Coatings: On attachments for electrolytic protection where attachments are in direct contact with copper tubing. C. Thermal-Hanger Shield Inserts: 100-psi minimum compressive-strength insulation, encased in sheet metal shield. 1. Manufacturers: a. Carpenter & Patterson, Inc. b. PHS Industries, Inc. c. Pipe Shields, Inc. d. Rilco Manufacturing Co., Inc. e. Value Engineered Products, Inc. 2. Material for Cold Piping: ASTM C 552, Type I cellular glass or water-repellent-treated, ASTM C 533, Type I calcium silicate with vapor barrier. 3. Material for Hot Piping: ASTM C 552, Type I cellular glass or water-repellent-treated, ASTM C 533, Type I calcium silicate. 4. For Trapeze or Clamped System: Insert and shield cover entire circumference of pipe. 5. For Clevis or Band Hanger: Insert and shield cover lower 180 degrees of pipe. 6. Insert Length: Extend 2 inches beyond sheet metal shield for piping operating below ambient air temperature. 2.3 MISCELLANEOUS MATERIALS A. Powder-Actuated Drive-Pin Fasteners: Powder-actuated-type, drive-pin attachments with pullout and shear capacities appropriate for supported loads and building materials where used. B. Mechanical-Anchor Fasteners: Insert-type attachments with pull-out and shear capacities appropriate for supported loads and building materials where used. C. Structural Steel: ASTM A 36/A 36M, steel plates, shapes, and bars, black and galvanized. PART 3 - EXECUTION 3.1 APPLICATIONS A. Specific hanger requirements are specified in Sections specifying equipment and systems. B. Comply with MSS SP-69 for pipe hanger selections and applications that are not specified in piping system Specification Sections. C. Horizontal-Piping Hangers and Supports: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: 1. Adjustable Steel Clevis Hangers (MSS Type 1): For suspension of noninsulated or insulated stationary pipes, NPS 1/2 to NPS 30. D. Building Attachments: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT

11 1. Steel or Malleable Concrete Inserts (MSS Type 18): For upper attachment to suspend pipe hangers from concrete ceiling. 2. Top-Beam C-Clamps (MSS Type 19): For use under roof installations with bar-joist construction to attach to top flange of structural shape. 3. Side-Beam or Channel Clamps (MSS Type 20): For attaching to bottom flange of beams, channels, or angles. 4. Center-Beam Clamps (MSS Type 21): For attaching to center of bottom flange of beams. 5. C-Clamps (MSS Type 23): For structural shapes. E. Shields: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: 1. Protection Shields (MSS Type 40): Of length recommended by manufacturer to prevent crushing insulation. 3.2 INSTALLATION A. Pipe Hanger and Support Installation: Comply with MSS SP-69 and MSS SP-89. Install hangers, supports, clamps, and attachments as required to properly support piping from building structure. B. Channel Support System Installation: Arrange for grouping of parallel runs of piping and support together on field-assembled channel systems. Field assemble and install according to manufacturer's written instructions. C. Install building attachments within concrete slabs or attach to structural steel. Space attachments within maximum piping span length indicated in MSS SP-69. Install additional attachments at concentrated loads, including valves, flanges, guides, strainers, and expansion joints, and at changes in direction of piping. Install concrete inserts before concrete is placed; fasten inserts to forms and install reinforcing bars through openings at top of inserts. D. Install powder-actuated drive-pin fasteners in concrete after concrete is placed and completely cured. Use operators that are licensed by powder-actuated tool manufacturer. Install fasteners according to powder-actuated tool manufacturer's operating manual. E. Install hangers and supports complete with necessary inserts, bolts, rods, nuts, washers, and other accessories. F. Install hangers and supports to allow controlled thermal and seismic movement of piping systems, to permit freedom of movement between pipe anchors, and to facilitate action of expansion joints, expansion loops, expansion bends, and similar units. G. Load Distribution: Install hangers and supports so that piping live and dead loads and stresses from movement will not be transmitted to connected equipment. H. Pipe Slopes: Install hangers and supports to provide indicated pipe slopes and so maximum pipe deflections allowed by ASME B31.9, "Building Services Piping," is not exceeded. I. Insulated Piping: Comply with the following: 1. Attach clamps and spacers to piping. a. Piping Operating above Ambient Air Temperature: Clamp may project through insulation. b. Piping Operating below Ambient Air Temperature: Use thermal-hanger shield insert with clamp sized to match OD of insert. c. Do not exceed pipe stress limits according to ASME B31.9. HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT

