Section 15-510

CHILLED WATER PIPING SYSTEM

Part 1: General
1/1 Section includes:
A. The Work under this Section consists of furnishing and installation of chilled water piping
system as indicated on the drawings and as specified herein.

1/2 References
A. ASME American Society of Mechanical Engineers

ASME B31.9 Building Services Piping.

B. ASTM American Society of Testing and Materials

ASTM A 53 Pipe, Steel, Black and Hot-Dipped, Zinc Coated (Galvanized), Welded and
Seamless.
ASTM A 234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated
Temperatures.
C. ANSI American National Standard Institute

ANSI
A. B1.20.1 Pipe Threads.
ANSI B16.1 Cast
ANSI B16.1 Iron Flanges and Flanged Fittings, Classes 25, 125, 250 and 800.

ANSI B16.3 Malleable-Iron Threaded Fittings, Classes 150 and 300.

ANSI B16.5 Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys.

ANSI B16.22 Wrought Copper and Copper Alloy Solder- Joint Pressure Fittings.

ANSI B16.39 Threaded Pipe Unions, Malleable-Iron, Classes 150, 250 and 300.

D. HI Hydraulic Institute:

HI E.35.1 Centrifugal Pumps.

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1/3 Submissions
A. Product Data: Submit manufacturer's technical product data and installation instructions for
chilled water piping materials and products.
B. Shop Drawings: Submit scaled layout drawings of chilled water piping and fittings including, but
not necessarily limited to, pipe sizes, location, elevations and slopes of horizontal runs, wall and
floor penetrations, and connections. Show interface and spatial relationship between piping and
proximate equipment.
C. Record Drawings: At project closeout, submit record drawings of installed chilled water piping
and piping products.
D. Maintenance Data: Submit maintenance data and parts lists for chilled water piping materials and
products.
E. Include this data, product data, shop drawings, and record drawings in maintenance manual.
F. Test Results: Submit test results as required.

Part (2): Products

2/1 Chilled Water Piping:

A. Pipes:
1. Pipes for above ground installation shall be, seamless, black steel, Schedule 40, conforming
to ASTM A 53, with beveled ends.
B. Fittings:
1. Install above ground black steel pipes with threaded joints and fittings for 50 mm (2 inch)
and smaller, and with VICTAULIC or approved equal fittings for 63 mm (2-1/2 inch) or
larger pipes.
a. Malleable-Iron Threaded Fittings: ANSI B16.3 ,Class 150, standard pattern, for
threaded joints. Treads shall confirm to ANSI B1.20.1.
2. Dielectric Union: Threaded or soldered end connections for the pipe material in which
installed; constructed to isolate dissimilar materials, prevent galvanic action, and prevent
corrosion.

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 3. Flexible Connectors: Stainless steel bellows with woven flexible bronze wire reinforcing
protective jacket; minimum 150 psig working pressure, maximum 250 oF operating
temperature. Connectors shall have flanged or threaded end connections to match equipment
connected; and shall be capable of 19 mm misalignment.
4. Gasket Material: Thickness, material, and type suitable for fluid to be handled, and design
temperatures and pressures.
5. Welding Materials (Where required): Comply with Section II, Part C ASME Boiler and
Pressure Vessel Code for welding materials appropriate for wall thickness and chemical
analysis of pipe material being used.
C. General Duty Valves:
1. As specified in Section 15100 - VALVES.
D. Special Duty Valves:
1. Calibrated Plug Valves: 175 psig water working pressure, 100oF maximum operating temperature,
bronze body, plug valve with calibrated orifice. Provide with connections for portable differential
pressure meter with integral check valves and seals. Valve shall have integral pointer and
calibrated scale to register degree of valve opening. Valves 50.8 mm and smaller shall have
threaded connections and the 63.5 mm valves shall have flanged connections.
2. Circuit Setters: A calibrated balance valve equipped with readout valves and provided with
differential pressure meter.
3. Self Contained Flow Control Valves: Class 150, cast iron housing, stainless steel operating parts;
threaded connections for 50 mm and smaller, flanged connection for 62 mm and larger. Factory
set to automatically control flow rates within plus or minus 5 percent design, while compensating
for system operating pressure differential. Provide quick disconnect valves for flow measuring
equipment. Provide a metal identification tag with chain for each valve, factory marked with the
zone identification, valve model number, and rate flow in m3/min.
E. Piping Specialties:

