HVAC DESIGN SPECIFICATIONS

28.0 Section 23 21 13 – Hydronic Piping

PART 1 GENERAL
SCOPE
The scope of this section comprises the supply and laying of pipes, pipe fittings and valves,
testing and balancing of all water and refrigerant piping required for the complete installation
as shown on the Drawings. All piping inclusive of fittings and valves shall follow the
applicable Indian Standards. All welders used for piping erection shall be well qualified
(certificate should be submitted to Project Manager for approval) and shall have minimum 8
to 10 years’ experience.
1.01 SECTION INCLUDES
A. Chilled water piping
B. Condenser water piping,
C. drains piping,
D. Unions, flanges, mechanical couplings, and dielectric connections.
E. Valves
F. Flow controls
1.02
RELATED REQUIREMENTS
A. Section 07 8400 Firestopping.
B. Section 08 3100 Access Doors and
Panels.
C. Section 09 9000 Painting and Coating.
D. Section 22 0516 Expansion Fittings and
Loops for Plumbing
Piping.
E. Section 22 0548 Vibration and Seismic
Controls for Plumbing
Piping and Equipment.
F. Section 22 0553 Identification for
Plumbing Piping and
Equipment.
G. Section 22 0719 Plumbing Piping
Insulation.
H. Section 23 0516 Expansion Fittings and
Loops for HVAC Piping.
I. Section 23 0548 Vibration and Seismic
Controls for HVAC
Piping and Equipment.
J. Section 23 0553 Identification for HVAC
Piping and Equipment.
K. Section 23 0719 - HVAC Piping
Insulation
L. Section 23 2114 Hydronic
Specialties.

M. . Section 23 2500 HVAC Water Treatment:

Pipe cleaning

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N. Section 26 2717 Equipment Wiring:

Electrical characteristics
and wiring connections.

1.03 REFERENCE STANDARDS

A. ASME (BPV IX) - Boiler and Pressure Vessel Code, Section IX - Welding and Brazing
Qualifications; The American Society of Mechanical Engineers; 2010.
B. ASME B16.3 - Malleable Iron Threaded Fittings: Classes 150 and 300; The American
Society of Mechanical Engineers; 2011.
C. ASME B16.18 - Cast Copper Alloy Solder Joint Pressure Fittings; The American Society of
Mechanical Engineers; 2012 (ANSI B16.18).
D. ASME B16.22 - Wrought Copper and Copper Alloy Solder Joint Pressure Fittings; 2001
(R2010).
E. ASME B31.5 - Refrigeration Piping and Heat Transfer Components; 2010.
F. ASME B31.9 - Building Services Piping; 2011 (ANSI/ASME B31.9).
G. ASTM A53/A53M - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-
Coated, Welded and Seamless; 2012.
H. ASTM A106/A106M - Standard Specification for Seamless Carbon Steel Pipe for High-
Temperature Service; 2011.
I. ASTM A123/A123M - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron
and Steel Products; 2012.
J. ASTM A183 - Standard Specification for Carbon Steel Track Bolts and Nuts; 2003
(Reapproved 2009).
K. ASTM A234/A234M - Standard Specification for Piping Fittings of Wrought Carbon Steel
and Alloy Steel for Moderate and High Temperature Service; 2011a.
L. ASTM A536 - Standard Specification for Ductile Iron Castings; 1984 (Reapproved 2009).
M. ASTM B32 - Standard Specification for Solder Metal; 2008.
N. ASTM B88 - Standard Specification for Seamless Copper Water Tube; 2009.
O. ASTM B88M - Standard Specification for Seamless Copper Water Tube (Metric); 2005
(Reapproved 2011).
P. ASTM D1785 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe,
Schedules 40, 80, and 120; 2012.
Q. ASTM D2000 - Standard Classification System for Rubber Products in Automotive
Applications; 2012.
R. ASTM D2235 - Standard Specification for Solvent Cement for Acrylonitrile-Butadiene-
Styrene (ABS) Plastic Pipe and Fittings; 2004 (Reapproved 2011).
S. ASTM D2241 - Standard Specification for Poly (Vinyl Chloride) (PVC) Pressure-Rated Pipe
(SDR Series); 2009.
T. ASTM D2310 - Standard Classification for Machine-Made "Fiberglass" (Glass-Fiber-
Reinforced Thermosetting-Resin) Pipe; 2006.
U. ASTM D2466 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings,
Schedule 40; 2006.
V. ASTM D2467 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings,
Schedule 80; 2006.
W. ASTM D2680 - Standard Specification for Acrylonitrile-Butadiene-Styrene (ABS) and
Poly(Vinyl Chloride) (PVC) Composite-Sewer Piping; 2001 (Reapproved 2009).
X. ASTM D2751 - Standard Specification for Acrylonitrile-Butadiene-Styrene (ABS) Sewer
Pipe and Fittings; 2005.
Y. ASTM D2855 - Standard Practice for Making Solvent-Cemented Joints with Poly(Vinyl
Chloride) (PVC) Pipe and Fittings; 1996 (Reapproved 2010).