12 2. Install MSS SP-58, Type 40 protective shields on cold piping. Shields shall span arc of 180 degrees. 3. Shield Dimensions for Pipe: Not less than 12 inches long and inch thick. 3.3 ADJUSTING A. Hanger Adjustment: Adjust hangers to distribute loads equally on attachments and to achieve indicated slope of pipe. 3.4 PAINTING A. Touching Up: Clean field welds and abraded areas of shop paint. Paint exposed areas immediately after erecting hangers and supports. Use same materials as used for shop painting. Comply with SSPC-PA 1 requirements for touching up field-painted surfaces. Apply paint by brush to provide a minimum dry film thickness of 2.0 mils. One coat of primer and two coats of finish, approved paint. B. Galvanized Surfaces: Clean welds, bolted connections, and abraded areas and apply galvanizing-repair paint to comply with ASTM A 780. END OF SECTION HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT

13 SECTION IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Equipment labels. 2. Warning signs and labels. 3. Pipe labels. 4. Duct labels. 1.2 ACTION SUBMITTAL A. Product Data: For each type of product indicated. PART 2 - PRODUCTS 2.1 EQUIPMENT LABELS A. Plastic Labels for Equipment: 1. Material and Thickness: Multilayer, multicolor, plastic labels for mechanical engraving, 1/8 inch thick, and having predrilled holes for attachment hardware. 2. Letter Color: Black. 3. Background Color: White. 4. Maximum Temperature: Able to withstand temperatures up to 160 deg F. 5. Minimum Label Size: Length and width vary for required label content, but not less than 2-1/2 by 3/4 inch. 6. Minimum Letter Size: 1/4 inch for name of units if viewing distance is less than 24 inches, 1/2 inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two-thirds to three-fourths the size of principal lettering. 7. Fasteners: Stainless-steel rivets or self-tapping screws. 8. Adhesive: Contact-type permanent adhesive, compatible with label and with substrate. B. Label Content: Include equipment's Drawing designation or unique equipment number, Drawing numbers where equipment is indicated (plans, details, and schedules), plus the Specification Section number and title where equipment is specified. C. Equipment Label Schedule: For each item of equipment to be labeled, on 8-1/2-by-11-inch (A4) bond paper. Tabulate equipment identification number and identify Drawing numbers where equipment is indicated (plans, details, and schedules), plus the Specification Section IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT

14 number and title where equipment is specified. Equipment schedule shall be included in operation and maintenance data. 2.2 WARNING SIGNS AND LABELS A. Material and Thickness: Multilayer, multicolor, plastic labels for mechanical engraving, 1/16 inch thick, and having predrilled holes for attachment hardware. B. Letter Color: Black. C. Background Color: Orange. D. Maximum Temperature: Able to withstand temperatures up to 160 deg F. E. Minimum Label Size: Length and width vary for required label content, but not less than 2-1/2 by 3/4 inch. F. Minimum Letter Size: 1/4 inch for name of units if viewing distance is less than 24 inches, 1/2 inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two-thirds to three-fourths the size of principal lettering. G. Fasteners: Stainless-steel rivets or self-tapping screws. H. Adhesive: Contact-type permanent adhesive, compatible with label and with substrate. I. Label Content: Include caution and warning information, plus emergency notification instructions. 2.3 PIPE LABELS A. General Requirements for Manufactured Pipe Labels: Preprinted, color-coded, with lettering indicating service, and showing flow direction. B. Pretensioned Pipe Labels: Precoiled, semirigid plastic formed to cover full circumference of pipe and to attach to pipe without fasteners or adhesive. C. Self-Adhesive Pipe Labels: Printed plastic with contact-type, permanent-adhesive backing. D. Pipe Label Contents: Include identification of piping service using same designations or abbreviations as used on Drawings, pipe size, and an arrow indicating flow direction. 1. Flow-Direction Arrows: Integral with piping system service lettering to accommodate both directions, or as separate unit on each pipe label to indicate flow direction. 2. Lettering Size: At least 1-1/2 inches high. IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT