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 1. Manual Air Vent: Bronze body and non-ferrous internal parts; 150 psig working pressure,
225°F operating temperature; manually operated with screw-driver or thumb-screws; and
having 3 mm discharge connection and 12.7 mm inlet connection.
2. Automatic Air Vent: Designed to vent automatically with float principles; bronze body and
non-ferrous internal parts; 150 psig working pressure, 240°F operating temperature; and
having 6 mm discharge connection and 12.7 inlet connection.
3. Pressure and Temperature Taps: Install pressure and temperature taps at all coil connections
across two port valves, pumps, chiller evaporator, or otherwise as indicated:
a. Taps shall be 13 mm solid brass fittings which shall receive either pressure or
temperature probe with valve core or NORDEL fitted color coded and marked cap
and gaskets, and rated at 135oC and 1000 psig.
b. Furnish No. 500 pressure gauge adapters with 3-8 mm probe and No. 701,125 mm
stem pocket thermometers with 25o-125o range for chilled water.
4. Chemical Feeder: Bypass type chemical feeders of 19 liter capacity, welded steel construction;
125 psig working pressure; complete with fill funnel and inlet, outlet, and drain valves.
5. Y-Pattern Strainers: Cast iron body, ASTM A126, Class B, flanged ends for 63.5 mm and
larger, threaded connections for 50.8 mm and smaller, bolted cover, perforated Type 304
stainless steel basket, bottom drain connection, 125 psig working pressure.

2/2 Diaphragm-Type Compression Tanks:

A. Size and number as indicated; construct of welded carbon steel for 125 psig working pressure,
375oF maximum operating temperature. Separate air charge from system water to maintain design
expansion capacity, by means of a flexible diaphragm securely sealed into tank. Provide taps for
pressure gauge and air charging fitting, and drain fitting. Support vertical tanks with legs or base;
support horizontal tanks with steel saddles. Tank, with taps and supports, shall be constructed,
tested, and labeled in accordance with ASME Pressure Vessel Code, Section VIII, Division 1.

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2/3 Make-Up Water Connection:

A. Provide pressure relief valve and automatic cold sweet water fill assembly complete with pressure
reducing valve, after meter arrester, sight glass, backflow preventer with test cocks, water filter,
vacuum breaker and valved by-pass.

2/4 Air Separator:

A. Type: The air release tank shall be of the in-the-pipe- line type with tangential openings for water
in and out. The inside shall be specifically designed to create a low velocity vortex for the
separation of free air from the water stream.
B. Size: The size of the air release tank shall be based on the line size of the pipe shown on the
drawings.
C. Shell: The shell shall be constructed of welded carbon steel; ASME constructed and labeled for
8.78 kg/cm2 (125 psig) water working pressure and 375°F operating temperature.
D. Strainer: The tank shall be equipped with an internal steel strainer with perforations sized for
water flow. The strainer shall be installed in a location of assist in the separation of air. The
strainer shall be removable from the bottom by unbolting the steel bolt heads.
E. Drain: The tank shall be equipped with a bottom drain and this drain shall be piped to the nearest
open site drain. The drain line shall be equipped with a gate valve and a union to facilitate the
removal of the strainer.

