HEATING, VENTILATING AND AIR CONDITIONING (HVAC)

Transcription

1 HEATING, VENTILATING AND AIR CONDITIONING (HVAC) GENERAL PROVISIONS A. HVAC Design Criteria Design and installation of HVAC systems and equipment shall comply with all applicable codes. These shall include the latest edition of the following: ICC Mechanical Code Requirement of local jurisdictions. B. All equipment, apparatus and systems shall be fabricated and installed in complete accordance with the latest edition or revision of the following applicable regulations, standards and codes: AHRI ASH RAE ASME ASTM AMCA NFPA NEC NEMA OSHA SMACNA UL Air Conditioning, Heating and Refrigeration Institute American Society of Heating, Refrigerating and Air Conditioning Engineers American Society of Mechanical Engineers American Society for Testing Material Air Moving and Conditioning Association National Fire Protection Association National Electrical Code National Electric Manufacturers Association Occupational Safety and Health Administration Sheet Metal and Air Conditioning Contractors National Association Underwriters Laboratories, Inc. C. Balancing All HVAC systems shall be balanced by a Certified (NEBB or AABC) independent balancing firm not affiliated with or owned by the construction contractor. Balance reports shall bear the seal of certification. END OF SECTION HEATING, VENTILATION AND AIR CONDITIONING

2 THIS PAGE INTENTIONALLY LEFT BLANK

3 COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT A. General 1. Motors larger than 1/2 HP shall be polyphase. 2. Motors shall be rated for continuous duty at 100% of rated load. B. Polyphase Motors 1. Multi-speed motors shall have separate windings for each speed. 2. Energy efficient motors shall be provided with nominal efficiency equal to or greater than that required by NEMA MG1 table 12-6C for that type and rating. 3. Motors shall be provided with internal thermal overload protection which operates when winding temperature exceeds the rating of the motor insulation. END OF SECTION COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT

4 THIS PAGE INTENTIONALLY LEFT BLANK

5 METERS AND GAGES FOR HVAC PIPING A. Thermometers 1. Scale Ranges: a. Chilled water 0 to 100 deg. F with 2-degree scale divisions. 2. Thermometers shall have an accuracy of plus or minus 1 percent of range span or plus or minus one scale division to maximum of 15 percent of range span. 3. Thermometer shall match type and dimensions of existing thermometers. B. Thermometer Wells 1. Thermometer wells shall be brass. 2. Thermometer wells shall have the same installed system design pressure rating as the system. 3. Thermometer wells shall be insulated with the same thickness as the pipe they are installed. C. Pressure Gages 1. Pressure gages shall be phosphor-bronze Bourdon-tube with bottom connection, and shall match type and dimensions of existing pressure gages. 2. Case shall be drawn steel, brass, or aluminum with a 4-1/2 inch diameter glass lens. 3. Pressure gage accuracy shall be plus or minus 1 percent of range span. 4. Pressure gage range shall be 30 inches Hg of vacuum to 15 psig of pressure or 2 times the system operating pressure. 5. Thermometers and Pressure Gages shall be installed in locations necessary to perform system and equipment capacity tests and balancing. Thermometers and pressure gages shall be installed as a minimum in all of the following: a. At the inlet and outlet of the chiller. b. Pressure gages at the suction and discharge of chilled water pump. END OF SECTION METERS AND GAGES FOR HVAC PIPING

6 THIS PAGE INTENTIONALLY LEFT BLANK

7 GENERAL DUTY VALVES FOR HVAC PIPING A. Quality Assurance 1. All valves of one type unless provided as part of a particular piece of equipment shall be of the same manufacturer. 2. Comply with various MSS Standard Practice documents as applicable for valve type and application. 3. Shutoff and isolation valves shall be of the same size as the upstream pipe. 4. Control valves shall be sized to operate at about 60 percent open at the maximum load of the equipment or system. B. Operators C. Valves 1. Lever handles shall be used quarter-turn valves 6 inches and smaller, except plug valves, which shall have square heads. 2. Extend stems shall be provided where pipe is to receive insulation. 1. Ball valves 4 inches and smaller shall comply with MSS SP-11 0 and have bronze body and bonnet, 2 piece construction, chrome-plated brass ball, standard port for 1/2-inch valves and smaller and conventional port for 3/4-inch valves and larger; blowout proof; bronze or brass stern; Teflon seats and seals. 2. Butterfly valves shall have cast iron body and bonnet, extended neck, stainless steel stem, field replaceable EPDM or BunaN sleeve and stem seals. Butterfly valves 6 inches and under shall be provided with lever handle operators with latch lock. Butterfly valves over 8 inches shall be provided with gear driven operators with position indicator. 3. Valves shall be installed in horizontal piping with stem at or above center of the pipe. 4. Valves shall be installed with unions or flanges at each piece of equipment arranged to allow servicing, maintenance and equipment removal without system shutdown. D. Valve Application 1. Chilled Water Systems: a. Ball valves, class 150, 600 psi CWP, with stem extension and memory stop. b. Butterfly valves nickel-plated ductile iron, aluminum bronze or elastomer coated ductile iron disc. GENERAL DUTY VALVES FOR HVAC PIPING