15 2.4 DUCT LABELS A. Material and Thickness: Multilayer, multicolor, plastic labels for mechanical engraving, 1/16 inch thick, and having predrilled holes for attachment hardware. B. Letter Color: White. C. Background Color: Green. D. Maximum Temperature: Able to withstand temperatures up to 160 deg F. E. Minimum Label Size: Length and width vary for required label content, but not less than 2-1/2 by 3/4 inch. F. Minimum Letter Size: 1/4 inch for name of units if viewing distance is less than 24 inches, 1/2 inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two-thirds to three-fourths the size of principal lettering. G. Adhesive: Contact-type permanent adhesive, compatible with label and with substrate. H. Duct Label Contents: Include identification of duct service using same designations or abbreviations as used on Drawings, duct size, and an arrow indicating flow direction. 1. Flow-Direction Arrows: Integral with duct system service lettering to accommodate both directions, or as separate unit on each duct label to indicate flow direction. 2. Lettering Size: At least 1-1/2 inches high. PART 3 - EXECUTION 3.1 PREPARATION A. Clean piping and equipment surfaces of substances that could impair bond of identification devices, including dirt, oil, grease, release agents, and incompatible primers, paints, and encapsulants. 3.2 EQUIPMENT LABEL INSTALLATION A. Install or permanently fasten labels on each major item of mechanical equipment. B. Locate equipment labels where accessible and visible. 3.3 PIPE LABEL INSTALLATION A. Locate pipe labels where piping is exposed or above accessible ceilings in finished spaces; machine rooms; accessible maintenance spaces such as shafts, tunnels, and plenums; and exterior exposed locations as follows: IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT

16 1. Near each valve and control device. 2. Near each branch connection, excluding short takeoffs for fixtures and terminal units. Where flow pattern is not obvious, mark each pipe at branch. 3. Near penetrations through walls, floors, ceilings, and inaccessible enclosures. 4. At access doors, manholes, and similar access points that permit view of concealed piping. 5. Near major equipment items and other points of origination and termination. 6. Spaced at maximum intervals of 50 feet along each run. Reduce intervals to 25 feet in areas of congested piping and equipment. 7. On piping above removable acoustical ceilings. Omit intermediately spaced labels. B. Pipe Label Color Schedule: 1. Heating Water Piping: a. Background Color: White. b. Letter Color: Green. 2. Refrigerant Piping: a. Background Color: White. b. Letter Color: Green. 3.4 DUCT LABEL INSTALLATION A. Install plastic-laminated duct labels with permanent adhesive on air ducts in the following color codes: 1. Blue: For cold-air supply ducts. 2. Yellow: For hot-air supply ducts. 3. Green: For exhaust-, outside-, relief-, return-, and mixed-air ducts. 4. ASME A13.1 Colors and Designs: For hazardous material exhaust. B. Locate labels near points where ducts enter into concealed spaces and at maximum intervals of 50 feet in each space where ducts are exposed or concealed by removable ceiling system. END OF SECTION IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT

17 SECTION TESTING, ADJUSTING, AND BALANCING FOR HVAC PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Balancing Air Systems: a. Constant-volume air systems. b. Variable-air-volume systems. 2. Balancing Hydronic Piping Systems: a. Variable-flow hydronic systems. 1.2 DEFINITIONS A. AABC: Associated Air Balance Council. B. NEBB: National Environmental Balancing Bureau. C. TAB: Testing, adjusting, and balancing. D. TABB: Testing, Adjusting, and Balancing Bureau. E. TAB Specialist: An entity engaged to perform TAB Work. 1.3 INFORMATIONAL SUBMITTALS A. Strategies and Procedures Plan: Testing, adjusting, and balancing strategies and step-by-step procedures. Include a complete set of report forms intended for use on this Project. These documents shall be submitted 60 days before any onsite TAB work is scheduled to start. B. Certified Testing, Adjusting, and Balancing Reports: Prepared on approved forms certified by the testing, adjusting, and balancing Agent. 1.4 QUALITY ASSURANCE A. Agent Qualifications: Engage a testing, adjusting, and balancing agent certified by AABC or NEBB. B. Certification of Testing, Adjusting, and Balancing Reports: Certify testing, adjusting, and balancing field data reports. This certification includes the following: TESTING, ADJUSTING, AND BALANCING FOR HVAC

18 1. Review field data reports to validate accuracy of data and to prepare certified TAB reports. 2. Certify that the TAB team complied with the approved TAB plan and the procedures specified and referenced in this Specification. C. Testing, Adjusting, and Balancing Reports: Use standard forms from AABC's "National Standards for Testing, Adjusting, and Balancing" or NEBB equivalent. D. Instrumentation Type, Quantity, Accuracy, and Calibration: As described in ASHRAE 111, Section 5, "Instrumentation." E. ASHRAE Compliance: Applicable requirements in ASHRAE 62.1, Section "Air Balancing." F. ASHRAE/IESNA Compliance: Applicable requirements in ASHRAE/IESNA 90.1, Section "System Balancing." 1.5 PROJECT CONDITIONS A. Owner Occupancy: Cooperate with the Owner during testing, adjusting, and balancing operations to minimize conflicts with the Owner's operations. All work must be complete without disruption to educational activities and school operation. 1.6 COORDINATION A. Coordinate efforts of factory-authorized service representatives for systems and equipment, HVAC controls installers, and other mechanics to operate HVAC systems and equipment to support and assist testing, adjusting, and balancing activities. B. Perform testing, adjusting, and balancing after leakage and pressure tests on air and water distribution systems have been satisfactorily completed. 1.7 WARRANTY A. National Project Performance Guarantee: Provide a guarantee on AABC'S "National Standards" forms or NEBB equivalent stating that AABC or NEBB will assist in completing the requirements of the Contract Documents if the testing, adjusting, and balancing Agent fails to comply with the Contract Documents. Guarantee includes the following provisions: 1. The certified Agent has tested and balanced systems according to the Contract Documents. 2. Systems are balanced to optimum performance capabilities within design and installation limits. TESTING, ADJUSTING, AND BALANCING FOR HVAC

19 1.8 PRODUCTS (Not Applicable) PART 2 - EXECUTION 2.1 EXAMINATION A. Examine the Contract Documents to become familiar with project requirements and to discover conditions in systems' designs that may preclude proper testing, adjusting, and balancing of systems and equipment. 1. Verify that balancing devices, such as test ports, gage cocks, thermometer wells, flowcontrol devices, balancing valves and fittings, and manual volume dampers, are required by the Contract Documents. Verify that quantities and locations of these balancing devices are accessible and appropriate for effective balancing and for efficient system and equipment operation. B. Examine approved submittal data of HVAC systems and equipment. C. Examine Project Record Documents. D. Examine equipment performance data, including fan and pump curves. 1. Relate performance data to Project conditions and requirements, including system effects that can create undesired or unpredicted conditions that cause reduced capacities in all or part of a system. 2. Calculate system-effect factors to reduce performance ratings of HVAC equipment when installed under conditions different from the conditions used to rate equipment performance. To calculate system effects for air systems, use tables and charts found in AMCA 201, "Fans and Systems," or in SMACNA's "HVAC Systems - Duct Design." Compare results with the design data and installed conditions. E. Examine system and equipment installations to verify that they are complete and that testing, cleaning, adjusting, and commissioning specified in individual Specification Sections have been performed. F. Examine system and equipment test reports. G. Examine HVAC system and equipment installations to verify that indicated balancing devices, such as test ports, gage cocks, thermometer wells, flow-control devices, balancing valves and fittings, and manual volume dampers, are properly installed, and their locations are accessible and appropriate for effective balancing and for efficient system and equipment operation. H. Examine systems for functional deficiencies that cannot be corrected by adjusting and balancing. I. Examine air-handling equipment to ensure clean filters have been installed, bearings are greased, belts are aligned and tight, and equipment with functioning controls is ready for operation. TESTING, ADJUSTING, AND BALANCING FOR HVAC

