CONSTRUCTION STANDARD SPECIFICATION

**SECTION 02558**

**PRE-INSULATED UNDERGROUND PIPE FOR STEAM**

**AND CONDENSATE SERVICE**

[Page]{.underline}

PART 1 -- GENERAL

[1.01 Summary 2](#summary)

[1.02 Definitions 2](#definitions)

[1.03 Quality Assurance 3](#quality-assurance)

[1.04 Submittals 3](#submittals)

[1.05 Project Conditions: 6](#project-conditions)

PART 2 -- PRODUCTS

[2.01 Materials And Manufactured Products:
6](#materials-and-manufactured-products)

[2.02 Pre-Engineered Systems: 7](#pre-engineered-systems)

[2.03 Steam Supply And Condensate Return Pipe And Fittings:
7](#steam-supply-and-condensate-return-pipe-and-fittings)

[2.04 Expansion Loops, Elbows And Eccentric Fittings:
9](#expansion-loops-elbows-and-eccentric-fittings)

[2.05 Field Joints, Patch & Repair: 10](#field-joints-patch-repair)

[2.06 Field Joints: 10](#field-joints)

[2.07 Valves: 10](#valves)

[2.08 Guides 10](#guides)

PART 3 -- EXECUTION

[3.01 Installation: 11](#installation)

[3.02 Backfill: 11](#backfill)

[3.03 General: 11](#general)

[3.04 Joints, Welded: 12](#joints-welded)

[3.05 Pre-Engineered System: 12](#pre-engineered-system)

**CONSTRUCION STANDARD SPECIFICATION**

**SECTION 02558**

**PRE-INSULATED UNDERGROUND PIPE FOR STEAM**

**AND CONDENSATE SERVICE**

# PART 1 -- GENERAL

## SUMMARY

> Underground steam and condensate distribution systems including steam,
> steam trenches, and pre-engineered systems.

## DEFINITIONS

> The following definitions are applicable:

A.  Systems: A complete underground heat distribution system with total
    manufactured components including all required components such as
    carrier piping, steel conduit, insulation, loops, ells, tees, end
    seals, gland seals, anchors, valves, manholes, cathodic protection
    (if required), and other appurtenances as specified herein and as
    recommended by the manufacturer.

B.  Project Drawings: The project drawings associated with this
    specification provide information on:

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1.  the size of carrier pipes, length, and site location of the system;

2.  the elevation of the piping along the path;

3.  location of manholes and valve boxes;

4.  the obstacles that must be avoided along the path;

5.  type of system required -- (i.e. multi-therm 500 or poly-therm)

6.  other pertinent general information as noted.

## 

> C. [Construction Complete]{.underline}: The point at which the Project
> Team determines the requirements of the Construction Phase including
> the construction contract are fulfilled. This includes the resolution
> of any open items.
>
>  
>
> [Project Complete]{.underline}: The point at which the Project Team
> determines that all project activities are completed, closed, and/or
> approved for normal operations.

## 1.03 QUALITY ASSURANCE

A.  Contractor shall provide a complete installation with all necessary
    specialties, materials and equipment fully and properly connected
    and coordinated. Installation shall be fully operational upon
    completion of work defined and as phased.

B.  Apply and install materials, equipment and specialties in accordance
    with manufacturer's instructions. Printed instructions shall be made
    available by the Contractor at the site during construction.

C.  Materials and workmanship shall conform to applicable local codes,
    American National Standards Institute, Power Piping Code,
    publications of the Manufacturers Standardization Society, American
    Welding Society, National Association of Corrosion Engineers,
    Federal Specifications, American Society of Testing Materials,
    current safety standards, all as defined in the section of this
    specification relating to Applicable Publications.

## SUBMITTALS

> Also refer to Section 01330, "Submittal Procedures" for submittal
> data.

A.  Submittals shall be in the form of descriptive literature, shop
    drawings, diagrams and catalog cuts, which shall include the
    manufacturer's name, trade name, catalog model or number, name plate
    data, size location, layout dimensions, capacity, pressure rating,
    specification reference' and all other information which will assist
    in evaluating the materials and equipment for compliance with the
    plans, specifications and purpose intended.

B.  All items listed under each group shall be submitted simultaneously.

C.  Group I Pre-Engineered Systems[:]{.underline}

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1.  The contractor shall, within 30 days after the date of award of the
    contract, submit 6 copies of the following documents to the Sandia
    Delegated Representative (SDR) for approval prior to commencing any
    work:

> a\. A detailed design layout of the system showing the size, type, and
> location of each component to be used in the system, including (if
> applicable) the transition point designed to aboveground or other type
> systems.

