SECTION 23 21 13

HYDRONIC PIPING

PART 1 - GENERAL

1.1 WORK INCLUDED

A. Steel Pipes and Fittings

B. Diffuser Piping

C. Mechanical Groove Joints

D. Surveillance (Alarm) System

E. Expansion Compensation

F. Condensate Drainage

G. Service Connections

H. Flushing and Charging of Hydronic Piping

1.2 RELATED SECTIONS

A. Division 31 00 00 Earthwork

B. Section 03 30 00 Cast-in-Place Concrete

C. Division 26 00 00 Electrical

D. Section 08 31 13 Access Doors

E. Section 09 91 13 External painting

F. Section 09 91 23 Internal Painting

G. Section 23 05 16 Expansion Fitting and Loops for HVAC Piping

H. Section 23 05 29 Hangers and Supports for HVAC Piping and Equipment

I. Section 23 05 53 Identification for HVAC Piping and Equipment

J. Section 23 05 48 Vibration & Seismic Controls for HVAC Piping and Equipment

K. Section 23 07 19 HVAC Piping Insulation

L. Section 23 07 16 HVAC Equipment Insulation

M. Section 23 21 16 Hydronic Specialities

N. Section 23 25 00 HVAC Water Treatment

1.3 REFERENCES

A. ASTM International:

1. ASTM A 53 - Steel Pipe, Black and Hot Dipped Zinc Coated, Welded and
Seamless, for Ordinary uses (BS 1387 / 3601) - Ref.: Steel in schedule

2. ASTM A 234 - Pipe Fittings of Wrot Carbon Steel and Alloy Steel for Moderate
and Elevated Temperatures

3. ASTM B 88 - Seamless Copper Water Tube (BS 2871)

Hydronic Piping III-2/23 21 13 - 1

 4. ASTM B 280 - Seamless Copper Tube for Air-conditioning and Refrigeration
Services (ACR)

B. American National Standard Institute:

1. ANSI B 16.3 - Black or Galvanised Malleable Iron Threaded Fittings (ANSI B

16.11 / BS 143 / ISO R 7)

2. ANSI B 16.9 - Specification for steel butt-welding fittings for petroleum industry
(BS 1640)

C. American Welding Society:

1. AWS D 10.9 - Standard for Building Services Piping

2. AWS D 1.1 - Structural Welding Code

D. ASME Standard:

1. ASME Sec. 9 - Welding and Brazing Qualifications

E. American Water Works Association:

1. AWWA C 606 - Grooved and shouldered pipe end couplings Dimensions

F. British Standard:

1. BS 638 - Arc Welding Plant, Equipment and Accessories

2. BS 1965 - Specification for butt-welding pipe fittings for pressure purposes

1.4 QUALITY ASSURANCE

A. Requirements of the following shall be conformed with, as appropriate:

1. Codes, ordinances, rules and regulations of the State of Kuwait and its lawful
agencies like Ministry of Electricity and Water

2. International Standards Organisation (ISO)

B. Requirements of Section 23 00 00 and related works shall be referred to and complied

with as appropriate.

C. Products used in the works covered by this Section shall be provided from specialized
manufacturer whose products have been in satisfactory use in similar service for
minimum period of five (5) years.

D. Materials

1. Materials incorporated in the work covered by this Section shall be unused, new
products in good condition. Materials spoiled due to improper storage or
mishandling shall be rejected.

2. Materials of similar nature shall be products of the same manufacturer. Mixing up

products of different standards or those of different manufactures shall not be
permitted for the same service.

3. Materials to equivalent British (BS), German (DIN), or Japanese (JIS) or other

international standards shall be acceptable, provided that the Contractor
substantiates their equivalence and ensures their compatibility with other
components of the system. Copies of the current version of the reference
standards shall be submitted for comparison, if required by the Engineer

Hydronic Piping III-2/23 21 13 - 2

 4. Test certificates for materials used in the work covered by this Section, from
approved independent laboratories or testing agencies shall be furnished at no
extra cost if required by the Engineer

5. Uniformity shall be maintained in respect of connection standards (threads or

Grooved /flanges), throughout. Where this is not practical due to justifiable
reasons; compatibility shall be ensured by using appropriate adapters,
conversion spools, mating flanges and the like; with the written approval of the
Engineer.

6. Valves and appurtenances shall have manufacturer's name, pressure rating and
size cast-on on the body.

7. Pipes and fittings used in the works shall have the standard of manufacturer,
type, class or rating etc. continuously printed or marked otherwise in compliance
with the standard of manufacture. Materials without such identification shall be
rejected.

8. Requirements of product quality, workmanship, materials etc. are identified by a

known product of a particular manufacturer and is written as Ref. :
..