20 J. Examine terminal units, such as variable-air-volume boxes and mixing boxes, to verify that they are accessible and their controls are connected and functioning. K. Examine strainers for clean screens and proper perforations. L. Examine heat-transfer coils for correct piping connections and for clean and straight fins. M. Examine system pumps to ensure absence of entrained air in the suction piping. N. Examine equipment for installation and for properly operating safety interlocks and controls. O. Examine automatic temperature system components to verify the following: 1. Dampers, valves, and other controlled devices operate by the intended controller. 2. Dampers and valves are in the position indicated by the controller. 3. Integrity of valves and dampers for free and full operation and for tightness of fully closed and fully open positions. This includes dampers in mixing boxes and variable-airvolume terminals. 4. Automatic modulating and shutoff valves, including two-way valves, are properly connected. 5. Thermostats and humidistats are located to avoid adverse effects of sunlight, drafts, and cold walls. 6. Sensors are located to sense only intended conditions. 7. Sequence of operation for control modes is according to the Contract Documents. 8. Controller set points are set at design values. Observe and record system reactions to changes in conditions. Record default set points if different from design values. 9. Interlocked systems are operating. P. Report deficiencies discovered before and during performance of TAB procedures. Observe and record system reactions to changes in conditions. Record default set points if different from indicated values. 2.2 PREPARATION A. Prepare a TAB plan that includes strategies and step-by-step procedures. B. Complete system-readiness checks and prepare reports. Verify the following: 1. Permanent electrical-power wiring is complete. 2. Hydronic systems are filled, clean, and free of air. 3. Automatic temperature-control systems are operational. 4. Equipment and duct access doors are securely closed. 5. Balance, smoke, and fire dampers are open. 6. Isolating and balancing valves are open and control valves are operational. 7. Ceilings are installed in critical areas where air-pattern adjustments are required and access to balancing devices is provided. 8. Windows and doors can be closed so indicated conditions for system operations can be met. TESTING, ADJUSTING, AND BALANCING FOR HVAC