D.  Group II Expose Piping (In Manholes):

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1.  Materials:

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a.  Piping: Shall conform with ANSI B31.1-73 and shall also be as
    follows:

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1)  2" and larger: Shall be schedule 40, black steel, seamless, beveled
    end, per ASTM A53-GRADE A or equivalent.

2)  1-1/2" and smaller: Shall be schedule 40, black steel, seamless,
    plain end, per ASTM A53-GRADE A or equivalent.

> b\. Fittings: Shall conform with ANSI B31.1-73, and shall be as
> follows:

1)  Flanges 2" and larger: Shall conform to ANSI B16.5-71 for 150

2)  Pound rated, steel, GRADE I flanges.

3)  Flanges 1-1/2" and smaller: Shall conform to ANSI B16.5-71 for

4)  For 150 Pound rated, steel, GRADE I flanges with threads conforming
    to ANSI B2.1-68.

5)  Fittings 2" and larger: Shall conform to ANSI B16.9-71 for

6)  Schedule 40, wrought steel butt-weld fittings.

7)  Fittings 1-1/2" and smaller: Shall conform to ANSI B16.3-71 for

8)  300 pound malleable-iron screwed fittings or 2000 pound forged

9)  steel socket weld, ANSI B16.11-66.

10) Gaskets: Shall be made of 1/16 inch thick compressed asbestos,

11) And shall be Flexitallic, Style CG.

12) Bolts and Nuts: Bolts shall conform to ASTM A193-71, GRADE

13) B7, and nuts shall conform to ASTM A194-72 CLASS 2H.

2\. Insulation in Manholes:

a.  Insulation for all pipes, valves, and fittings shall be moulded type

> Fiberglass (mineral wool) pipe insulation having a factory applied
> 0.016 inch thick embossed aluminum jacketing. The insulation shall
> have a minimum density rating of 7 pounds per cubic foot, a thermal
> conductivity (k) of 0.30 at 200 F mean temperature, a temperature
> rating of 400 F, and shall conform with the other requirements of ASTM
> C547, and shall be OWENS-CORNING Fiberglass. The thickness of the
> insulation shall be as follows:
>
> [Pipe Size]{.underline} [Insulation Thickness]{.underline}
>
> 3 inch and smaller 1-1/2 inches
>
> 4 inch and larger 2 inches
>
> When necessary use a moulding cement by Owens-Corning. The installed
> moulding cement shall be finished with two coats of aluminum colored
> weather resistant mastic such as Foster 60-65, or approved equal,
> reinforced with opean weave glass fabric.

b.  Excluding unions and expansion joints, all pipe, valves, fittings
    and

> Flanges in the steam and condensate lines shall be insulated. All
> threaded valves, unions, traps, strainers, flash tanks, and finned
> tubes in the manhole condensate drainage system shall not be
> insulated.
>
> insulation shall be applied with the longitudinal lock seam of the
> metal jacket in the four o'clock position on the pipe to shed water.
> Butt joints shall be sealed with factory furnished joint scaling
> strips with integral mastic and secured in place with ½ inch aluminum
> bands tightened to insure weather seal. When pipe hangers or supports
> occur
>
> on exterior of aluminum jacket, a 22 gauge galvanized iron sleeve
> shall be installed between the aluminum jackets and pipe hangers.

E.  Group IV Pipe Trenches[:]{.underline}

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1.  Trench plans, profiles, sections and details.

2.  Pipe and fittings (concealed in trenches).

3.  Pipe anchors, supports. Pipe insulation, jackets and wrapping
    materials.

## 1.05 PROJECT CONDITIONS: 

A.  Phasing of demolition and construction shall be in accordance with
    the provisions of the Specifications Section 15050, "General
    Material & Work Requirements, and as indicated on drawings.

B.  Interruption of Existing Service: Arrange, phase and perform work
    and provide temporary facilities, materials, equipment, and
    connections to utilities, to assure adequate steam and condensate
    return service for existing installations at all times. Only such
    absolutely necessary interruptions as may be required for making
    connections will be permitted, and only at such times when approval
    is obtained from SDR. See drawing for additional information.

# PART 2 -- PRODUCTS 

## MATERIALS AND MANUFACTURED PRODUCTS: 

A.  All items to be installed must have approval of the SDR prior to
    installation. SDR has the right to reject any item which is not in
    compliance with contract requirements.