8 THIS PAGE INTENTIONALLY LEFT BLANK

9 HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT 1. Hangers, supports and components shall be factory fabricated according to MSS-SP Components shall have galvanized coatings where installed for piping and equipment that will not have a field applied finish. 3. Non-metallic coatings shall be applied for pipe attachments in direct contact with copper tubing. 4. Parallel runs of horizontal pipe shall be grouped and supported together on field fabricated heavy-duty trapeze hangers where possible. 5. Fire protection systems piping shall be supported independent of other piping. 6. Hangers and support shall allow for movement of piping systems, permit freedom of movement between pipe anchors and facilitate action of expansion joints, expansion loops, expansion bends and similar units. END OF SECTION HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT

10 THIS PAGE INTENTIONALLY LEFT BLANK

11 SECTION TESTING, ADJUSTING, AND BALANCING FOR HVAC PART 1- GENERAL A. RELATED DOCUMENTS 1. Drawings and general prov1s1ons of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. B. SUMMARY 1. Section Includes: a. Balancing Hydronic Piping Systems: i. Constant-flow hydronic systems. b. Testing, Adjusting, and Balancing Equipment: i. Motors. ii. Chillers. c. Testing, adjusting, and balancing existing systems and equipment. d. Sound tests. e. Vibration tests. f. Control system verification. C. DEFINITIONS 1. AABC: Associated Air Balance Council. 2. BAS: Building automation systems. 3. NEBB: National Environmental Balancing Bureau. 4. TAB: Testing, adjusting, and balancing. 5. TABB: Testing, Adjusting, and Balancing Bureau. 6. TAB Specialist: An independent entity meeting qualifications to perform TAB work. 7. TDH: Total dynamic head. D. PREINSTALLATION MEETINGS 1. TAB Conference: If requested by the Owner, conduct a TAB conference at Project site after approval of the TAB strategies and procedures plan to develop a mutual TESTING ADJUSTING AND BALANCING FOR HVAC

12 understanding of the details. Provide a minimum of 14 days' advance notice of scheduled meeting time and location. a. Minimum Agenda Items: i. The Contract Documents examination report. ii. The TAB plan. iii. Needs for coordination and cooperation of trades and subcontractors. iv. Proposed procedures for documentation and communication flow. E. INFORMATIONAL SUBMITTALS 1. Qualification Data: Within 30 days of Contractor's Notice to Proceed, submit documentation that the TAB specialist and this Project's TAB team members meet the qualifications specified in "Quality Assurance" Article. 2. Contract Documents Examination Report: Within 30 days of Contractor's Notice to Proceed, submit the Contract Documents review report as specified in Part Strategies and Procedures Plan: Within 30 days of Contractor's Notice to Proceed, submit TAB strategies and step-by-step procedures as specified in "Preparation" Article. 4. System Readiness Checklists: Within 60 days of Contractor's Notice to Proceed, submit system readiness checklists as specified in "Preparation" Article. 5. Examination Report: Submit a summary report of the examination review required in "Examination" Article. 6. Certified TAB reports. 7. Sample report forms. 8. Instrument calibration reports, to include the following: a. Instrument type and make. b. Serial number. c. Application. d. Dates of use. e. Dates of calibration. F. QUALITY ASSURANCE 1. TAB Specialists Qualifications: Certified by AABC or NEBB. a. TAB Field Supervisor: Employee of the TAB specialist and certified by AABC or NEBB. b. TAB Technician: Employee of the TAB specialist and certified by AABC or NEBB as a TAB technician. TESTING ADJUSTING AND BALANCING FOR HVAC

13 2. Instrumentation Type, Quantity, Accuracy, and Calibration: Comply with requirements in ASHRAE 111, Section 4, "Instrumentation." 3. ASHRAE Compliance: Applicable requirements in ASHRAE 62.1, Section "Air Balancing." 4. ASHRAE/IESNA Compliance: Applicable requirements in ASHRAE/IESNA 90.1, Section "System Balancing." G. FIELD CONDITIONS 1. Full Owner Occupancy: Owner will occupy the site and existing building during entire TAB period. Cooperate with Owner during TAB operations to minimize conflicts with Owner's operations. 2. Partial Owner Occupancy: Owner may occupy completed areas of building before Substantial Completion. Cooperate with Owner during TAB operations to minimize conflicts with Owner's operations. PART 2- PRODUCTS (Not Applicable) PART 3- EXECUTION A. EXAMINATION 1. Examine the Contract Documents to become familiar with Project requirements and to discover conditions in systems designs that may preclude proper TAB of systems and equipment. 2. Examine installed systems for balancing devices, such as test ports, gage cocks, thermometer wells, flow-control devices, balancing valves and fittings, and manual volume dampers. Verify that locations of these balancing devices are applicable for intended purpose and are accessible. 3. Examine the approved submittals for chiller systems and equipment. 4. Examine design data including chiller system descriptions, statements of design assumptions for environmental conditions and systems output, and statements of philosophies and assumptions about chiller system and equipment controls. 5. Examine equipment performance data including pump curves. a. 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. 6. Examine system and equipment installations and verify that field quality-control testing, cleaning, and adjusting specified in individual Sections have been performed. TESTING ADJUSTING AND BALANCING FOR HVAC