9. Factory Certification: Following shall be certified by the manufacturer(s)

/applicator(s), as appropriate. Engineer shall be furnished with certification prior
to unloading of material at the site.

a. Chemical composition of samples from each batch of pipes, fittings and

valves

b. Verification / certification of the physical dimensions and unit weights of

samples from each batch of pipes, fittings and valves

c. Hydraulic pressure tests of each piece of pipes, fittings and valves

E. Requirements of AWS code shall be conformed to in respect of welding materials and

procedures and welders shall be certified in accordance with ASME Section 9.

F. Valves and similar control gear, used in the works, shall have the manufacturer's name
or logo, size, pressure rating and direction of flow cast-on, on the body.

G. Copper alloys used in the construction of valves, pipe fittings, hydronic specialities etc.;
which comes in contact with water; shall be dezincification resistant type.

H. All grooved joint couplings, fittings, valves, and specialties shall be the products of a
single manufacturer. Grooving tools shall be of the same manufacturer as the grooved
components.

I. All castings used for coupling housings, fittings, valve bodies, etc., shall be date stamped
for quality assurance and traceability.

Hydronic Piping III-2/23 21 13 - 3

1.5 LEED CERTIFICATION

A. The Project has an aspiration to be assessed against the requirements of LEED for New
Construction 2009 edition, and during the design phase is targeting a LEED Gold
Certification. For an explanation of the LEED certification process and description of the
LEED credits targeted refer division-01 documents-Section (01 81 13) for LEED
Requirements and Appendix.

B. Grooved End Products shall contribute to achieving LEED points based on performance
requirement. Integrating Grooved End Products & solutions into a buildings
infrastructure may/shall contribute to obtaining LEED points under the category of
Sustainable Site, Energy & Atmosphere, Indoor Environmental Quality & Innovation &
Design process.

1.6 SUBMITTALS

A. Product data, samples and shop drawings:

1. Manufacturers printed brochures and catalogues (one original and three copies)
with relevant information highlighted (or irrelevant information struck out), along
with write up of selection criteria

2. Third party certification in respect of conformance of products with specified

standards

3. General piping layout drawings to a scale not smaller than 1: 500 along with
profiles to same horizontal scale; indicating supports, thrust block and the like

4. Builders work drawings of valve chambers and the like to a scale of 1:50 / 1: 20
as appropriate along with details of sleeves and penetrations to same scale

5. Installation details of valves, air valves, vacuum breakers and similar

appurtenances to a scale of 1:20 / 1:10

6. Calculations / details to substantiate shop drawings

B. Project record documents of all works installed under this Section, including:

1. As-Built Drawings

2. Copies of certificates of competency issued to welders

3. Certification of Contractors personnel by the piping system manufacturer

4. Inspection reports / certificates by the piping system manufacturer

C. Product data including data on pipe materials, pipe fittings, valve and accessories and
recommended coating materials, samples and manufacturer's installation instructions or
recommendations shall be submitted under provisions of the General Conditions of
Contract.

D. Copies of valve ordering schedules shall be submitted for approval prior to placing the
orders.

E. Certification of Welders: Names and original Certificates of Competency (to be returned

after verification) issued by the National Joint Industrial Council of Heating and
Ventilation Industry, British Oxygen Company, Lloyds or other nationally recognised
authority shall be submitted prior to starting of any welding / brazing work at site.

Hydronic Piping III-2/23 21 13 - 4

 F. Review of Submittals: Time expended for repetitive reviewing (more than twice) due to
Contractors inability to comply with the requirements of the Contract shall be billed to the
Contractor at the Engineers standard hourly rates

G. Grooved joint couplings and fittings shall be shown on drawings and product submittals,
and shall be specifically identified with the applicable style or series designation.

1.7 CLOSEOUT SUBMITTALS

A. Section 01 78 00 Closeout Submittals: Closeout procedures.

B. Project Record Documents: Record actual locations of valves, equipment and

accessories.

C. Operation and Maintenance Data: Submit instructions for installation and changing
components, spare parts lists, exploded assembly views.

1.8 QUALITY ASSURANCE

A. Perform Work in accordance with ASME B31.1 ASME B31.9 code for installation of
piping systems and ASME Section IX for welding materials and procedures.

B. Perform Work in accordance with applicable authority AWS D1.1 for welding hanger and
support attachments to building structure.

C. Maintain one copy of each document on site.

1.9 QUALIFICATIONS

A. Manufacturer: Company specializing in manufacturing products specified in this section

with minimum three years documented experience, and with service facilities within 100
miles of Project.

B. Fabricator or Installer: Company specializing in performing Work of this section with

minimum three years documented experience approved by manufacturer.