21 2.3 GENERAL PROCEDURES FOR TESTING AND BALANCING A. Perform testing and balancing procedures on each system according to the procedures contained in SMACNA's "HVAC Systems - Testing, Adjusting, and Balancing" and in this Section. B. Cut insulation, ducts, pipes, and equipment cabinets for installation of test probes to the minimum extent necessary for TAB procedures. 1. After testing and balancing, patch probe holes in ducts with same material and thickness as used to construct ducts. 2. Install and join new insulation that matches removed materials. Restore insulation, coverings, vapor barrier, and finish according to Section "Duct Insulation," Section "HVAC Equipment Insulation," Section "HVAC Piping Insulation." C. Mark equipment and balancing devices, including damper-control positions, valve position indicators, fan-speed-control levers, and similar controls and devices, with paint or other suitable, permanent identification material to show final settings. D. Take and report testing and balancing measurements in inch-pound (IP) units. 2.4 GENERAL PROCEDURES FOR BALANCING AIR SYSTEMS A. Prepare test reports for both fans and outlets. Obtain manufacturer's outlet factors and recommended testing procedures. Crosscheck the summation of required outlet volumes with required fan volumes. B. Prepare schematic diagrams of systems' "as-built" duct layouts. C. For variable-air-volume systems, develop a plan to simulate diversity. D. Determine the best locations in main and branch ducts for accurate duct-airflow measurements. E. Check airflow patterns from the outdoor-air louvers and dampers and the return- and exhaust-air dampers through the supply-fan discharge and mixing dampers. F. Locate start-stop and disconnect switches, electrical interlocks, and motor starters. G. Verify that motor starters are equipped with properly sized thermal protection. H. Check dampers for proper position to achieve desired airflow path. I. Check for airflow blockages. J. Check condensate drains for proper connections and functioning. K. Check for proper sealing of air-handling-unit components. L. Verify that air duct system is sealed as specified in Section "Metal Ducts." TESTING, ADJUSTING, AND BALANCING FOR HVAC

22 2.5 PROCEDURES FOR CONSTANT-VOLUME AIR SYSTEMS A. Adjust fans to deliver total indicated airflows within the maximum allowable fan speed listed by fan manufacturer. 1. Measure total airflow. a. Where sufficient space in ducts is unavailable for Pitot-tube traverse measurements, measure airflow at terminal outlets and inlets and calculate the total airflow. 2. Measure fan static pressures as follows to determine actual static pressure: a. Measure outlet static pressure as far downstream from the fan as practical and upstream from restrictions in ducts such as elbows and transitions. b. Measure static pressure directly at the fan outlet or through the flexible connection. c. Measure inlet static pressure of single-inlet fans in the inlet duct as near the fan as possible, upstream from the flexible connection, and downstream from duct restrictions. d. Measure inlet static pressure of double-inlet fans through the wall of the plenum that houses the fan. 3. Measure static pressure across each component that makes up an air-handling unit, rooftop unit, and other air-handling and -treating equipment. a. Report the cleanliness status of filters and the time static pressures are measured. 4. Measure static pressures entering and leaving other devices, such as sound traps, heatrecovery equipment, and air washers, under final balanced conditions. 5. Obtain approval from Professional for adjustment of fan speed higher or lower than indicated speed. Comply with requirements in Sections for air-handling units for adjustment of fans, belts, and pulley sizes to achieve indicated air-handling-unit performance. 6. Do not make fan-speed adjustments that result in motor overload. Consult equipment manufacturers about fan-speed safety factors. Modulate dampers and measure fan-motor amperage to ensure that no overload will occur. Measure amperage in full-cooling, fullheating, economizer, and any other operating mode to determine the maximum required brake horsepower. B. Adjust volume dampers for main duct, submain ducts, and major branch ducts to indicated airflows within specified tolerances. 1. Measure airflow of submain and branch ducts. a. Where sufficient space in submain and branch ducts is unavailable for Pitot-tube traverse measurements, measure airflow at terminal outlets and inlets and calculate the total airflow for that zone. 2. Measure static pressure at a point downstream from the balancing damper, and adjust volume dampers until the proper static pressure is achieved. TESTING, ADJUSTING, AND BALANCING FOR HVAC