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Z. ASTM F708 - Standard Practice for Design and Installation of Rigid Pipe Hangers; 1992
(Reapproved 2008).
AA. ASTM F876 - Standard Specification for Crosslinked Polyethylene (PEX) Tubing; 2010.

AB. ASTM F877 - Standard Specification for Crosslinked Polyethylene (PEX) Plastic Hot- and
Cold-Water Distribution Systems; 2011.
AC. ASTM F1476 - Standard Specification for Performance of Gasketed Mechanical Couplings
for Use in Piping Applications; 2007.
AD. AWS A5.8/A5.8M - Specification for Filler Metals for Brazing and Braze Welding; 2011 and
errata.
AE. AWS D1.1/D1.1M - Structural Welding Code - Steel; 2010.
AF. AWWA C105/A21.5 - Polyethylene Encasement for Ductile-Iron Pipe Systems; 2010
(ANSI/AWWA C105/A21.5).
AG. AWWA C110/A21.10 - American National Standard for Ductile-Iron and Gray-Iron Fittings, 3
In. Through 48 In. (75 mm Through 1200 mm), for Water and Other Liquids; American
Water Works Association; 2012.
AH. AWWA C111/A21.11 - Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings;
American Water Works Association; 2012 (ANSI/AWWA C111/A21.11).
AI. AWWA C151/A21.51 - Ductile-Iron Pipe, Centrifugally Cast, for Water; American Water
Works Association; 2009 (ANSI/AWWA C151/A21.51).
AJ. AWWA C606 - Grooved and Shouldered Joints; 2011 (ANSI/AWWA C606).
AK. MSS SP-58 - Pipe Hangers and Supports - Materials, Design and Manufacture, Selection,
Application, and Installation; Manufacturers Standardization Society of the Valve and
Fittings Industry, Inc.; 2009.
AL. IS 1239 (Part 1):2004 - Steel Tubes, Tubulars and Other Wrought Fittings Part 1: Steel
Tubes
AM. IS 3589:2001- Steel Pipes for Water and Sewage (168.3 To 2540 mm Outside Diameter)
AN. IS 13205: 1991- Rigid phenolic foam for thermal insulation – Specification
AO. IS 2062:2011 -Hot Rolled Medium and High Tensile Structural Steel.
AP.

1.04 ADMINISTRATIVE REQUIREMENTS

A. Coordination: Coordinate the installation of Pipes with size, location and installation of
service utilities.
B. Preinstallation Meeting: Conduct a preinstallation meeting one week prior to the start of the
work of this section; require attendance by all affected installers.
C. Sequencing: Ensure that utility connections are achieved in an orderly and expeditious
manner.
D. Scheduling:
1.05 SUBMITTALS
A. Refer SCC for Administrative Requirements, for submittal procedures.
B. Welders Certificate: Include welders’ certification of compliance with ASME (BPV IX).
C. Product Data:
1. Include data on pipe materials, pipe fittings, valves, and accessories.
2. Provide manufacturers catalogue information.
3. Indicate valve data and ratings.
4. Show grooved joint couplings, fittings, valves, and specialties on drawings and product
submittals, specifically identified with the manufacturer's style or series designation.
D. Manufacturer's Installation Instructions: Indicate hanging and support methods, joining
procedures.