B.  Manufactured Products: Manufactured products incorporated shall meet
    following conditions:

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1.  When two or more units of equipment serve same function, they shall
    be products of on manufacturer.

2.  Manufacturers of equipment assemblies which include components made
    by others shall assume complete responsibility for final assembled
    unit.

a\. All components of an assembled unit need not be products of same
manufacturer.

> b\. Constituent parts which are alike shall be products of a single
> manufacturer.

c\. Components shall be compatible with each other and with the total
assembly for intended service.

C.  Manufacturer's Identification: Components of equipment shall bear
    manufacturer's name or trademark and model number on a name plate
    securely affixed in a conspicuous place, or cast integral with,
    stamped or otherwise permanently marked upon the components of the
    equipment.

## PRE-ENGINEERED SYSTEMS: 

A.  Steam System Requirements: The system provided shall be approved for
    Class A groundwater conditions, an operating temperature of 350
    degrees F for steam system, 250 degrees F for condensate system and
    mildly corrosive soil conditions. Design the system for steam and
    condensate service.

B.  Valves, Pressure Gages, Steam Traps, Strainers, Ball Joints: These
    items must conform to the specifications. Do not furnish these items
    as part of the "Pre-Engineered Systems".

## STEAM SUPPLY AND CONDENSATE RETURN PIPE AND FITTINGS:

A.  General:

1\. All underground steam shall be multi-therm 500 and all underground
condensate shall be poly-therm as manufactured by Perma-Pipe, Inc. or
equivalent. The system supplier shall have fabricated systems of the
composition defined herein for at least three years. All straight
sections, fittings, anchors and other accessories shall be factory
prefabricated to job dimensions and designed to minimize the number of
field welds. Each system layout shall be computer analyzed by the piping
system manufacturer to determine stresses on the carrier pipe and
anticipated thermal movement on the service pipe. The system design
shall be in strict conformance with ANSI B31.1, latest edition. Factory
trained field technical assistance shall be provided for the critical
periods of installation; i.e., unloading, field joint instruction and
testing.

B.  Service Piping:

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1.  Internal piping shall be standard weight Schedule 40 carbon steel
    except for condensate piping which shall be Schedule 80 carbon
    steel. All joints shall be buttwelded for sizes 2-1/2 inches and
    greater, and socket welded for 2 inches and below. Where possible,
    straight sections shall be supplied in 40-foot nominal length with 6
    inches of piping exposed at each end for field joint fabrication.
    Steel Pipe: ASTM A53 Grade B or A106 Grade B.

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C.  Sub-Assemblies:

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1.  Steam Piping: End seals, gland seals and anchors shall be designed
    and factory prefabricated to prevent the ingress of moisture into
    the system. All subassemblies shall be designed to allow for
    complete draining and drying of the conduit system.

2.  Condensate Piping: End seals and anchors shall be designed and
    factory prefabricated to prevent the ingress of moisture into the
    system.

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D.  Insulation:

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1.  Steam Piping: Carrier pipe insulation shall be calcium silicate or
    mineral wool. Split insulation shall be held in place by stainless
    steel bands installed on 18 inch centers. The insulation shall be
    passed the most recent boiling test and other requirements specified
    in the Federal Agency Guidelines Specification

2.  Condensate Piping: Carrier pipe insulation shall be 2 pound per
    cubic foot density polyurethane foam for straight sections and
    preformed polyurethane form for all fittings.

3.  Steam and Condensate Piping: Minimum insulation thickness shall be:

> [Pipe Size (in.)]{.underline} [Insulation Thickness (in.)]{.underline}
>
> Up to 1 1
>
> 1 1/2 -- 3 1.5
>
> 4 -- 6 2
>
> 8 -- 14 2.5
>
> 16 -- up 3

E.  Steel Conduit:

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1.  Steam Piping: The steel conduit casing shall be smooth wall, welded
    steel conduit of the thicknesses specified below:

> [Conduit Size]{.underline} [Conduit Thickness]{.underline}
>
> Up to -- 26\" 10 Gauge

28\" -- 36\" 6 Gauge

38\" -- 42\" 4 Gauge

Changes in casing size, as required at oversized casing to allow for
carrier pipe expansion, shall be accomplished by eccentric and
concentric fittings and shall provide for continuous drainage.

2.  Condensed Piping: does not apply.

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F.  Pipe Supports:

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1.  Steam Piping: All pipes shall be supported at not more than 10 foot
    intervals. These supports shall be designed to allow for continuous
    airflow and drainage of the conduit in place. The straight supports
    shall be designed to occupy not more than 10% of the annular air
    space. Supports shall be of the type where insulation thermally
    isolated the carrier pipe from the other conduit. The surface of the
    insulation shall be protected at the support by a sleeve not less
    than 12 inches long, fitted with traverse and, where required,
    rotational arresters.