23 3. Remeasure each submain and branch duct after all have been adjusted. Continue to adjust submain and branch ducts to indicated airflows within specified tolerances. C. Measure air outlets and inlets without making adjustments. 1. Measure terminal outlets using a direct-reading hood or outlet manufacturer's written instructions and calculating factors. D. Adjust air outlets and inlets for each space to indicated airflows within specified tolerances of indicated values. Make adjustments using branch volume dampers rather than extractors and the dampers at air terminals. 1. Adjust each outlet in same room or space to within specified tolerances of indicated quantities without generating noise levels above the limitations prescribed by the Contract Documents. 2. Adjust patterns of adjustable outlets for proper distribution without drafts. 2.6 PROCEDURES FOR VARIABLE-AIR-VOLUME SYSTEMS A. Compensating for Diversity: When the total airflow of all terminal units is more than the indicated airflow of the fan, place a selected number of terminal units at a minimum set-point airflow with the remainder at maximum airflow condition until the total airflow of the terminal units equals the indicated airflow of the fan. Select the reduced-airflow terminal units so they are distributed evenly among the branch ducts. B. Pressure-Independent, Variable-Air-Volume Systems: After the fan systems have been adjusted, adjust the variable-air-volume systems as follows: 1. Set outdoor-air dampers at minimum, and set return- and exhaust-air dampers at a position that simulates full-cooling load. 2. Select the terminal unit that is most critical to the supply-fan airflow and static pressure. Measure static pressure. Adjust system static pressure so the entering static pressure for the critical terminal unit is not less than the sum of the terminal-unit manufacturer's recommended minimum inlet static pressure plus the static pressure needed to overcome terminal-unit discharge system losses. 3. Measure total system airflow. Adjust to within indicated airflow. 4. Set terminal units at maximum airflow and adjust controller or regulator to deliver the designed maximum airflow. Use terminal-unit manufacturer's written instructions to make this adjustment. When total airflow is correct, balance the air outlets downstream from terminal units the same as described for constant-volume air systems. 5. Set terminal units at minimum airflow and adjust controller or regulator to deliver the designed minimum airflow. Check air outlets for a proportional reduction in airflow the same as described for constant-volume air systems. a. If air outlets are out of balance at minimum airflow, report the condition but leave outlets balanced for maximum airflow. 6. Remeasure the return airflow to the fan while operating at maximum return airflow and minimum outdoor airflow. TESTING, ADJUSTING, AND BALANCING FOR HVAC

24 a. Adjust the fan and balance the return-air ducts and inlets the same as described for constant-volume air systems. 7. Measure static pressure at the most critical terminal unit and adjust the static-pressure controller at the main supply-air sensing station to ensure that adequate static pressure is maintained at the most critical unit. 8. Record final fan-performance data. C. Pressure-Dependent, Variable-Air-Volume Systems without Diversity: After the fan systems have been adjusted, adjust the variable-air-volume systems as follows: 1. Balance variable-air-volume systems the same as described for constant-volume air systems. 2. Set terminal units and supply fan at full-airflow condition. 3. Adjust inlet dampers of each terminal unit to indicated airflow and verify operation of the static-pressure controller. When total airflow is correct, balance the air outlets downstream from terminal units the same as described for constant-volume air systems. 4. Readjust fan airflow for final maximum readings. 5. Measure operating static pressure at the sensor that controls the supply fan if one is installed, and verify operation of the static-pressure controller. 6. Set supply fan at minimum airflow if minimum airflow is indicated. Measure static pressure to verify that it is being maintained by the controller. 7. Set terminal units at minimum airflow and adjust controller or regulator to deliver the designed minimum airflow. Check air outlets for a proportional reduction in airflow the same as described for constant-volume air systems. a. If air outlets are out of balance at minimum airflow, report the condition but leave the outlets balanced for maximum airflow. 8. Measure the return airflow to the fan while operating at maximum return airflow and minimum outdoor airflow. a. Adjust the fan and balance the return-air ducts and inlets the same as described for constant-volume air systems. D. Pressure-Dependent, Variable-Air-Volume Systems with Diversity: After the fan systems have been adjusted, adjust the variable-air-volume systems as follows: 1. Set system at maximum indicated airflow by setting the required number of terminal units at minimum airflow. Select the reduced-airflow terminal units so they are distributed evenly among the branch ducts. 2. Adjust supply fan to maximum indicated airflow with the variable-airflow controller set at maximum airflow. 3. Set terminal units at full-airflow condition. 4. Adjust terminal units starting at the supply-fan end of the system and continuing progressively to the end of the system. Adjust inlet dampers of each terminal unit to indicated airflow. When total airflow is correct, balance the air outlets downstream from terminal units the same as described for constant-volume air systems. 5. Adjust terminal units for minimum airflow. 6. Measure static pressure at the sensor. TESTING, ADJUSTING, AND BALANCING FOR HVAC