C. Design piping system hangers and supports under direct supervision of Professional
Engineer experienced in design of this Work and licensed at Project location in State of.

1.10 PRE-INSTALLATION MEETINGS

A. Section 01 31 19 Project Meetings.

B. Convene minimum one week prior to commencing work of this section.

1.11 GUARANTEE / WARRANTY

A. Requirements of the General Conditions of Contract shall be referred to and complied

with as appropriate.

B. Piping system shall be warranted for a period of 15 years. Warranty certificate duly
registered with the manufacturer shall be furnished to the Employer as a prerequisite for
issuance of substantial completion certificate.

Hydronic Piping III-2/23 21 13 - 5

1.12 DELIVERY, STORAGE AND HANDLING

A. Products shall be delivered to site, stored and protected under provisions of the General
Conditions of Contract.

B. Two (2) coats of approved primer shall be applied to all untreated ferrous pipes prior to
storage.

C. Pipes shall not be allowed to come in contact with any sharp objects during
transportation, loading, unloading and stacking. Suitable type of web slings shall be used
for handling of pipes. Metallic cables, chains or hooks shall not be used on the pipes
under any circumstance

D. Pipes shall be stored in a flat, level ground; raised on timber bearers such that the lowest
part of the pipe is not less than 150 mm above the ground

E. Pipes shall be stored on elevated racks and the ends kept closed with factory-
manufactured plugs to prevent the entry of foreign matter.

F. Rubber and plastic products shall be stored out of direct sunlight and protected in an
appropriate manner to prevent deterioration.

G. Valves shall be delivered and stored in shipping containers with labelling in place.
Further:

1. Plug and ball valves shall be kept in open position and gate / globe valves in
closed position to prevent damage to valve seats

2. Flange / thread protectors shall be retained on the valves, until installation, to

prevent damage to the flange faces / threads

H. Pipes supplied in pallets or crates shall be kept as such until time of installation. Piping
supplied loose shall be stored in layers, not exceeding four high. Socket ended pipes
shall be stored with the socket at either end in alternate layers. Pipes of different sizes
and / or thickness shall be stacked separately.

I. Valves shall be supplied with plastic caps to prevent damage to the ends.

1.13 FACTORY / THIRD PARTY CERTIFICATION

A. Technical and financial proposals from a minimum of three agencies Approved by

Ministry of Public Works (MPW) for third party inspection of pipes, fittings and valves at
the manufacturing plant(s); shall be submitted along with the tender. Costs of third party
certification shall be allowed for in the tender, as a provisional sum. Employer may
accept or reject any such proposals without assigning any causes.

B. Test certificates from agencies (approved for the purpose by the Employer) and / or
approved, independent laboratories or testing agencies shall be furnished in respect of
the following:

1. Conformance of insulation / jacketing with minimum requirements of reference

standards, in respect of:

a. Impact strength, and

b. Chemical resistance as confirmed by immersion of the finished product

in acid, alkali and de-ionised water.

2. Verification / certification of the physical dimensions and unit weights of samples

from each batch consignment of pipes, fittings and valves

Hydronic Piping III-2/23 21 13 - 6

 3. Hydraulic pressure tests of each piece of pipes, fittings and valves

4. Chemical composition of samples from each batch / consignment of pipes,

fittings and valves

1.14 SYSTEM DESCRIPTION

A. HVAC chilled water supply and return system pipe work starting from the outlet of header
connection(s) within the HVAC plant room to flanged outlets of service connections
within building served shall be included in the scope of this Section.

PART 2 - PRODUCTS

2.1 ACCEPTABLE MANUFACTURERS

A. Black Steel Pipes

1. Sumitomo, Japan

2. ThyssenKrupp Steel, Germany

3. Mannesman, Germany

4. Arcelor Mittal Steel, Romania

5. Nova Hut, Czec Republic

6. Arcelor Mittal Steel, Romania

7. Wuxi Taihu, China

B. Mechanical Grooved Joints

1. Victaulic Co. USA

2. Grinnell, USA

3. Shurjoint, USA

2.2 PIPES

Service Location Materials

Chilled Water Pipes

All areas above grade Seamless Black Steel Schedule 40
Up to DN 600 (18 inch)

Chilled Water Pipes

LSAW Black Steel with min.(12.7 mm)
DN 650 (20 inch) and All areas above grade
wall thickness / API 5L Std.
Above

Condenser Water Pipes Seamless Black Steel

All areas above grade
Up to DN 600 (24 inch) Schedule 40

Condenser Water Pipes LSAW Black Steel with min.(12.7 mm)

All areas above grade
DN 650 (26inch) and Above wall thickness / API 5L Std

Refrigerant Pipes All areas above grade Copper Type L, soft

Hydronic Piping III-2/23 21 13 - 7

 Up to DN 40 (1 inch)

Condensate Drainage HDPE

Above grade for FCUs
All Sizes PN 10

Condensate Drainage All areas for Mech.