2.  Condensate Piping: does not apply.

G. Steel Conduit Insulation

1\. Steam Piping: Conduit insulation shall be spray applied polyurethane
foam, having a nominal 2 pound per cubic foot density for all straight
lengths and fittings. The insulation thickness shall be 1 inch. Quality
assurance procedures for the insulation shall include either a visual
check prior to jacketing or infrared, or x-ray of the entire length, to
insure there are no insulation voids. The urethane foam shall meet ASTM
C591 and have the minimum characteristics of .14K-factor, density of 2
pcf and a closed cell content of 90 to 95%.

2\. Condensate Piping: does not apply

H. Protective Jacket:

1\. Steam and Condensate Piping: All straight sections of the insulated
piping system shall be filament wound, polyester resin/fiberglass
reinforcement composite directly applied on the insulating foam.
Thermoplastic casing material, e.g. PVC or PE, shall not be allowed.

> The minimum thickness for FRP jacket shall be as follows: For jacket
> diameter up to 15.5 inches -- thickness = 0.055 inches, jacket
> diameter between 15.6 inches and 24.5 inches thickness -- 0.085
> inches, jacket diameter above 24.6 inches, thickness = .110 inches.
> All fittings shall be pre-fabricated.

## EXPANSION LOOPS, ELBOWS AND ECCENTRIC FITTINGS:

A.  Steam Piping: Expansion loops and elbows shall be factory
    manufactured utilzing the same casing thicknesses, material and
    coating as the straight conduit lengths. Loops and elbows shall be
    sized to allow carrier pipe thermal movement without damage to the
    insulation. Eccentric fittings shall be factory manufactured, coated
    and utilized whenever changes in casing size are warranted as
    determined by the manufacturer.

B.  Condensate Piping shall utilize external expansion compensation at
    loops and elbows as required and recommended by the system
    manufacture to allow thermal movement.

## 2.05 FIELD JOINTS, PATCH & REPAIR:

A.  [Field joints]{.underline} shall be applied by the insulation
    contractor utilizing the manufacturer's furnished kit and
    instructions. Field joints shall not be applied until after carrier
    pipe has been hydrostatically tested and approved.

B.  Patch and repair existing piping to remain with Dri-Therm installed
    according to manufacturer's installation instructions.

## FIELD JOINTS:

A.  [Field joints]{.underline} shall be applied by the insulation
    contractor utilizing the manufacturer's furnished kit and
    instructions. Field joints shall not be applied until after carrier
    pipe has been hydrostatically tested and approved.

## VALVES:

A.  Gate Valves 2" and Larger: Shall be of cast steel, 150 pound rating,
    with outside

> screw and yoke, rising stem, and with flanged ends and shall conform
> to ANSI B16.10. The trim and stem shall be 316 stainless steel per
> ASTM A276. Gate valves 2" and larger for steam shall have factory
> installed globe valve by-pass.
>
> The by-pass valve shall be cast steel Y-type globe valve with yoke
> cast integral with the body. The by-pass shall be ½" thru 4" gate
> valves, ¾" for 5" thru 8" gate valves, and 1" for 10" or over gate
> valves. Gate valves shall be walworth 5202F.

## GUIDES

A.  Guides shall be constructed of materials in accordance with ANSI
    B31.1-73, Section 121.2.1. Prefabricated pipe alignment guides with
    steel spider and segmented steel cylinder shall be:

    1.  Flexonics Piping Alignment Guide, or Tube-Turn Series A Guides.

##### PART 3 -- EXECUTION

## 3.01 INSTALLATION:

> A. The installing contractor shall handle the system in accordance
> with the directions furnished by the manufacturer and as approved by
> the SDR. The installing contractor shall be responsible to excavate,
> string conduit, weld, test, place in trench, backfill or otherwise
> treat and install the system as per directions furnished by the
> manufacturer and approved by the Sandia design engineer in accordance
> with plans and specifications. The conduit shall be air tested at 15
> psig and the carrier piping hydrostatically tested to 1 ½ times the
> working pressure; test pressure shall hold for two hours. Holiday
> testing of conduit coating shall be the responsibility of the
> contractor under the directions furnished by the manufacturer. All
> holidays shall be recoated and retested. A qualified representative of
> the manufacturer shall be present at the job site during critical
> periods of the installation such as unloading, commencement of the
> installation and testing. Backfill shall not commence until approval
> of tests by the manufacturer's representative. Upon completion of the
> installation, the manufacturer shall provide a certificate that the
> installing contractor has accomplished the work in accordance with the
> manufacturer's directions. Additionally, the installing contractor
> shall certify that he has complied with the manufacturer's directions.