25 7. Measure the return airflow to the fan while operating at maximum return airflow and minimum outdoor airflow. Adjust the fan and balance the return-air ducts and inlets the same as described for constant-volume air systems. 2.7 GENERAL PROCEDURES FOR HYDRONIC SYSTEMS A. Prepare test reports with pertinent design data, and number in sequence starting at pump to end of system. Check the sum of branch-circuit flows against the approved pump flow rate. Correct variations that exceed plus or minus 5 percent. B. Prepare schematic diagrams of systems' "as-built" piping layouts. C. Prepare hydronic systems for testing and balancing according to the following, in addition to the general preparation procedures specified above: 1. Open all manual valves for maximum flow. 2. Check liquid level in expansion tank. 3. Check makeup water-station pressure gage for adequate pressure for highest vent. 4. Check flow-control valves for specified sequence of operation, and set at indicated flow. 5. Set differential-pressure control valves at the specified differential pressure. Do not set at fully closed position when pump is positive-displacement type unless several terminal valves are kept open. 6. Set system controls so automatic valves are wide open to heat exchangers. 7. Check pump-motor load. If motor is overloaded, throttle main flow-balancing device so motor nameplate rating is not exceeded. 8. Check air vents for a forceful liquid flow exiting from vents when manually operated. 2.8 PROCEDURES FOR VARIABLE-FLOW HYDRONIC SYSTEMS A. Balance systems with automatic two- and three-way control valves by setting systems at maximum flow through heat-exchange terminals and proceed as specified above for hydronic systems. 2.9 PROCEDURES FOR MOTORS A. Motors, 1/2 HP and Larger: Test at final balanced conditions and record the following data: 1. Manufacturer's name, model number, and serial number. 2. Motor horsepower rating. 3. Motor rpm. 4. Efficiency rating. 5. Nameplate and measured voltage, each phase. 6. Nameplate and measured amperage, each phase. 7. Starter thermal-protection-element rating. B. Motors Driven by Variable-Frequency Controllers: Test for proper operation at speeds varying from minimum to maximum. Test the manual bypass of the controller to prove proper TESTING, ADJUSTING, AND BALANCING FOR HVAC

26 operation. Record observations including name of controller manufacturer, model number, serial number, and nameplate data PROCEDURES FOR CONDENSING UNITS A. Verify proper rotation of fans. B. Measure entering- and leaving-air temperatures. C. Record compressor data PROCEDURES FOR HEAT-TRANSFER COILS A. Measure, adjust, and record the following data for each water coil: 1. Entering- and leaving-water temperature. 2. Water flow rate. 3. Water pressure drop. 4. Dry-bulb temperature of entering and leaving air. 5. Wet-bulb temperature of entering and leaving air for cooling coils. 6. Airflow. 7. Air pressure drop. B. Measure, adjust, and record the following data for each electric heating coil: 1. Nameplate data. 2. Airflow. 3. Entering- and leaving-air temperature at full load. 4. Voltage and amperage input of each phase at full load and at each incremental stage. 5. Calculated kilowatt at full load. 6. Fuse or circuit-breaker rating for overload protection. C. Measure, adjust, and record the following data for each steam coil: 1. Dry-bulb temperature of entering and leaving air. 2. Airflow. 3. Air pressure drop. 4. Inlet steam pressure. D. Measure, adjust, and record the following data for each refrigerant coil: 1. Dry-bulb temperature of entering and leaving air. 2. Wet-bulb temperature of entering and leaving air. 3. Airflow. 4. Air pressure drop. 5. Refrigerant suction pressure and temperature. TESTING, ADJUSTING, AND BALANCING FOR HVAC