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E. Project Record Documents: Record actual locations of valves.

F. Maintenance Data: Include installation instructions, spare parts lists, exploded assembly
views.
G. Maintenance Materials: Furnish the following for Owner's use in maintenance of project.
.
1.06 QUALITY ASSURANCE
A. Manufacturer Qualifications: Company specializing in manufacturing products of the type
specified in this section, with minimum ten years of documented experience.
B. Installer Qualifications: Company specializing in performing work of the type specified in
this section, with minimum ten years of experience.
C. Provide all grooved joint couplings, fittings, valves, specialties, and grooving tools from a
single manufacturer.
D. Date stamp all castings used for coupling housings, fittings, valve bodies, etc. for quality
assurance and traceability.
E. Coupling Manufacturer:
1. Perform on-site training by factory-trained representative to the Contractor's field
personnel in the proper use of grooving tools and installation of grooved joint products.
2. Periodic job site visits by factory-trained representative to ensure best practices in
grooved joint installation.
3. A distributor's representative is not considered qualified to perform the training.
F. Welder Qualifications: Certify in accordance with ASME (BPV IX).
1. Provide certificate of compliance from authority having jurisdiction, indicating approval
of welders.
1.07 DELIVERY, STORAGE, AND HANDLING
A. Accept valves on site in shipping containers with labeling in place. Inspect for damage.
B. Provide temporary protective coating on cast iron and steel valves.
C. Provide temporary end caps and closures on piping and fittings. Maintain in place until
installation.
D. Protect piping systems from entry of foreign materials by temporary covers, completing
sections of the work, and isolating parts of completed system.
1.08 FIELD CONDITIONS
A. Do not install underground piping when bedding is wet or frozen.

PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Manufacturers: Refer SCC.
2.02 HYDRONIC SYSTEM REQUIREMENTS
A. PIPE SIZES

Pipe sizes shall be as required for the individual fluid flows. Various pipe sizes have been
indicated on the Drawings, these are for Contractor’s guidance only and shall not relieve
contractor of responsibility for providing smooth noiseless balanced circulation of fluids.

B. Comply with ASME B31.9 and applicable federal, state, and local regulations.
C. Following material shall be used for pipes and fittings.

Pipes Nominal size (mm) Material Specification

<150 IS 1239 Part-1
200 and above IS 3589 Gr. FE 410 (8mm thick)
Fittings Nominal size (mm) Material Specification
<40 Socket welded, ASTM A105 construction as per ANSI
B16.11

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50-150 Butt welded, ASTM A234 Gr. WPB as per ANSI

B16.11
>200 Site fabricated from IS 3589 Gr. FE 410 (8mm thick)
Flanges Nominal size (mm) Material Specification
< 150 IS 2062 Gr.A construction as per ANSI B16.5
> 200 IS 2062 Gr.A, construction as per ANSI B16.5

2.03 COLD WATER AND DRAIN PIPING

A. All pipes to be used for cold water (makeup), drain, condensate drain and fittings shall be GI / U-
PVC as indicated in SOQ.

B. All jointing in the pipe system shall be by screwed joints and/or by screwed flanges using 3 mm
3 ply rubber insertion gaskets. Pipe threads and flanges shall be as per relevant BIS Codes.

C. All pipes support shall be mild steel, thoroughly cleaned and given one primary coat of red oxide
paint before being installed.

D. Fittings shall be galvanized steel `medium class’ malleable casting of pressure rating suitable for
the piping system. Supply of flanges shall include bolts, nuts, gaskets as required. Sufficient
number of flanges and unions shall be provided for future cleaning and servicing of piping. Tee-
off connection shall be through equal or reducing tees. All equipment and valve connections, or
connections to any other mating pipes shall be through flanges required for the mating
connections. Fittings & flanges shall form part of piping and are not separately identified in
Schedule of Quantities.

E. Gate valves, globe valves, check valves and strainers shall be like those specified for chilled,
condensing and hot water piping.