## BACKFILL:

A.  A 4-inch layer of sand or fine gravel shall be placed and tamped in
    the trench to provide a uniform bedding for the conduit. The entire
    trench shall be evenly backfilled with a similar material as the
    bedding, in 6 inch compacted layers to a minimum height of 6 inches
    above the top of the insulated piping system. Bedding and backfill
    materials shall be as recommended by the manufacturer. Refer to
    Section 02200, "Earthwork" for additional backfill above the pipes.

## GENERAL:

A.  Connecting to Existing Work: Connect new work to existing work in a
    neat and workmanlike manner. Where an existing structure must be cut
    or existing utilities interfere, such obstruction shall be bypassed,
    removed, replaced or relocated, patched and repaired. Work disturbed
    or damaged shall be replaced to its prior condition.

B.  Coordination: The Contractor shall coordinate the location of all
    items of equipment and work of all trades. An essential feature of
    the design is to maintain operability and maintainability of the
    equipment and systems. Any relocation of equipment or systems to
    comply with the requirement of operability and maintainability shall
    be performed by the Contractor at his cost.

C.  Grading: Unless otherwise shown on drawings, steam and condensate
    lines shall be graded downward not less than 1-inch in 20-feet.
    Provide eccentric reducing fittings on steam mains and branches
    (except on vertical piping). Install said fittings to maintain
    continuity of grade in bottom of pipeline. Install properly dripped
    and trapped risers on steam lines where shown on drawings and where
    space restrictions prevent continuous grading.

D.  No excavation shall be initiated without a digging permit. Permits
    are available through the SDR.

## JOINTS, WELDED:

A.  Welded Joints:

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1.  Welding material and labor shall be in accordance with welding
    procedure of ANSI Piping Codes.

2.  Branch connections shall be made with welding tees.

3.  Mitering of pipe to form tees will not be permitted. All pipe and
    fittings shall be cleaned before welding and installation in system.

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B.  Fittings: All pipe intersections and all changes in direction shall
    be made with factory-built reinforced fittings. Field-fabricated
    fittings and miters are not permitted.

## 3.05 PRE-ENGINEERED SYSTEM:

A.  Contract Requirements: The Contractor, if not the system supplier,
    shall employ the services of a system supplier who has
    pre-engineered system for the groundwater conditions, operating
    temperature, and soil classification specified by SNL. The system
    supplier shall design and oversee the installation and testing of
    the system in strict accordance with the requirements specified
    herein.

B.  Excavation, Trenching, and Backfilling: The Contractor is
    responsible for excavation, trenching, and backfilling as required
    by and described in the system supplier's approved brochure and as
    required by the system supplier's design.

C.  Reports to SDR: The Contractor shall obtain periodic (3-minimum)
    written reports from the representative of the system supplier. The
    original report shall be presented to the Contracting Officer on the
    same day it is prepared, and one copy shall be forwarded to the
    manufacturer's main office. The report shall be signed by the
    manufacturer's representative. The report shall state whether or not
    the condition and quality of the materials used and the installation
    of the system are in accordance with the plans, specifications, and
    is satisfactory in all respects. If any work connected with the
    installation is unsatisfactory, the report shall state what
    corrective action has been taken or shall contain the system
    supplier's recommendations for corrective action. The report shall
    identify any conditions that could result in an unsatisfactory
    installation including such items as open conduit ends left in the
    trench overnight and improper manhole entries. The representative
    shall take prompt action to return to the factory all damaged or
    defective material, and shall order prompt replacement of such
    material. The representative of the system supplier shall be present
    at the job site to inspect all delivery of materials and all
    installation work, tests, and backfilling. The Contractor shall not
    perform any of this work in the absence of the representative of the
    system supplier. Upon completion of the work and before final
    acceptance, the Contractor shall deliver to the SDR a notarized
    statement signed by a principal officer of both the supplying and
    the contracting firm, stating that the installation is satisfactory
    and in accordance with the plans and specifications.

D.  Cleaning of Piping: The Contractor is responsible for cleaning the
    interior of the carrier pipe as required by the described in the
    system supplier.

> E. Field Tests: The Contractor is responsible for performing all field
> tests required by and described by system supplier.

END OF SECTION