SECTION 22 1500

COMPRESSED-AIR SYSTEMS

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LANL MASTER SPECIFICATION

This template must be edited for each project.  In doing so, specifier
must add job-specific requirements.  Brackets are used in the text to
indicate designer choices or locations where text must be supplied by
the designer.  Once the choice is made or text supplied, remove the
brackets.  The specifications must also be edited to delete
specification requirements for processes, items, or designs that are not
included in the project \-- and specifier's notes such as these.  To
seek a variance from requirements in the specifications that are
applicable, contact the Engineering Standards Manual Mechanical
[POC](http://engstandards.lanl.gov/engrman/6mech/htmls/mechnew2.htm).
Please contact POC with suggestions for improvement as well.\
\
When assembling a specification package, include applicable
specifications from all Divisions, especially Division 1, General
requirements.\
\
Specification developed for ML-4 projects.  For ML-1, 2, and 3
applications, additional requirements and independent reviews should be
added if increased confidence in procurement or execution is desired;
see ESM Chapter 1 Section Z10 Specifications and Quality sections.

**NOTE:** When compressed air system exceeds 150 psig, verify all
material specified meets the design pressure/temperature requirements.

Refer to LANL Standard Drawings ST-D2090-1 for compressed air component
details.

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1.  GENERAL

    1.  SUMMARY

        A.  SECTION INCLUDES

            1.  Pipe fittings, valves, and accessories

            2.  Filters

            3.  Automatic drain valves

            4.  Torpedo Oil/Water separators

            5.  Air dryers

            6.  Pressure regulating valves

            7.  Air receivers

            8.  Safety valves

            9.  Air compressors

    2.  SUBMITTALS

        A.  Submit the following in accordance with Section 01 3300,
            Submittal Procedures:

            1.  Catalog data

            2.  Installation instructions

            3.  Materials/Parts list

            4.  Operational and Maintenance data

            5.  Warranties

            6.  Welding Procedures, per ASME section 9.

            7.  Welder Certifications, per ASME section 9.

            8.  Welding Inspection Reports, as applicable.

    3.  QUALITY ASSURANCE

        A.  Manufacturer Qualifications: Company specializing in
            manufacturing products specified in this section with
            minimum 5 years experience and having maintenance service
            based within 200 miles radius of installation.

        B.  Material and Installation: Conform to ASME B31.9, Building
            Services Piping for systems operating at pressure of 150
            psig or less and at temperature of 200 degrees F or less.
            For systems beyond above pressure and temperature
            limitations, conform to ASME B31.1, Power Piping.

    4.  WARRANTIES

        A.  Provide a minimum of 1-year manufacturer's warranty, parts
            and labor, for air compressor system.

2.  PRODUCTS

    1.  PRODUCT OPTIONS AND SUBSTITUTION

        A.  Alternate products may be accepted; follow Section 01 2500,
            Substitution Procedures.

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    1.  COPPER TUBING AND FITTINGS (up to 2 inches)

        A.  Tubing: Copper, hard drawn, ASTM B88, Type L

        B.  Fittings: Wrought copper, ASME B16.22

        C.  Joints: ASTM B32, solder, Grade 95TA

    2.  STEEL PIPE AND FITTINGS (over 2 inches)

        A.  Pipe: Black steel, ASTM A53, Schedule 40

        B.  Fittings: Steel, ASTM A234, Grade B, Schedule 40,
            butt-welding type

        C.  Joints: Welded

    3.  VALVES

        A.  Gate Valves: Class 125 or 150, bronze body, bronze trim,
            rising stem, handwheel, inside screw, solid wedge disc, ends
            to suit piping.

        B.  Ball Valves: Class 150, bronze, chrome-plated brass ball,
            full port, teflon seats and stuffing box ring, lever handle,
            ends to suit piping.

        C.  Globe Valve: Class 150, bronze body, bronze trim, ends to
            suit piping.

        D.  Swing Check Valve: Class 125, bronze body and cap, bronze
            swing disc with rubber seat, ends to suit piping system.

    4.  STRAINER

        A.  "Y" type, Class 150, 20 mesh stainless steel screen, cast
            iron body, with blowoff gate valve and plug, ends to suit
            piping system.

    5.  UNIONS AND FLANGES

        A.  Unions

            1.  Ferrous Pipe: 150 psi malleable iron threaded unions.

            2.  Copper Tube and Pipe: 150 psi bronze unions with
                soldered joints.

        B.  Dielectric Unions

            1.  Union with galvanized or plated steel threaded end,
                copper solder end, water-impervious isolation barrier.

        C.  Flanges

            1.  Forged carbon steel, ASTM A105, Class \[150\]

    6.  FLEXIBLE CONNECTOR

        A.  Manufacturer: Flex-Hose, Pumpsaver Connectors.

        B.  Braided bronze or stainless steel flexible connector with
            corrugated metal hose, minimum working pressure 200 psi at
            70 degree F, minimum temperature rating 400 degree F, with
            ends to suit piping system.