Galvanized Steel
All Sizes Rooms and Roof

2.3 FITTINGS

A. Pipe fittings shall be of Ductile Iron with Grooved End or Same Material of Construction,
Strength & Method of jointing as pipes.

B. Mechanical Grooved joints manufacturers should provide necessary calculations for

location of rigid / flexible coupling as per the drawing layout.

C. Prefabricated fittings supplied by the piping system manufacturers may be used, where
appropriate, subject to the approval of the Engineer.

2.4 JOINTS

A. Malleable iron Fitting Up to DN 50 (2 inch) : Threaded, with Teflon tape or joining

compound (non-toxic) applied to pipe threads

B. DN 65 (2 inch) and above: Mechanical Grooved Joints.

C. Copper Type K / L: B Cup-5 brazed joints / Grooved Joints above 2 dia.

D. Pressure ratings of Pipe / Fitting / joints (Figures stated are working water pressures at
ambient temperature):

1. Malleable iron Fitting (items A,B,C & D) : 2,065 kPa (300 psig)

2. Copper Type K / L (item E): 1,379 kPa (200 psig)

2.5 FLANGES, UNIONS, AND COUPLINGS

A. For pipe sizes up to DN 50 (2 inch):

1. Black Steel Fittings: Malleable Iron unions with brass seat, threaded ends

2. Copper Fittings for All sizes: Bronze unions, brazing ends

B. For pipe sizes DN 65 (2 inch) and above:

1. Black steel piping: Cast / forged steel threaded / welding neck / slip-on flanges

2. Compressed fibre gaskets shall be used at all flanges (use of rubber gaskets is
prohibited)

C. Dielectric connections:

1. Up to DN 50 (2 inch): Unions with one end malleable iron threaded and the other
end copper solder

2. DN 65 (2 inch) and Above: Flanged fittings for pipe sizes

3. Both unions and flanges shall have water impervious isolation barrier certified to
withstand a minimum 600 volts on a dry line with no flashover

D. Pressure ratings of Flanges, unions and couplings shall be rated for 1,724 kPa (250
psig) working water pressure at ambient temperature.

Hydronic Piping III-2/23 21 13 - 8

2.6 MECHANICAL GROOVED JOINTS

Joints using grooved pipe ends and rigid / flexible grooved couplings with EPDM gaskets.

A. Pipe end preparation: Rolled or cut as appropriate to pipe material, wall thickness,
pressures, size and method of joining. Pipe ends to be grooved in accordance with
manufacturers current listed standards.

B. Fittings: Full flow ductile iron fittings with grooves or shoulders designed to accept
grooved end couplings; all as listed in manufacturers current catalogue.

C. Valves: Ductile Iron Grooved End / Flanged valves designed to accept grooved
end/Flange couplings as listed in manufacturers current catalogue

D. Housing: Cast malleable / ductile iron, forged / fabricated steel housing clamps Rigid or
Flexible type designed to engage and lock; permitting limited angular deflection,
contraction and expansion. Galvanized housing shall be used for galvanized pipes.

E. Gasket: "C" shaped EDPM rated to 110O C sealing gasket. Alternative gasket materials
shall be used where appropriate to match with the coupling.

F. Fasteners: High tensile steel bolts with track head; nuts and washers.

G. Pressure Rating: Fittings and valves with grooved ends and joints shall be rated for
2,065 kPa (300psig) working water pressure at ambient temperature as appropriate.

H. Grooved End Products shall confirm to LEED requirements under applicable categories.

I. COUPLINGS:

1. Sizes through DN 300 (12 inch):

a. Rigid Type: Housings shall be cast with offsetting angle-pattern bolt pads
to provide rigidity and system support and hanging in accordance with
ANSI B31.1 and B31.9.

i. DN 50 (2 inch) through DN 150 (6 inch): Installation-Ready, for

direct stab installation without field disassembly, with grade EHP
gasket rated to 120 deg C (250 deg F).

b. Flexible Type: For use in locations where vibration attenuation and

stress relief are required. Three flexible couplings may be used in lieu of
a flexible connector. The couplings shall be placed in close proximity to
the source of the vibration.

2. Sizes DN 350 (14 inch) through DN 600 (24 inch): Advanced Grooved Series
(AGS) with lead-in chamfer on housing key and wide width gasket.

a. Rigid Type: Housing key shall fill the wedge shaped AGS groove and
provide rigidity and system support and hanging in accordance with
ANSI B31.1 and B31.9.

b. Flexible Type: Housing key shall fit into the wedge shaped AGS groove
and allow for linear and angular pipe movement.