14 7. Examine test reports specified in individual system and equipment Sections. 8. Examine chiller and pump equipment and verify that bearings are greased, and equipment with functioning controls is ready for operation. 9. Examine strainers. Verify that startup screens have been replaced by permanent screens with indicated perforations. 10. Examine system pumps to ensure absence of entrained air in the suction piping. 11. Examine operating safety interlocks and controls on chiller equipment. 12. 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. B. PREPARATION 1. Prepare a TAB plan that includes the following: a. Equipment and systems to be tested. b. Strategies and step-by-step procedures for balancing the systems. c. Instrumentation to be used. d. Sample forms with specific identification for all equipment. 2. Perform system-readiness checks of chiller systems and equipment to verify system readiness for TAB work. Include, at a minimum, the following: a. Hydronics: i. Verify leakage and pressure tests on water distribution systems have been satisfactorily completed. ii. Piping is complete with terminals installed. iii. Water treatment is complete. iv. Systems are flushed, filled, and air purged. v. Strainers are pulled and cleaned. vi. Control valves are functioning per the sequence of operation. vii. Shutoff and balance valves have been verified to be 100 percent open. viii. Pumps are started and proper rotation is verified. ix. Pump gage connections are installed directly at pump inlet and outlet flanges or in discharge and suction pipe prior to valves or strainers. x. Variable-frequency controllers' startup is complete and safeties are verified. xi. Suitable access to balancing devices and equipment is provided. C. GENERAL PROCEDURES FOR TESTING AND BALANCING 1. Perform testing and balancing procedures on each system according to the procedures contained in AABC's "National Standards for Total System Balance", ASHRAE 111, NEBB's "Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems". TESTING ADJUSTING AND BALANCING FOR HVAC

15 2. Cut insulation, pipes, and equipment cabinets for installation of test probes to the minimum extent necessary for TAB procedures. a. Install and join new insulation that matches removed materials. Restore insulation, coverings, vapor barrier, and finish according to Section "HVAC Piping Insulation." 3. Mark equipment and balancing devices, including valve position indicators, and similar controls and devices, with paint or other suitable, permanent identification material to show final settings. 4. Take and report testing and balancing measurements in inch-pound (IP) units. D. GENERAL PROCEDURES FOR HYDRONIC SYSTEMS 1. Prepare test reports for pumps, coils, and heat exchangers. Obtain approved submittals and manufacturer-recommended testing procedures. Crosscheck the summation of required coil and heat exchanger flow rates with pump design flow rate. 2. Prepare schematic diagrams of systems' "as-built" piping layouts. 3. In addition to requirements in "Preparation" Article, prepare hydronic systems for testing and balancing as follows: a. Check liquid level in expansion tank. b. Check highest vent for adequate pressure. c. Check flow-control valves for proper position. d. Locate start-stop and disconnect switches, electrical interlocks, and motor starters. e. Verify that motor starters are equipped with properly sized thermal protection. f. Check that air has been purged from the system. E. PROCEDURES FOR CONSTANT-FLOW HYDRONIC SYSTEMS 1. Adjust pump to deliver total design gpm. a. Measure pump TDH as follows: i. Measure discharge pressure directly at the pump outlet flange or in discharge pipe prior to any valves. ii. Measure inlet pressure directly at the pump inlet flange or in suction pipe prior to any valves or strainers. iii. Convert pressure to head and correct for differences in gage heights. iv. Verify pump impeller size by measuring the TDH with the discharge valve closed. Note the point on manufacturer's pump curve at zero flow, and verify that the pump has the intended impeller size. v. With valves open, read pump TDH. Adjust pump discharge valve until design water flow is achieved. b. Monitor motor performance during procedures and do not operate motor in an overloaded condition. TESTING ADJUSTING AND BALANCING FOR HVAC

16 2. Verify final system conditions as follows: a. Re-measure and confirm that total water flow is within design. b. Re-measure final pumps' operating data, TDH, volts, amps, and static profile. c. Mark final settings. F. PROCEDURES FOR MOTOR 1. Motors 1/2 HP and Larger: Test at final balanced conditions and record the following data: a. Manufacturer's name, model number, and serial number. b. Motor horsepower rating. c. Motor rpm. d. Phase and hertz. e. Nameplate and measured voltage, each phase. f. Nameplate and measured amperage, each phase. g. Starter size and thermal-protection-element rating. h. Service factor and frame size. G. PROCEDURES FOR CHILLER 1. Balance water flow through each evaporator and condenser to within specified tolerances of indicated flow with all pumps operating. Do not exceed the flow for the maximum tube velocity recommended by the chiller manufacturer. Measure and record the following data with chiller operating at design conditions: a. Evaporator-water entering and leaving temperatures, pressure drop, and water flow. b. Evaporator and condenser refrigerant temperatures and pressures, using instruments furnished by chiller manufacturer. c. Power factor if factory-installed instrumentation is furnished for measuring kilowatts. d. Kilowatt input if factory-installed instrumentation is furnished for measuring kilowatts. e. Capacity: Calculate in tons of cooling. f. For air-cooled chillers, verify condenser-fan rotation and record fan and motor data including number of fans and entering- and leaving-air temperatures. H. CONTROLS VERIFICATION 1. In conjunction with system balancing, perform the following: a. Verify temperature control system is operating within the design limitations. b. Confirm that the sequences of operation are in compliance with Contract Documents. c. Verify that controllers are calibrated and function as intended. d. Verify that controller set points are as indicated. e. Verify the operation of lockout or interlock systems. TESTING ADJUSTING AND BALANCING FOR HVAC