    7.  PREFILTER, HIGH-EFFICIENCY COALESCING

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When selecting filter, assume maximum flow conditions at the minimum
operating pressure. Match inlet and outlet connections to system pipe
size.

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A.  Manufacturers:

    1.  Van Air, Housing Series F200, Filter Grade C

    2.  Pneumatics Products, Housing Series P2001, Filter Grade SU

B.  High-efficiency coalescing filter efficiency 99.99 percent at 0.6
    microns, maximum oil carryover 0.008 ppm by weight, maximum inlet
    temperature 125 degrees F, maximum clean dry pressure drop 1.50
    psid. Housing maximum working pressure 250 psig at 225 degrees F,
    furnish with optional two-sided color-coded pressure differential
    indicator, and without internal float drain.

    1.  In/Out Connection: \[ \] inches NPT

    2.  Flow Capacity: \[ \] scfm at 100 psig

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8.  AFTERFILTER, HIGH-EFFICIENCY PARTICULATE

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When selecting filter, assume maximum flow conditions at the minimum
operating pressure. Match inlet and outlet connections to system pipe
size.

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A.  Manufacturers:

    1.  Van Air, Housing Series F200, Filter Grade RC

    2.  Pneumatics Products, Housing Series P2001, Filter Grade AF

B.  High-efficiency particulate filter efficiency 99.99 percent at 0.9
    microns, maximum inlet temperature 150 degrees F, maximum clean dry
    pressure drop 1.50 psid. Housing maximum working pressure 250 psig
    at 225 degrees F, furnish with optional two-sided color-coded
    pressure differential indicator, and without internal float drain.

    1.  In/Out Connection: \[ \] inches NPT

    2.  Flow Capacity: \[ \] scfm at 100 psig

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9.  AUTOMATIC DRAIN VALVE

    A.  Manufacturer: Van Air, Model EDV-2002

    B.  Solenoid valve, brass body, NEMA 4 enclosure, rated at 300 psig,
        open time 1 to 60 seconds cycle time 1-60 minutes, 6 foot power
        cord with plug, electrical \[115V/ 1 PH/60 Hz\] \[230V/ 1 PH/ 60
        Hz\], maximum fluid temperature 210 degrees F, ambient
        temperature range 32‑150 degrees F.

        1.  Valve In/Out Port Size: \[1/4\] \[1/2\] inch NPT

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10. Automatic drain valve (zero air loss)

    A.  Manufacturer: Zeks, Model NCC1701-D.

    B.  Zero air loss drain valve, 1/2 inch NPT connections, pressure
        range 0-230 psi, temperature range 36 - 120 degree F, electrical
        connection \[115\] \[230\] VAC, NEMA 4 enclosure, and
        Y-strainer. Operation, 50 volume checks/second.

11. TORPEDO OIL/WATER SEPARATOR

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Consult with FM facility engineer for type of oil/water separator
(torpedo or commercially available) to be specified. Specify 2 inch
diameter torpedo for compressors less than or equal to 5hp; 4 inch
diameter torpedo for compressors greater than 5hp. Alternative is to
specify a commercially available oil/water separator such as Van Air
Model ES Series. Consult with manufacturers' representative for
application and sizing information. If a commercially available
oil/water separator is specified, revise standard detail ST-D2090-1
accordingly.

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A.  Manufacturer: Eggelhof Inc., Albuquerque, \[4 inch, Model No. 4 - 20
    ABS\] \[2 inch, Model 2 - 20 ABS\].

B.  4 inch diameter oil/water torpedo separator, ABS construction, 20
    inch long.

C.  2 inch diameter oil/water torpedo separator, ABS construction, 20
    inch long.

D.  Furnish above with safety cable and 20 x 20 inch polypropylene
    absorbent pad.

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12. REGENERATIVE AIR DRYER

    A.  Manufacturers:

        1.  Van Air, Model HLS-\[ \], HL-\[ \].

        2.  Pneumatic Products, DHA Series, Model \[ \].

    B.  Heatless, regenerative dryer, minus 40 degrees F pressure dew
        point, solid state controller, twin towers, with adsorbent
        desiccant, purge exhaust valve and muffler, drain connection and
        cycle saver control option that adjusts dryer purge to actual
        moisture load condition and includes failure to switch (FTS)
        alarm.

        1.  Capacity: \[ \] scfm at \[ \]psig

        2.  Power Voltage: \[ \] V, \[ \] phase, 60 Hz.

13. REFRIGERATED AIR DRYER (Air Cooled)

    A.  Manufacturers:

        1.  Van Air, \[Model RD \].

        2.  Hankison, \[Model HPR \].

    B.  Refrigerated air dryer, air cooled condenser, 35‑38 degrees F
        pressure dew point, indoor installation (ambient temperature
        40‑100 degrees F), automatic drain valve, and charged with R134a
        or R22 refrigerants.