2.7 SURVEILLANCE (ALARM) SYSTEM

A. Entire piping network shall be monitored by an alarm system using a documented and
proven technique measuring the resistance between the copper wires and between
copper wires and the pipe for detecting leaks. The system will comprise:

1. A pair of non-insulated copper conductors shall be embedded within the piping

insulation and made integral with the pipe assembly. Joints shall be crimped and
soldered

Hydronic Piping III-2/23 21 13 - 9

 2. Approved hygroscopic material, placed around the joint, so as to ensure rapid
detection of any leakage

3. Control cabinet(s), tools, portable measuring instrument(s) and wiring diagram

4. Means and methods for break in alarm wire and locating faults

5. Operation manual

B. Controller, complete with power supply, interface with Building Management System,
wiring / cabling to power source as well as BMS shall be provided by this Section.

2.8 EXPANSION COMPENSATION

A. Contractor shall calculate expansion / contraction and provide for all required
appurtenances, in his tender.

B. Where, expansion compensation is not required, in the opinion of the Grooved piping
system manufacturer; this shall be clearly stated in the tender and correlated with
warranty requirements.

C. Expansion calculations shall be based on:

1. Heating applications: 5C (40F) installation temperature to 60C (140F) for

domestic hot water, and 82C (180F) for hot water heating and high
temperature domestic hot water plus 30 percent safety factor

2. Cooling applications: 65C (150F) installation temperature for exposed piping

and 46C (115F) installation temperature for indoor piping to 5C (40F) for
domestic cold water and chilled water plus 30 percent safety factor

D. Piping expansion / contraction shall be accommodated by providing one or more of the

following, as appropriate:

1. Directional changes: Bends and U-loops shall be provided along each sector.
Pipe work shall be anchored at midpoints of long straight runs to direct
expansion / contraction towards bends and / or U-loops

2. Heat Pre-stressing: Pipe work shall be cooled / heated to a temperature,

corresponding to middle of service range, during installation; further expansion /
contraction being absorbed by the piping itself

3. For water systems, use adequate numbers of flexible couplings in header/piping

to accommodate thermal expansion and contraction, and for the elimination of
expansion loops.

4. Accommodation of Seismic Movement: In Grooved piping system, seismic

motion shall accommodated by installing swing joints consisting of flexible
couplings, pipe nipples and elbows that provide simultaneous movement in all
directions, or other seismic movement compensation devices such as loops,
offsets, or Style 155 expansion joints (when an in-line device is required) to
provide flexibility to the system and help reduce pipe stresses.

E. Piping shall be covered with foam pads made from granulated, compressed, soft
polyurethane foam with a density of approx. 100 kg/M3, in expansion zones; to
accommodate movements due to expansion / contraction. This shall generally be used
at bends, service connections and similar areas.

PART 3 - EXECUTION

3.1 COORDINATION

Hydronic Piping III-2/23 21 13 - 10

 A. Contractor shall study all drawings and specifications and familiarize with the structural
and architectural details and the work of other trades.

B. Contractor shall ensure that the work under this section shall not interfere with those of
other trades and are compatible with the architectural finishes prior to placing orders,
fabrication and installation.

C. Electrical power supply requirements and location and type of the interface shall be co-
ordinated with the Electrical Works of the project. Information as required by MEW, for
obtaining approvals, shall be furnished.

D. Contractor shall furnish templates, patterns, setting out plans and other items for
incorporation in works of other trades and ensure the placement of sleeves, inserts etc.
in their work; on time.

E. Where work is installed in close proximity to or will interfere with work of other trades, the
Contractor shall assist in working out satisfactory space arrangements. Composite shop
drawings shall be prepared, to a suitable scale, showing how the work is installed in
relation to the work of other trades.

F. Sufficiency of dimensions of plant areas, doorways etc. and suitability of slabs and other
structural members for placement, operation and maintenance of equipment shall be
verified and shortcomings brought to the attention of the Engineer.

G. Contractor shall resolve conflicts in requirements with other trades. Only those, which
cannot be solved without changes to structure or those, which involves major changes to
system design, shall be referred to the Engineer.

3.2 TRAINING OF CONTRACTORS PERSONNEL

A. Services of a competent representative of the piping system manufacturer shall be

provided to instruct and train the Contractors personnel, including the engineer-in-
charge, employed at the site for executing the work.

B. Contractors personnel, who have satisfactorily completed such training, shall be

provided with a certified badge, which shall be carried on their person at all times on the
site.

C. A list of such trained personnel shall be furnished to the Engineer prior to starting of
works at site.

D. Personnel, not included in the said list, and not carrying such identification of training
shall not be allowed to partake in activities related to the execution of the works.