17 f. Verify the operation of valve and damper actuators. g. Verify that controlled devices are properly installed and connected to correct controller. h. Verify that controlled devices travel freely and are in position indicated by controller: open, closed, or modulating. i. Verify location and installation of sensors to ensure that they sense only intended temperature, humidity, or pressure. 2. Reporting: Include a summary of verifications performed, remaining deficiencies, and variations from indicated conditions. I. TOLERANCES 1. Set HVAC system's water flow rates within the following tolerances: a. Cooling-Water Flow Rate: Plus or minus 10 percent. 2. Maintaining pressure relationships as designed shall have priority over the tolerances specified above. J. FINAL REPORT 1. General: Prepare a certified written report; tabulate and divide the report into separate sections for tested systems and balanced systems. a. Include a certification sheet at the front of the report's binder, signed and sealed by the certified testing and balancing engineer. b. Include a list of instruments used for procedures, along with proof of calibration. c. Certify validity and accuracy of field data. 2. Final Report Contents: In addition to certified field-report data, include the following: a. Pump curves. b. Manufacturers' test data. c. Field test reports prepared by system and equipment installers. d. Other information relative to equipment performance; do not include Shop Drawings and Product Data. 3. General Report Data: In addition to form titles and entries, include the following data: a. Title page. b. Name and address of the TAB specialist. c. Project name. d. Project location. e. Engineer's name and address. f. Contractor's name and address. g. Report date. h. Signature of TAB supervisor who certifies the report. i. Table of Contents with the total number of pages defined for each section of the report. Number each page in the report. j. Summary of contents including the following: TESTING ADJUSTING AND BALANCING FOR HVAC

18 i. Indicated versus final performance. ii. Notable characteristics of systems. iii. Description of system operation sequence if it varies from the Contract Documents. k. Nomenclature sheets for each item of equipment. I. Notes to explain why certain final data in the body of reports vary from indicated values. m. Test conditions and pump performance forms including the following: i. System operating conditions that affect performance. 4. System Diagrams: Include schematic layouts and hydronic distribution systems. Present each system with single-line diagram and include the following: a. Water flow rates. b. Outlet, and inlet sizes. c. Pipe and valve sizes and locations. d. Position of balancing devices. 5. Pump Test Reports: Calculate impeller size by plotting the shutoff head on pump curves and include the following: a. Unit Data: i. Unit identification. ii. Location. iii. Service. iv. Make and size. v. Model number and serial number. vi. Water flow rate in gpm. vii. Water pressure differential in feet of head or psig. viii. Required net positive suction head in feet of head or psig. ix. Pump rpm. x. Impeller diameter in inches. xi. Motor make and frame size. xii. Motor horsepower and rpm. xiii. Voltage at each connection. xiv. Amperage for each phase. xv. Full-load amperage and service factor. xvi. Seal type. b. Test Data (Indicated and Actual Values): i. Static head in feet of head or psig. ii. Pump shutoff pressure in feet of head or psig. iii. Actual impeller size in inches. iv. Full-open flow rate in gpm. v. Full-open pressure in feet of head or psig. vi. Final discharge pressure in feet of head or psig. vii. Final suction pressure in feet of head or psig. viii. Final total pressure in feet of head or psig. ix. Final water flow rate in gpm. TESTING ADJUSTING AND BALANCING FOR HVAC

19 x. Voltage at each connection. xi. Amperage for each phase. 6. Instrument Calibration Reports: a. Report Data: i. Instrument type and make. ii. Serial number. iii. Application. iv. Dates of use. v. Dates of calibration. K. VERIFICATION OF TAB REPORT 1. The TAB specialist's test and balance engineer shall conduct the inspection in the presence of Owner and Construction Manager. 2. Owner and Construction Manager shall randomly select measurements, documented in the final report, to be rechecked. Rechecking shall be limited to either 10 percent of the total measurements recorded or the extent of measurements that can be accomplished in a normal 8-hour business day. 3. If rechecks yield measurements that differ from the measurements documented in the final report by more than the tolerances allowed, the measurements shall be noted as "FAILED." 4. If the number of "FAILED" measurements is greater than 10 percent of the total measurements checked during the final inspection, the testing and balancing shall be considered incomplete and shall be rejected. 5. If TAB work fails, proceed as follows: a. TAB specialists shall recheck all measurements and make adjustments. Revise the final report and balancing device settings to include all changes; resubmit the final report and request a second final inspection. b. If the second final inspection also fails, Owner may contract the services of another TAB specialist to complete TAB work according to the Contract Documents and deduct the cost of the services from the original TAB specialist's final payment. c. If the second verification also fails, Owner and design professional may contact AABC Headquarters regarding the AABC National Performance Guaranty. 6. Prepare test and inspection reports. L. ADDITIONAL TESTS 1. Within 90 days of completing TAB, perform additional TAB to verify that balanced conditions are being maintained throughout and to correct unusual conditions. TESTING ADJUSTING AND BALANCING FOR HVAC

20 2. Seasonal Periods: If initial TAB procedures were not performed during near-peak summer and winter conditions, perform additional TAB during near-peak summer and winter conditions. END OF SECTION TESTING ADJUSTING AND BALANCING FOR HVAC