2/5 Chilled Water Pumps:

A. General:
1. Centrifugal pump fabrication, installation and testing shall be in conformance with Hydraulic
Institute Standards.
2. The selection of pump type and pump drive shall be based on each specific application
requirements. Pump drivers shall be selected to be non-overloading over the whole range of
the Q-TDH curves, consideration temperature variations of the fluid being pumped
3. Pump Q-TDH curve shall be such that it provides stable operation for the pump when
operating at any point on the curve. Shut-off head shall be approximately 25 to 35 percent
above the rated head.
4. Pumps shall be of variable or constant speed drive as required and capable of parallel
operation.

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 5. For pumps with variable speed drive, the control system shall include as a minimum, the
programmable logic pump controller, adjustable frequency drive(s) and remote
sensor/transmitter as required. All additional items required to properly execute the sequence
of operation shall be provided.
B. Pumps shall be of the capacities and types as shown on the drawings.
C. Chilled water pump shall be double suction horizontal split case type equipped with mechanical
seals. Specific pump ratings and types shall be as indicated on plans.
D. Pump and motor shall be mounted on a high grade, heat- treated cast-iron common baseplate.
E. Casing: Cast iron, split volume, rated for greater than 10.54 kg/cm2 (150 psi) actual working
discharge, with renewable bronze wearing rings, flanged suction and discharge and gauge taping.
F. Impeller: Bronze enclosed double suction type, keyed to shaft with a slightly press and suitable
lock-nut arrangement.
G. Shaft: Of high grade alloy steel with stainless steel conduit.
H. Drive: Flexible coupling with coupling guard.
Pre-lubricated grease, or oil-lubricated bearings shall be used.
I. Mechanical or packing seals suitable for specific application shall be used.
J. Pump performance tests shall be conducted in accordance with the Hydraulic Institute test codes
as described in HI E.35.01, E.37.01 and E.39.01. In addition, each pump shall be tested at five
points of operation from shutoff head to runout condition, including the guaranteed pump's
performance point.
K. The manufacturer shall submit certificate, including test data to show that pump meets
performance specifications.

2/6 Chemical Treatment for Chilled Water System:

A. The analysis and treatment recommendation shall be made by a specialist with a minimum of 5
years experience in this field.
B. The Contractor shall supply and/or install the water treatment facilities and chemicals as listed
below.Chemicals shall be specially formulated to prevent accumulation of scale and corrosion in
piping system and connected equipment, developed based on a water analysis of make-up water.
1. Chemical pot feeder complete with sampling point and valving as indicated.
2. Corrosion scale and electrolytic action inhibiter dosing in the chilled water system.
3. Test Kit.

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 4. Carry out tests on local water necessary to finalize details of the water treatment.
C. Treatment:
1. Thoroughly clean and system of oil grease and swarf deposits using an approved soluble
solvent in accordance with the manufacturer's instructions.
Circulate the solution for at least one hour, drain and then flush system thorough with fresh
water.
2. Put the chemical that is corrosion resisting and electrolytic action inhibitor.
D. Handover:
1. The Contractor shall supply a test kit and instruct the user in its use.
2. Full instructions shall be given to the user on the dosing methodology.
3. Prior to handover, Contractor shall carry out his own tests and ensure the system is correctly
dosed.
4. Provide the user with 6 months supply of chemicals.

2/7 Insulation:

A. Refer to Section 15250 - MECHANICAL INSULATION.

Part (3) - Execution

3/1 Installation:

A. Refer to Section 15050 - BASIC PIPING MATERIALS AND METHODS for basic piping
installation instructions. Refer to the drawings for further details. The entire chilled water system
installation shall conform to the requirements of ASME B 31.9 Building Services Piping, IAPMO
Uniform Mechanical Code, ARI Standard 260, and ANSI B 9.1, or equivalent.

B. Install above ground black steel pipes with threaded joints and fittings for 50 mm (2 inch) and
smaller, and with Victaulic fittings for 63 mm (2-1/2 inch) or larger.