3.3 SUPERVISION

A. Services of a competent representative of the piping contractor shall be provided for all
hydronic piping other than pre-insulated piping, to inspect and to certify works executed
at site in the following three stages:

1. First ten (10) joints

2. Midway through the works, and

3. Final testing and commissioning

B. Manufacturers representative for Pre-insulated piping shall, during each such visit,
prepare reports and furnish copies directly to the Employer.

3.4 INSPECTION BEFORE INSTALLATION

A. Materials shall be carefully inspected visually for damages and other defects; while
suspended above the trench immediately before installation in final position.

Hydronic Piping III-2/23 21 13 - 11

 B. Material not conforming to specifications, or which are found to be defective or damaged
shall be rejected and removed from the works.

C. If more than 10 % of materials from a batch are rejected, the Engineer will have the right
to reject the whole consignment.

3.5 REMEDIAL WORKS ON LINING (S) / COATING (S)

A. Damage to piping, insulation or sheath caused at any stage of manufacture,

transportation or erection shall be made good prior to installation as appropriate.

3.6 PIPING - SETTING OUT

A. Existing ground along the line of the pipe work shall be cleared, particularly at all
manholes, building connections and other appurtenances.

B. Sight rails shall be set in position, using a surveyor's level and properly established
temporary benchmarks alongside the work. Transferring levels by means of a straight
edge and spirit level will not be allowed.

C. Where long lengths of slightly sloping pipe work are to be laid in trenches, sight rails
shall be fixed across the trench at intervals not exceeding 20 M, at a height equal to the
length of the boning rod, at the point where the sight rail is fixed. There shall, at all times,
no less than three sight rails in position on each length of pipe work under construction,
at any one gradient.

D. Deviations from given levels may not be greater than 20 mm and in gradients not
greater than 1/20 of the given gradient.

3.7 PIPING - PREPARATION

A. Pipes shall be cut perpendicular to the axis, with approved cutting tools. Spigot ends
shall be tapered by a grinder and a fast drying coal tar applied at the bared areas.

B. Scale and dirt, on inside and outside and weld splatter shall be removed before
assembly.

C. Piping connections to valves and equipment shall be made with Flanges or Grooved End
wherever possible.

D. Coating on galvanized iron pipes and fittings shall be repaired with approved paint
(recommended by the manufacturer) where factory coating has been damaged.

E. Sleeves shall be provided for pipe passing through partitions, walls and floors.

3.8 GROOVED JOINT PIPING

A. Grooved joints shall be installed in accordance with the manufacturers latest published
installation instructions.

B. Grooved ends shall be clean and free from indentations, projections, and roll marks in
the area from pipe end to groove.

C. Gaskets shall be of an elastomer grade suitable for the intended service, and shall be
molded and produced by the coupling manufacturer.

D. The grooved coupling manufacturers factory trained representative shall provide on-site
training for contractors field personnel in the use of grooving tools and installation of
grooved joint products.

E. The representative shall periodically visit the jobsite and review contractor is following
best recommended practices in grooved product installation.

3.9 SPACING AND LOCATION

Hydronic Piping III-2/23 21 13 - 12

 A. Piping shall be installed in such a way that conserves building space and not interfering
with the use of space.

B. Exposed piping shall be installed parallel or at right angles to the building walls, except
where otherwise shown on the Contract drawings.

C. Minimum clearances shall be provided between piping covered by this Section and those
of other trades.

D. Adequate clearance shall be provided around the piping for the installation of insulation
and access to valves and fittings.

E. Piping shall be grouped at common elevations, wherever possible.

F. Piping shall be installed in such a way that allows for expansion and contraction without
stressing pipe joints or connected equipment. Requirements of Section 23 05 16 shall be
referred to and complied with in all respects.

G. Access doors shall be provided where valves and fittings are not exposed. Size and
location of access doors shall be co-ordinated with relevant trades.

3.10 PIPE FITTINGS

A. Tapered reducer fittings shall be installed where changes occur in pipe sizes (use of site
fabricated fittings or bushings will not be permitted).

B. Tapered, factory manufactured reducer fittings (eccentric type at suction and concentric
type at discharge) shall be installed at pump connections. Eccentric reducer fittings shall
be installed with level crown.

C. Factory manufactured Grooved End fittings shall be installed where changes occur in
pipe direction. Bending or forming of piping shall not be permitted without the written
permission of the Engineer.

D. Use of main sized saddle branch connections or directly connecting profiled branches
(weldolets) to mains in steel piping is allowed if main is two pipe sizes larger than the
branch (branches shall not project inside the main pipe).