21 SECTION HVAC EQUIPMENT INSULATION PART 1 -GENERAL A. SUMMARY 1. Section includes insulating the following HVAC equipment that is not factory insulated: a. Chilled-water pump. B. ACTION SUBMITTALS 1. Product Data: For each type of product indicated. 2. Shop Drawings: Include plans, elevations, sections, details, and attachments to other work. a. Detail application of protective shields, saddles, and inserts at hangers for each type of insulation and hanger. b. Detail removable insulation at equipment connections. c. Detail application at linkages of control devices. d. Detail field application for each equipment type. C. INFORMATIONAL SUBMITTALS 1. Field quality-control reports. D. QUALITY ASSURANCE 1. Surface-Burning Characteristics: For insulation and related materials, as determined by testing identical products according to ASTM E 84, by a testing agency acceptable to authorities having jurisdiction. Factory label insulation and jacket materials and adhesive, mastic, tapes, and cement material containers, with appropriate markings of applicable testing agency. a. Insulation Installed Indoors: Flame-spread index of 25 or less, and smoke-developed index of 50 or less. b. Insulation Installed Outdoors: Flame-spread index of 75 or less, and smoke-developed index of 150 or less. HVAC EQUIPMENT INSULATION

22 PART 2 - PRODUCTS A. INSULATION MATERIALS 1. Products shall not contain asbestos, lead, mercury, or mercury compounds. 2. Products that come in contact with stainless steel shall have a leachable chloride content of less than 50 ppm when tested according to ASTM C Insulation materials for use on austenitic stainless steel shall be qualified as acceptable according to ASTM C Foam insulation materials shall not use CFC or HCFC blowing agents in the manufacturing process. 5. Flexible Elastomeric Insulation: Closed-cell, sponge- or expanded-rubber materials. Comply with ASTM C 534, Type I for tubular materials and Type II for sheet materials. B. ADHESIVES 1. Materials shall be compatible with insulation materials, jackets, and substrates and for bonding insulation to itself and to surfaces to be insulated unless otherwise indicated. 2. Flexible Elastomeric Adhesive: Comply with MIL-A-24179A, Type II, Class I. a. For indoor applications, adhesive shall have a VOC content of 50 g/l or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24). b. Adhesive shall comply with the testing and product requirements of the California Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small Scale Environmental Chambers." C. SEALANTS 1. Joint Sealants: a. Materials shall be compatible with insulation materials, jackets, and substrates. b. Permanently flexible, elastomeric sealant. c. Service Temperature Range: Minus 100 to plus 300 deg F. d. Color: White or gray. e. For indoor applications, sealants shall have a VOC content of 420 g/l or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24). HVAC EQUIPMENT INSULATION

23 D. SECUREMENTS 1. Aluminum Bands: ASTM B 209, Alloy 3003, 3005, 3105, or 5005; Temper H- 14, inch thick, 1/2 inch wide with closed seal. 2. Staples: Outward-clinching insulation staples, nominal 3/4-inch-wide, stainless steel or Monel. 3. Wire: inch nickel-copper alloy soft-annealed, stainless steel inch soft-annealed, galvanized steel. E. CORNER ANGLES 1. Aluminum Corner Angles: inch thick, mm1mum 1 by 1 inch, aluminum according to ASTM B 209, Alloy 3003, 3005, 3105, or 5005; Temper H-14. PART 3- EXECUTION A. PREPARATION 1. Surface Preparation: Clean and dry surfaces to receive insulation. Remove materials that will adversely affect insulation application. 2. Coordinate insulation installation with the trade installing heat tracing. Comply with requirements for heat tracing that apply to insulation. 3. Mix insulating cements with clean potable water; if insulating cements are to be in contact with stainless-steel surfaces, use demineralized water. B. GENERAL INSTALLATION REQUIREMENTS 1. Install insulation materials, accessories, and finishes with smooth, straight, and even surfaces; free of voids throughout the length of equipment. 2. Install insulation materials, forms, vapor barriers or retarders, jackets, and thicknesses required for each item of equipment as specified in insulation system schedules. 3. Install accessories compatible with insulation materials and suitable for the service. Install accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state. 4. Install insulation with longitudinal seams at top and bottom of horizontal runs. 5. Install multiple layers of insulation with longitudinal and end seams staggered. 6. Keep insulation materials dry during application and finishing. HVAC EQUIPMENT INSULATION

24 7. Install insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by insulation material manufacturer. 8. Install insulation with least number of joints practical. 9. Where vapor barrier is indicated, seal joints, seams, and penetrations in insulation at hangers, supports, anchors, and other projections with vapor-barrier mastic. a. Install insulation continuously through hangers and around anchor attachments. b. For insulation application where vapor barriers are indicated, extend insulation on anchor legs from point of attachment to supported item to point of attachment to structure. Taper and seal ends at attachment to structure with vapor-barrier mastic. c. Install insert materials and install insulation to tightly join the insert. Seal insulation to insulation inserts with adhesive or sealing compound recommended by insulation material manufacturer. d. Cover inserts with jacket material matching adjacent insulation. Install shields over jacket, arranged to protect jacket from tear or puncture by hanger, support, and shield. 10. Apply adhesives, mastics, and sealants at manufacturer's recommended coverage rate and wet and dry film thicknesses. 11. Cut insulation in a manner to avoid compressing insulation more than 75 percent of its nominal thickness. 12. Finish installation with systems at operating conditions. Repair joint separations and cracking due to thermal movement. 13. Repair damaged insulation facings by applying same facing material over damaged areas. Extend patches at least 4 inches beyond damaged areas. Adhere, staple, and seal patches similar to butt joints. 14. For above ambient services, do not install insulation to the following: a. Vibration-control devices. b. Testing agency labels and stamps. c. Nameplates and data plates. d. Manholes. e. Handholes. f. Cleanouts. C. FIELD QUALITY CONTROL 1. Perform tests and inspections. HVAC EQUIPMENT INSULATION