        1.  Capacity: \[ \] scfm at \[ \]degrees F inlet temperature and
            \[ \] psig inlet pressure.

        2.  Power Voltage: \[ \] V, \[ \] phase, 60 Hz.

14. REFRIGERATED AIR DRYER (Water Cooled)

    A.  Manufacturers:

        1.  Van Air, Model RDW-\[ \].

        2.  Hankison, Model HPRFW \[ \].

    B.  Refrigerated air dryer, water cooled, 35‑38 degrees F pressure
        dew point, indoor installation (ambient temperature 40‑100
        degrees F), automatic drain valve, and water regulating valve.

        1.  Capacity: \[ \] scfm at \[ \] degrees F inlet temperature
            and \[ \] psig inlet temperature.

        2.  Power Voltage: \[ \] V, \[ \] phase, 60 Hz.

15. PRESSURE GAUGE

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Refer to manufacturer's recommendations for pressure ranges. Generally,
a range of twice the working pressure is recommended, with a maximum
working pressure not exceeding 75 percent of the range.

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A.  Manufacturer: Ashcroft, Type 1009.

B.  ASME B40.100, Grade 1A, minimum 2 1/2 inch dial, 1/4 inch NPT brass
    bottom connection, maximum plus or minus 1 percent full scale
    accuracy, stainless steel case, phosphor bronze bourdon tube, and
    isolation valve.

    1.  Range: \[ \] psi or \[as specified on drawings\].

    2.  Cock Valve: 1/4 inch brass plug, 250 psi working pressure
        valve.\
        Manufacturer: Anderson Metals, PAC-56NB, Part No. 138-00110.

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16. PRESSURE REGULATING VALVE

    A.  Manufacturer: Watts, No. R119 Series

    B.  Reduced pressure type, range \[0‑125 psig\], diaphragm operated,
        relieving spring adjustment mechanism, rated at 300 psig
        maximum, temperature range 40 ‑ 120 degrees F.

17. DEW POINT TEST FITTING

    A.  Manufacturer: Hansen, No. GR-602.

    B.  Brass quick-disconnect fitting, 1/4 inch FPT x QD.

18. MOISTURE INDICATOR

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Provide visible moisture indicator when not provided with regenerative
dryer. Do not install on system with refrigerated dryer.

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A.  Manufacturers:

    1.  Van Air, No. 46-2300.

    2.  Pneumatic Products, Aquadex.

B.  Visible moisture indicator assembly, with indicating silica gel that
    changes from blue to pink at dew point of 0 - 10 degrees F, and back
    to blue when dew point is lower than minus 10 degree F.

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19. AIR RECEIVER

    A.  Manufacturer: Hanson Tank

    B.  Carbon steel tank built and tested to ASME Section VIII,
        Division 1 Pressure Vessel Code, "U" stamped.

        1.  Configuration: \[Vertical\] \[Horizontal\] tank with ring
            base and standard, screw or flange inlet and outlet
            connections with factory exterior prime coat.

        2.  Size: \[ \] gallons, rated at \[ \] psi, \[ \] diameter x \[
            \] long.

20. SAFETY VALVE

    A.  Manufacturer: Kunkle Model 6010.

    B.  Safety valve for air service, side outlet, full nozzle design,
        bronze body, brass and bronze trim, pressure range 15-250 psig,
        temperature range minus 60 to 406 degrees F, NPT ends, built and
        tested to ASME Section VIII, Division 1 Pressure Code, "UV"
        stamped.

        1.  Inlet Size: \[ \] inch.

        2.  Set Pressure: \[ \] psi.

        3.  Capacity: \[ \] scfm.

21. AIR COMPRESSOR

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Consult with manufacturer's representative, CSRF Spectext, and the LANL
Engineering Manual chapter when writing an air compressor specification.
Furnish compressors with an after cooler, mechanical separator and an
intake air filter silencer. If sound control is a factor, an intake
filter silencer, muffler or sound enclosure may be required. Furnish
duplex compressors with hour meters.

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3.  EXECUTION

    1.  INSTALLATION

        A.  Install compressor unit on concrete housekeeping pad.

        B.  Install compressor unit on vibration isolators. Level and
            bolt in place.

        C.  Route condensate drains to nearest floor drain.

        D.  Provide drain valves at low points of piping system.

        E.  Install take-offs to outlets from top of main, with shutoff
            valve after take-off. Slope take-off piping to outlets.

        F.  Install compressed air couplings, female quick connectors,
            and pressure gages where branch outlets are indicated.

        G.  Labeling: Refer to Section 22 0548, Vibration and Seismic
            Controls for Plumbing Piping and Equipment..

        H.  Pressure Testing: Refer to Section 22 0813, Testing Piping
            Systems.

        I.  Cap or seal ends of piping when not connected to mechanical
            equipment to ensure contamination by foreign material does
            not occur.

END OF SECTION

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Do not delete the following reference information:

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FOR LANL USE ONLY

This project specification is based on LANL Master Specification 22 1500
Rev. 2, dated June 10, 2008.