3.11 PIPING - INSTALLATION

A. Piping shall be installed in such a way that conserves space and does not interfere with
the use of space.

B. Minimum clearances shall be provided between piping covered by this Section and those
of other trades.

C. Pipes shall be handled with utmost care so as not to subject the pipes to shocks, which
may crack or break the sheath.

D. Piping shall be protected against the ingress of foreign material before the pipe is placed
in new line.

E. If pipe or appurtenance cannot be placed into the trench and in place, without getting
earth into it, each end shall be covered with a heavy, tightly woven canvas bag of
suitable size before lowering them into the trench. The bag shall be left there until the
connection is to be made to the adjacent pipe.

F. Pipes shall be laid and connected at the required depth in straight line and true to the
gradient on an even foundation as shown on the drawings, for the full length of the
barrel.

G. Piping shall be kept free of earth, dirt, and extraneous matter and clean every pipe after
installation by special cleaning tools approved by the Engineer. Mirrors, lamps and

Hydronic Piping III-2/23 21 13 - 13

 necessary personnel shall be provided as directed, to enable the Engineer to inspect the
pipeline at any time during construction.

H. Pipe shall not be laid when, in the opinion of the Engineer, conditions are unsuitable.

I. Grooved joints shall be installed in accordance with the manufacturers latest published
installation instructions (I-100).

3.12 SLOPES AND INVERTS

A. Piping shall be sloped and arranged to drain at the system low points. Additional drain
valves / automatic ball drips shall be provided at pipe segments that cannot be drained
otherwise their discharge piped to a convenient location.

B. All drains connected to Terminal Building sanitary sewer system, to include siphon

C. Automatic air vents shall be installed at system high points.

3.13 THREADS AND SEALANTS

A. Full depth threads shall be cut on prepared pipe ends, preferably using power driven
machines using cutting fluids. Threads shall be cleaned thoroughly before applying
thread sealant.

B. Teflon thread sealing tapes or hard setting, non-toxic sealing compounds shall be used
on the male thread (only) before making joints. Joints opened for repairs shall be
brushed clean and given fresh sealing tape or compound.

3.14 WELDING OF STEEL PIPING

A. Requirements of Section 23 05 00 shall be referred to and complied with as appropriate.

3.15 BRAZING OF COPPER PIPING

A. Requirements of Section 23 05 00 shall be referred to and complied with as appropriate.

3.16 VALVES

A. Valves shall be installed with stem upright or horizontal, not inverted; except with the
written permission of the Engineer, for each location.

B. Valves shall be same size as pipeline, except where shown otherwise on the Contract
Drawings.

C. Gate, ball or butterfly valves shall be used for shutoff and to isolate equipment, risers or
branches serving two or more cooling terminals.

D. Globe / plug valves shall be used for throttling service. Non-lubricated plug valves shall
be used only when shut-off or isolating valves are also provided.

E. Drain valves shall be installed at system low points and at the foot of risers.

F. In-line spring loaded check valves shall be installed at the discharge of pumps.

G. Valves shall be pad-locked in open or closed position with leather straps, as required.

H. Appropriate valve gland packing, sealing and gasket materials shall be selected for the
temperature and pressure encountered.

I. Water overflow from safety valves to drains to be visible to operation/maintenance staff

3.17 UNIONS AND FLANGES

A. Flanges / unions shall be provided on horizontal pressure piping at spacing not

exceeding 18.0 m (60 feet).

Hydronic Piping III-2/23 21 13 - 14

 B. Grooved mechanical couplings and fasteners shall be used in all the locations as and
where required.

C. Unions or flanges shall be installed downstream of valves and at equipment or apparatus

connections.

D. Dielectric unions or flanged fittings shall be used wherever joining dissimilar metals.

3.18 PROTECTION DURING CONSTRUCTION

A. Ends of piping shall be kept closed with factory manufactured plugs or blind flanges with
integral indicating flags, to prevent the entry of foreign matter, during the progress of the
work. Such plugs or flanges shall be removed on completion of the works.

B. Piping surface shall be protected from splashes of cement, plaster, paint and similar
construction materials.

C. Piping shall be blown out using dry compressed air, prior to testing.

3.19 TESTING OF PRESSURIZED PIPING

A. Pipes shall be jointed, plugged and shall have been in position for at least 24 hours,
before the tests are carried out.

B. Piping shall be tested for line, gradient and water tightness. Labour and necessary
testing instruments such as gauges, pumps etc. shall be provided by the Contractor as
directed by the Engineer. A minimum of two (2) # identical pressure gauges shall be
installed at extremities of the piping circuit to be tested.

C. Piping shall be filled with clean fresh water, leaving all high points open to allow for
purging of air.

D. System shall be pressure tested using manual pumps in increments of 25 % of the test
pressure. A standing period of 10 minutes shall be allowed after each pressure
increment. Pressure testing using motor driven pump shall not be permitted.