25 2. Tests and Inspections: Inspect field-insulated equipment, by removing fieldapplied jacket and insulation in layers in reverse order of their installation. Extent of inspection shall be limited to one location(s) for each type of equipment defined in the "Equipment Insulation Schedule" Article. For large equipment, remove only a portion adequate to determine compliance. 3. All insulation applications will be considered defective Work if sample inspection reveals noncompliance with requirements. END OF SECTION HVAC EQUIPMENT INSULATION

26 THIS PAGE INTENTIONALLY LEFT BLANK

27 SECTION HVAC PIPING INSULATION PART 1 -GENERAL A. SUMMARY 1. Section includes insulating the following HVAC piping systems: a. Chilled-water piping, indoors and outdoors. B. ACTION SUBMITTALS 1. Product Data: For each type of product indicated. a. 2. Shop Drawings: Include plans, elevations, sections, details, and attachments to other work. a. Detail application of protective shields, saddles, and inserts at hangers for each type of insulation and hanger. b. Detail insulation application at elbows, fittings, flanges, valves, and specialties for each type of insulation. c. Detail removable insulation at piping specialties. d. Detail application of field-applied jackets. e. Detail application at control devices. C. INFORMATIONAL SUBMITTALS 1. Field quality-control reports. D. QUALITY ASSURANCE 1. Surface-Burning Characteristics: For insulation and related materials, as determined by testing identical products according to ASTM E 84, by a testing and inspecting agency acceptable to authorities having jurisdiction. Factory label insulation and jacket materials and adhesive, mastic, tapes, and cement material containers, with appropriate markings of applicable testing agency. a. Insulation Installed Indoors: Flame-spread index of 25 or less, and smokedeveloped index of 50 or less. b. Insulation Installed Outdoors: Flame-spread index of 75 or less, and smokedeveloped index of 150 or less. HVAC PIPING INSULATION

28 PART 2- PRODUCTS A. INSULATION MATERIALS 1. Products shall not contain asbestos, lead, mercury, or mercury compounds. 2. Products that come in contact with stainless steel shall have a leachable chloride content of less than 50 ppm when tested according to ASTM C Insulation materials for use on austenitic stainless steel shall be qualified as acceptable according to ASTM C Foam insulation materials shall not use CFC or HCFC blowing agents in the manufacturing process. 5. Flexible Elastomeric Insulation: Closed-cell, sponge- or expanded-rubber materials. Comply with ASTM C 534, Type I for tubular materials. 6. Mineral-Fiber Blanket Insulation: Mineral or glass fibers bonded with a thermosetting resin. Comply with ASTM C 1290, Type I. 7. Mineral-Fiber, Preformed Pipe Insulation: a. Type I, 850 deg F Materials: Mineral or glass fibers bonded with a thermosetting resin. Comply with ASTM C 547, Type I, Grade A, with factory-applied ASJ. B. INSULATING CEMENTS 1. Mineral-Fiber, Hydraulic-Setting Insulating and Finishing Cement: Comply with ASTM C449. C. ADHESIVES 1. Materials shall be compatible with insulation materials, jackets, and substrates and for bonding insulation to itself and to surfaces to be insulated unless otherwise indicated. 2. Flexible Elastomeric and Polyolefin Adhesive: Comply with MIL-A-24179A, Type II, Class I. a. For indoor applications, adhesive shall have a VOC content of 50 g/l or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24). 3. Mineral-Fiber Adhesive: Comply with MIL-A-3316C, Class 2, Grade A. a. For indoor applications, adhesive shall have a VOC content of 80 g/l or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24). HVAC PIPING INSULATION

29 b. Adhesive shall comply with the testing and product requirements of the California Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers." 4. ASJ Adhesive, and FSK and PVDC Jacket Adhesive: Comply with MIL-A-3316C, Class 2, Grade A for bonding insulation jacket lap seams and joints. a. For indoor applications, adhesive shall have a VOC content of 50 g/l or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24). b. Adhesive shall comply with the testing and product requirements of the California Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers." D. MASTICS 1. Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL-PRF-19565C, Type II. a. For indoor applications, use mastics that have a VOC content of 50 g/l or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24). 2. Vapor-Barrier Mastic: Water based; suitable for indoor use on below-ambient services. a. Water-Vapor Permeance: ASTM E 96/E 96M, Procedure B, perm at 43-mil dry film thickness. b. Service Temperature Range: Minus 20 to plus 180 deg F. c. Solids Content: ASTM D 1644, 58 percent by volume and 70 percent by weight. d. Color: White. E. SEALANTS 1. Joint Sealants: a. Materials shall be compatible with insulation materials, jackets, and substrates. b. Permanently flexible, elastomeric sealant. c. Service Temperature Range: Minus 100 to plus 300 deg F. d. Color: White or gray. e. For indoor applications, sealants shall have a VOC content of 420 g/l or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24). f. Sealants shall comply with the testing and product requirements of the California Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers." 2. FSK and Metal Jacket Flashing Sealants: a. Materials shall be compatible with insulation materials, jackets, and substrates. b. Fire- and water-resistant, flexible, elastomeric sealant. c. Service Temperature Range: Minus 40 to plus 250 deg F. d. Color: Aluminum. HVAC PIPING INSULATION