For underground pre-insulated pipe use Victaulic fittings. Provide concrete support at the interval
of maximum 4000 mm, at both sides of coupling and at change of direction. Provide concrete
thrust blocks at each change of direction. Details of concrete support and thrust block shall be
as approved by the Engineer.

C. Proper foundations for mounting of piping system shall be provided, including supports,
vibration isolators, guides, anchors, clamps and brackets.

D. Pumps shall be installed in strict conformance with manufacturer's written instructions.

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 E. If oil grease lubricated bearings are supplied with the pumps, the oiler shall be filled with the
specified lubricating oil, or bearings shall be pre-lubricated with specified grease prior to start-up.

F. Field testing of the pumps shall be performed at the time of overall system start-up and testing.
Installed pumps shall meet the performance specifications.

G. Pipe Workmanship: Install completed system, size as shown on the drawings. Install piping
parallel or perpendicular to the building construction. Allow for expansion.

H. Air Vents: Provide at all changes in elevation downward in direction of flow. Except where
shown, provide automatic air vents. Also provide air vents at system high points.

I. The air separator shall be installed dead level in both directions and shall be supported from the
structure so that all pipes can be removed without moving the air separator. The separator shall
be installed so that the strainer can be removed without moving the tank.

J. The chilled water piping, valves, fittings, separator and expansion tank shall be insulated as per
Section 15250 - MECHANICAL INSULATION.

K. Chilled Water Treatment:

1. Water for the chiller system shall be chemically analyzed and shall be treated to insure its
suitability as the permanent system charge. Additional water treatment shall be provided
whenever required after final analysis at no additional cost to Owner.

2. Results of the chemical analysis and the proposed treatment method are to be submitted to
the Engineer for review and approval prior to the Contractor's filling the system.

3/2 Field Quality Control

A. Preparation for testing: Prepare chilled water piping in accordance with ASME B 31.9 and as
follows:
1. Leave joints uninsulated and exposed for examination during the test.
2. Provide temporary restraints for expansion joints, which cannot sustain the reactions due to
test pressure.
3. Flush system with clean water. Clean strainers.
4. Isolate equipment that is not to be subjected to the test pressure from the piping.
5. Install relief valve set at a pressure no more than 1/3 higher than the test pressure, to protect
against damage by expansion of liquid or other source of over pressure during the test.

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 B. Testing: Test chilled water piping as follows:
1. Use ambient temperature water as testing medium.
2. Use vents installed at high points in the system to release trapped air while filling the system.
Use drains installed at low points for complete removal of the liquid.
3. Subject piping system to a hydrostatic test pressure which at every point in the system in not
less than 1.5 times the design working pressure. The test pressure shall not exceed the
maximum pressure for any vessel, pump, valve, or other component in the system under test.
Make a check to verify that the stress due to pressure at the bottom of vertical runs does not
exceed either 90 percent of specified minimum yield strength, or 1.7 times the "SE" value in
Appendix A of ASME B 31.9, Code for pressure piping, building services piping.
4. After the hydrostatic test pressure has been applied for at least 10 minutes, examine piping,
joints, and connections for leakage. Eliminate leaks by tightening, repairing, or replacing
components as appropriate, and repeat hydrostatic test until there are no leaks.
5. For further requirements refer to Section 15990 - TESTING, ADJUSTING AND
BALANCING.
3/3 Adjusting and Cleaning
A. Clean and flush chilled water piping system. Remove, clean, and replace strainer screens. After
cleaning and flushing chilled water piping system, but before balancing, remove disposable fine
mesh strainers in pump suction diffusers.
B. Mark calibrated name plates of pump discharge valve after chilled water system balancing has
been completed, to permanently indicate final balanced position.
C. Chemical treatment: Provide a water analysis prepared by the chemical treatment supplier to
determine the type and level of chemicals required for prevention of scale and corrosion. Preform
initial treatment after completion of system testing.
D. Check expansion tanks to determine that they are not air bound and that the system is completely
full of water.

END OF SECTION

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