E. System shall not be over-pressurised under any circumstance. Calibrated pressure relief
valves shall be installed in the tested circuit, if the test pressure is close to the maximum
permissible working pressure of any of the system components.

F. Valves and control devices shall be kept in the open position, during. After completion of
pressure test, valves shall be closed, one at a time, starting from the pressure release
end, so as to ensure tightness of the valve.

G. Piping shall be tested with water at a pressure of 689 kPa (100 psig) or 1.5 times the
system working pressure, whichever is greater, but limited to 1,379 kPa (200 psig).
Pressure shall be maintained for at least 4 hours. Temperature of the circuit shall be
recorded along with the pressure readings and pressure fluctuations due to ambient
temperature variations shall be allowed for.

H. Joints shall be checked for leaks by swabbing with a dry tissue. Drop in pressure to the
order of 10 kPa (1.5 psig) per hour, but without any visible leaks, shall be considered as
acceptable.

I. Chilled / hot water coils and control valves shall not be subjected to the test pressure.

J. Piping shall be tested in segments during the progress of the work. An official log book
shall be maintained for recording the tests carried out on sections of piping, including test
pressure, date of test and approval signature of Engineer's representative witnessing the
test.

K. Provision shall be made for emptying of pipes without letting water out and flooding the
trench (Contractor shall provide temporary basins, pumps etc. as appropriate).

Hydronic Piping III-2/23 21 13 - 15

3.20 PIPING PROTECTION

Following protective coatings / wrappings shall be given to the piping, on completion of the
works. Piping above louvered ceilings shall be painted black as further described in architectural
finish schedule.

A. Exposed, insulated black steel piping:

1. Two (2) coats of red oxide primer

B. Concealed (in shafts), insulated black steel piping:

1. Two (2) coats of red oxide primer

C. Insulated / non-insulated steel piping; buried or in underground pipe trenches:

1. Two (2) coats of red oxide primer

2. One (1) layer of asphalt impregnated felt wrap with 25 mm (1 inch) overlaps

D. Exposed, insulated galvanized iron piping:

1. Two (2) coats of zinc chromate primer

E. Concealed (in shafts), insulated galvanized iron piping:

1. Two (2) coats of zinc chromate primer

F. Exposed / concealed (in shafts), non-insulated galvanized iron piping:

1. Two (2) coats of zinc chromate primer

G. Insulated / non-insulated galvanized iron piping; buried or in underground pipe trenches

1. Two (2) coats of Zinc Chromate primer

2. One (1) layer of asphalt impregnated felt wrap with 25 mm (1 inch) overlaps

H. Exposed, insulated copper piping:

1. Two (2) coats of clear, synthetic lacquer

I. Exposed, non-insulated copper piping:

1. Two (2) coats of clear, synthetic lacquer

2. Two (2) coats of enamel paint (or colour matching with the surrounding
architectural finish, in areas exposed to view)

J. Insulated / non-insulated Copper piping; buried or in underground pipe trenches

1. Two (2) coats of clear synthetic lacquer

2. One (1) layer of asphalt impregnated felt wrap with 25 mm (1 inch) overlaps

3.21 SYSTEM FLUSHING AND CHARGING

A. Piping shall be flushed with fresh water, intended for HVAC services, after completion of
tests.

B. No segment of ferrous / copper piping shall be left partially filled with water at any time,
to prevent the occurrence of internal corrosion.

C. Suitable proprietary and / or conventional cleaning chemical(s) shall be used for a period
of 2 to 4 days for this purpose.

3.22 CLEANING AND FINISHING

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 A. On completion of the system and testing of all the parts thereof, exposed pipe work and
steelwork including pipe supports shall be thoroughly cleaned of all dirt, grease and
scale and brought to normal "clean" condition, in accordance with the requirements of
the General Conditions of Contract.

3.23 SYSTEM DEMONSTRATIONS / COMMISSIONING

A. Services of a competent engineer shall be provided by the Contractor to supervise the

commissioning of all equipment and to train the Employer's personnel in all aspects of
operation, control and maintenance of the installation, during a five (5) working days
period, during normal working hours. All expenses in connection with the above shall be
allowed for by the Contractor.

B. System demonstrations shall be conducted only after the substantial completion of the
project. A minimum of one week's written notice shall be given and the Employer's
written consent obtained, prior to such demonstrations.

C. After completion of works, the piping system shall be filled completely (gravity head
only) with clean fresh water of less than 20 microns filtration fineness (as supplied by
plumbing services).

D. Valves at inlets and outlets kept closed and sealed by chains and padlocks, until system
start-up, and keys handed over to the Employer.

END OF SECTION

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