30 e. For indoor applications, sealants shall have a VOC content of 420 g/l or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24). f. Sealants shall comply with the testing and product requirements of the California Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers." F. FIELD-APPLIED FABRIC-REINFORCING MESH 1. Woven Polyester Fabric: Approximately 1 oz./sq. yd. with a thread count of 10 strands by 10 strands/sq. in., in a Lena weave, for pipe. G. FIELD-APPLIED JACKETS 1. Field-applied jackets shall comply with ASTM C 921, Type I, unless otherwise indicated. 2. Aluminum Jacket: Comply with ASTM B 209, Alloy 3003, 3005, 3105, or 5005, Temper H-14. a. Sheet and roll stock ready for shop or field sizing. b. Finish and thickness are indicated in field-applied jacket schedules. c. Moisture Barrier for Indoor Applications: 3-mil-thick, heat-bonded polyethylene and kraft paper. d. Moisture Barrier for Outdoor Applications: 3-mil-thick, heat-bonded polyethylene and kraft paper. e. Factory-Fabricated Fitting Covers: i. Same material, finish, and thickness as jacket. ii. Preformed 2-piece or gore, 45- and 90-degree, short- and long-radius elbows. iii. Tee covers. iv. Flange and union covers. v. End caps. vi. Beveled collars. vii. Valve covers. viii. Field fabricate fitting covers only if factory-fabricated fitting covers are not available. H. SECUREMENTS 1. Aluminum Bands: ASTM B 209, Alloy 3003, 3005, 3105, or 5005; Temper H-14, inch thick, 1/2 inch wide with closed seal. HVAC PIPING INSULATION

31 PART 3 - EXECUTION A. PREPARATION 1. Surface Preparation: Clean and dry surfaces to receive insulation. Remove materials that will adversely affect insulation application. 2. Coordinate insulation installation with the trade installing heat tracing. Comply with requirements for heat tracing that apply to insulation. 3. Mix insulating cements with clean potable water; if insulating cements are to be in contact with stainless-steel surfaces, use demineralized water. B. GENERAL INSTALLATION REQUIREMENTS 1. Install insulation materials, accessories, and finishes with smooth, straight, and even surfaces; free of voids throughout the length of piping including fittings, valves, and specialties. 2. Install insulation materials, forms, vapor barriers or retarders, jackets, and thicknesses required for each item of pipe system as specified in insulation system schedules. 3. Install accessories compatible with insulation materials and suitable for the service. Install accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state. 4. Install insulation with longitudinal seams at top and bottom of horizontal runs. 5. Install multiple layers of insulation with longitudinal and end seams staggered. 6. Do not weld brackets, clips, or other attachment devices to piping, fittings, and specialties. 7. Keep insulation materials dry during application and finishing. 8. Install insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by insulation material manufacturer. 9. Install insulation with least number of joints practical. 10. Where vapor barrier is indicated, seal joints, seams, and penetrations in insulation at hangers, supports, anchors, and other projections with vapor-barrier mastic. a. Install insulation continuously through hangers and around anchor attachments. b. For insulation application where vapor barriers are indicated, extend insulation on anchor legs from point of attachment to supported item to point of attachment to structure. Taper and seal ends at attachment to structure with vapor-barrier mastic. HVAC PIPING INSULATION

32 c. Install insert materials and install insulation to tightly join the insert. Seal insulation to insulation inserts with adhesive or sealing compound recommended by insulation material manufacturer. d. Cover inserts with jacket material matching adjacent pipe insulation. Install shields over jacket, arranged to protect jacket from tear or puncture by hanger, support, and shield. 11. Apply adhesives, mastics, and sealants at manufacturer's recommended coverage rate and wet and dry film thicknesses. 12. Cut insulation in a manner to avoid compressing insulation more than 75 percent of its nominal thickness. 13. Finish installation with systems at operating conditions. Repair joint separations and cracking due to thermal movement. 14. Repair damaged insulation facings by applying same facing material over damaged areas. Extend patches at least 4 inches beyond damaged areas. Adhere, staple, and seal patches similar to butt joints. 15. For above-ambient services, do not install insulation to the following: a. Vibration-control devices. b. Testing agency labels and stamps. c. Nameplates and data plates. d. Handholes. C. PENETRATIONS 1. Insulation Installation at Aboveground Exterior Wall Penetrations: Install insulation continuously through wall penetrations. a. Seal penetrations with flashing sealant. b. For applications requiring only indoor insulation, terminate insulation inside wall surface and seal with joint sealant. For applications requiring indoor and outdoor insulation, install insulation for outdoor applications tightly joined to indoor insulation ends. Seal joint with joint sealant. c. Extend jacket of outdoor insulation outside wall flashing and overlap wall flashing at least 2 inches. d. Seal jacket to wall flashing with flashing sealant. 2. Insulation Installation at Fire-Rated Wall and Partition Penetrations: Install insulation continuously through penetrations of fire-rated walls and partitions. a. Comply with requirements in Section "Penetration Firestopping" for firestopping and fire-resistive joint sealers. HVAC PIPING INSULATION