F. For proper drainage of AHU Condensate, ‘U’ trap shall be provided in the drain piping.

G. All condensate drain piping shall be insulated and painted as per the section “Insulation” as
indicated in Schedule of Quantities.
2.04 PRE-INSULATED PIPES

Pre insulated pipes, as called for in schedule of quantities shall be sourced from the factory in
length of minimum 6m. Metered dose of Polyurethane foam shall be injected in annular space
between pipe OD and outer jacket to achieve average density of 36 Kg/m3. After expanding,
homogenous foam shall be formed between the cavity with no air gaps. Suitability of temperature
range shall be from (-) 200C to 1200C.

Outer jacket shall be of AL as indicated in schedule of quantities.

2.05 PRE-INSULATED BURIED PIPES

Pre-insulated buried chilled water MS ERW heavy class piping confirming to IS:1239/IS:3589 with
necessary clamps, supports and fittings such as bends, tees, reducers etc. duly insulated with
providing and applying CFC free Polyurethane Foam insulation Cast-in-Situ of density 45+15%
kg/m3 and cladded with minimum 5mm thick HDPE cladding complete as per specifications.
Thermal conductivity of Polyurethane Foam shall be 0.023 W/mK at 100C mean temperature and
shall conform to IS :13205, IS: 12436.

2.06 Pressure Gages And Thermometers

A. Pressure gages shall be stainless steel and shall be provided at suction and at
discharge of each pump, at chilled water supply and return at each air handling unit, at each

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chillers and condenser, and as shown on the Drawings and included in Schedule of Quantities.
Care shall be taken to protect pressure gages during testing.

Pressure gage sockets on insulated pipes and accessories shall be extended upto insulation to
avoid damage of insulation for replacement of gages. Pressure gauges shall be provided with
ball valve and syphon tube.

B. Thermometers shall be stainless steel and shall be provided at chilled water supply
and return at each air handling unit, at each chiller and condenser, and as shown on Drawings
and included in Schedule of Quantities.

C. Thermometers on CHW lines shall be with long stem. Thermometer socket shall be
extended upto insulation thickness so that the thermometer shall be removable without damaging
the insulation.

2.06 PIPE HANGERS AND SUPPORTS

A. Provide hangers and supports that comply with MSS SP-58.or specified in related section.
2.07 VALVES
A. Manufacturers: Refer SCC.
B. Ball and butterfly valves conforming to the following specifications shall be provided as shown
on Drawings:

Size Construction Ends Type

15 to 40 mm Forged Brass Screwed Ball

50 mm and over Body Cast iron Wafer Butterfly

Type and requirements shall be as indicated in Schedule of Quantities. Valves shall have non-
rising spindles unless specified otherwise and shall be suitable for PN 16 (unless specified
otherwise in SOQ) rating. Butterfly valve should be of wafer type long neck construction single
stem design with centre lugs to ensure proper alignment of pipe flanges. Mount valve onto flanges
only after flanges have been welded to pipes using a tool piece and cooled down to room
temperature to prevent damage to resilient seat. The rubber liner should be fully supported by the
valve flanges. Appropriate dimensions and thickness of Flanges and Bolts, as per the Flange
Tables ANSI B16.5 should be used. The flanges should be properly aligned with each other so
that bolts are exactly perpendicular to the flanges. Evenly tighten the flange bolts to secure the
valves. Counter flanges with nut-bolts and gaskets shall be provided by valve manufacturer.
C. Butterfly valves shall perform the function of isolating valves and shall be suitable for PN 16
(unless specified otherwise in SOQ) rating. Butterfly valves shall have Epoxy Coated cast
iron body with Integrally moulded EPDM liner of replaceable type. The liner shall be integrally
moulded on hard backup ring and shall be suitable for PN 16 (unless specified otherwise in
SOQ) rating. All butterfly valves shall be provided with locking devices. Valves 250 mm and
above dia shall be gear driven.
D. Automatic balancing valves shall automatically control flow rates within ± 5% accuracy. Valve
control mechanism shall consist of a stainless steel cartridge with a ported cup and coil /
helical spring to avoid corrosion. Four operating ranges shall be available with the minimum
range requiring less than 14 kPa to actuate the mechanism. Manufacturer shall provide
independent laboratory tests verifying assurance of performance.
E. Balancing cum control valves shall be sized based on flow rates and pressure drops across

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