33 D. GENERAL PIPE INSULATION INSTALLATION 1. Requirements in this article generally apply to all insulation materials except where more specific requirements are specified in various pipe insulation material installation articles. 2. Insulation Installation on Fittings, Valves, Strainers, Flanges, and Unions: a. Install insulation over fittings, valves, strainers, flanges, unions, and other specialties with continuous thermal and vapor-retarder integrity unless otherwise indicated. b. Insulate pipe elbows using preformed fitting insulation or mitered fittings made from same material and density as adjacent pipe insulation. Each piece shall be butted tightly against adjoining piece and bonded with adhesive. Fill joints, seams, voids, and irregular surfaces with insulating cement finished to a smooth, hard, and uniform contour that is uniform with adjoining pipe insulation. c. Insulate tee fittings with preformed fitting insulation or sectional pipe insulation of same material and thickness as used for adjacent pipe. Cut sectional pipe insulation to fit. Butt each section closely to the next and hold in place with tie wire. Bond pieces with adhesive. d. Insulate valves using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. For valves, insulate up to and including the bonnets, valve stuffing-box studs, bolts, and nuts. Fill joints, seams, and irregular surfaces with insulating cement. e. Insulate strainers using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. Fill joints, seams, and irregular surfaces with insulating cement. Insulate strainers so strainer basket flange or plug can be easily removed and replaced without damaging the insulation and jacket. Provide a removable reusable insulation cover. For belowambient services, provide a design that maintains vapor barrier. f. Insulate flanges and unions using a section of oversized preformed pipe insulation. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. g. Cover segmented insulated surfaces with a layer of finishing cement and coat with a mastic. Install vapor-barrier mastic for below-ambient services and a breather mastic for above-ambient services. Reinforce the mastic with fabricreinforcing mesh. Trowel the mastic to a smooth and well-shaped contour. 3. Insulate instrument connections for thermometers, pressure gages, pressure temperature taps, test connections, flow meters, sensors, switches, and transmitters on insulated pipes. Shape insulation at these connections by tapering it to and around the connection with insulating cement and finish with finishing cement, mastic, and flashing sealant. 4. Install removable insulation covers at locations indicated. Installation shall conform to the following: HVAC PIPING INSULATION

34 a. Make removable flange and union insulation from sectional pipe insulation of same thickness as that on adjoining pipe. Install same insulation jacket as adjoining pipe insulation. b. When flange and union covers are made from sectional pipe insulation, extend insulation from flanges or union long at least two times the insulation thickness over adjacent pipe insulation on each side of flange or union. Secure flange cover in place with stainless-steel or aluminum bands. Select band material compatible with insulation and jacket. c. Construct removable valve insulation covers in same manner as for flanges, except divide the two-part section on the vertical center line of valve body. d. When covers are made from block insulation, make two halves, each consisting of mitered blocks wired to stainless-steel fabric. Secure this wire frame, with its attached insulation, to flanges with tie wire. Extend insulation at least 2 inches over adjacent pipe insulation on each side of valve. Fill space between flange or union cover and pipe insulation with insulating cement. Finish cover assembly with insulating cement applied in two coats. After first coat is dry, apply and trowel second coat to a smooth finish. E. INSTALLATION OF FLEXIBLE ELASTOMERIC INSULATION 1. Seal longitudinal seams and end joints with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated. 2. Insulation Installation on Pipe Flanges: a. Install pipe insulation to outer diameter of pipe flange. b. Make width of insulation section same as overall width of flange and bolts, plus twice the thickness of pipe insulation. c. Fill voids between inner circumference of flange insulation and outer circumference of adjacent straight pipe segments with cut sections of sheet insulation of same thickness as pipe insulation. d. Secure insulation to flanges and seal seams with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated. 3. Insulation Installation on Pipe Fittings and Elbows: a. Install mitered sections of pipe insulation. b. Secure insulation materials and seal seams with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated. 4. Insulation Installation on Valves and Pipe Specialties: a. Install preformed valve covers manufactured of same material as pipe insulation when available. b. When preformed valve covers are not available, install cut sections of pipe and sheet insulation to valve body. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation. c. Install insulation to flanges as specified for flange insulation application. HVAC PIPING INSULATION

35 d. Secure insulation to valves and specialties and seal seams with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated. F. INSTALLATION OF MINERAL-FIBER PREFORMED PIPE INSULATION 1. Insulation Installation on Straight Pipes and Tubes: a. Secure each layer of preformed pipe insulation to pipe with wire or bands and tighten bands without deforming insulation materials. b. Where vapor barriers are indicated, seal longitudinal seams, end joints, and protrusions with vapor-barrier mastic and joint sealant. c. For insulation with factory-applied jackets on above-ambient surfaces, secure laps with outward-clinched staples at 6 inches o.c. d. For insulation with factory-applied jackets on below-ambient surfaces, do not staple longitudinal tabs. Instead, secure tabs with additional adhesive as recommended by insulation material manufacturer and seal with vapor-barrier mastic and flashing sealant. 2. Insulation Installation on Pipe Flanges: a. Install preformed pipe insulation to outer diameter of pipe flange. b. Make width of insulation section same as overall width of flange and bolts, plus twice the thickness of pipe insulation. c. Fill voids between inner circumference of flange insulation and outer circumference of adjacent straight pipe segments with mineral-fiber blanket insulation. d. Install jacket material with manufacturer's recommended adhesive, overlap seams at least 1 inch, and seal joints with flashing sealant. 3. Insulation Installation on Pipe Fittings and Elbows: a. Install preformed sections of same material as straight segments of pipe insulation when available. b. When preformed insulation elbows and fittings are not available, install mitered sections of pipe insulation, to a thickness equal to adjoining pipe insulation. Secure insulation materials with wire or bands. 4. Insulation Installation on Valves and Pipe Specialties: a. Install preformed sections of same material as straight segments of pipe insulation when available. b. When preformed sections are not available, install mitered sections of pipe insulation to valve body. c. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation. d. Install insulation to flanges as specified for flange insulation application. HVAC PIPING INSULATION