CEMP-CE

Engineer 

Pamphlet

415-1-261

Volume 4

Department of the Army

U.S. Army Corps of Engineers

Washington, DC 20314-1000

EP 415-1-261

Volume 4

2 January 1992

Construction

QUALITY ASSURANCE

REPRESENTATIVES GUIDE

SPECIAL CONSTRUCTION, CONVEYING

SYSTEMS, MECHANICAL, AND

ELECTRICAL FEATURES OF BUILDING 

CONSTRUCTION

Distribution Restriction Statement

Approved for public release; distribution is 

unlimited.

i

DEPARTMENT OF THE ARMY EP 415-1-261

U.S. Army Corps of Engineers

CEMP-CE Washington, D.C. 20314-1000

Pamphlet

No.415-1-261 1 Dec 1992

Construction

QUALITY ASSURANCE REPRESENTATIVE*S GUIDE

FOREWORD

This guide is one of four volumes reprinted with revisions

from guides first published in 1964. The reason for their

existence and continuance is to provide Quality Assurance 

Representatives (QARs), those with either quality control or

quality assurance responsibilities, a reliable checklist type

reference for each phase of construction.

QARs will find the information fundamental and appropriate to

their role of controlling and assuring quality in accordance with

the plans and specifications. The guide will, therefore, become a

valuable reference to supplement the project plans and

specifications. Its contents will also help refresh the memory of

experience, training, and good old common sense. The use of

knowledge with appropriate responsibility and authority will

result in the decisions and actions so necessary for successful 

quality assurance. The objective is to produce quality products

for our customers throughout the world.

FOR THE COMMANDER:

WILLIAM D. BROWN

Colonel, Corps of Engineers

Chief of Staff

This Volume 4 of EP 415-1-261 supersedes Volume 4 EP 415-1-261,

December 1986
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ii

TABLE OF CONTENTS

Chapter

Number Page

13A X-RAY SHIELDING 13A-1

13B PRE-ENGINEERED BUILDINGS 13B-1

13C SOLAR ENERGY SYSTEMS 13C-1

13D LIQUID AND GAS STORAGE TANKS 13D-1

14A ELEVATORS 14A-1

14B HOISTS AND CRANES 14B-1

14C MATERIAL HANDLING SYSTEMS 14C-1

15A PIPING SYSTEMS 15A-1

15B DUCTWORK 15B-1

15C MECHANICAL INSULATION 15C-1

15D PLUMBING SYSTEMS 15D-1

15E HEATING SYSTEMS 15E-1

15F VENTILATING, AIR SUPPLY AND 15F-1

DISTRIBUTION SYSTEMS

15G REFRIGERATION AND AIR 15G-1

CONDITIONING

15H FIRE PROTECTION SYSTEMS 15H-1

16A INTERIOR ELECTRICAL 16A-1

16B EXTERIOR ELECTRICAL 16B-1

16C ELECTRICAL HEATING 16C-1

16D ALARM AND DETECTION SYSTEMS 16D-1

16E ALUMINUM CONDUCTORS 16E-1

Chapters numbered in the guides contain the same subject

information as the numbered divisions in the specifications for

both military and civil works construction projects. They are

identified by specific volume as follows:

Chapter

Number Volume 1 Subject

1 General Reguirements.

2 Sitework: earthwork,

underground utilities,

paving, plantings, and

railroads.

2 Volume 2

Sitework (continued):

piles, levees, dams,

relief wells, drilling,

lock and dam gates,

penstocks, revetments,

dredging, jetty,

breakwater, and groin

construction.

Volume 3

3 Concrete

4 Masonry

5 Metals

6 Wood and Plastics

7 Thermal & Moisture

Protection

8 Door & Windows Finishes

9 Finishes

10 Accessories &

Specialties

12 Furnishing & Casework
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iii

Chapter

Number Volume 4 Subject

13 Special

Construction

14 Conveying

Systems

15 Mechanical

16 Electrical
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iv

CHAPTER 13A

X-RAY SHIELDING

INDEX

Para. Title Page

13A-01 GENERAL 13A-1

13A-02 MATERIALS 13A-1

a. Shop Drawings 13A-1

b. Lead-Lined Materials

and Equipment 13A-1

13A-03 ERECTION 13A-2

a. General 13A-2

b. Construction of X-ray

shielded rooms 13A-2

13A-04 VERIFICATION 13A-5

a. Survey Test 13A-5

b. Certification 13A-5

c. Designations 13A-5
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1 Dec 92

13A-1

CHAPTER 13A

X-RAY SHIELDING

13A-01 GENERAL

a. This chapter covers specific information for the

materials and construction of medical and dental radiation

facilities.

b. Check for specific structural features which may be

different than usual, such as:

(1) Recessed floor slab

(2) Closer wall stud spacing

(3) Blocking between wall studs

(4) Heavier steel bar joists for support of lead-lined

ceiling

(5) Lead-lined floor above structural flooring

c. Make spot checks of the lead sheet and lead linings for

specified thickness and uniformity.

d. During erection check for continuity of protection with

specified laps, joint strips, patches and sleeves of lead.

13A-02 MATERIALS

a. Shop Drawings

(1) Check for conflicts between approved shop drawings,

contract drawings, and specifications.

(2) Check for details of joints to make the required lead

shielding laps or joint strips.

(3) Shielding of penetrations is crucial. Check for these

requirements on the details of penetrations. Get clarification

from your supervisor where no details exist.

b. Lead-Lined Materials and Equipment

(1) The grade of lead sheet specified indicates product

quality, purity. Check label and make a close inspection for

conformance.

(2) Masonry units for shielding are different than usual

CMU and manufactured to provide a 1⁄2-inch mortar joint with

extended lead liner to lap the lead liner of adjacent units.

(3) Approve surface texture of masonry when a plaster

finish will be applied or for painted finish.

(4) For prefinished wall panels, check the labeling with

inspection of the sample and representative units for contract

requirements.

(5) Do the shop drawings detail the lead liner joints at

corners of rooms for panel construction?
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13A-2

(6) Are the lead—lined lath segments designed to lap the

lead at joints? Lap the lath?

(7) Check for type fasteners to attach lath.

(8) Lead lined gypsum wallboard is very difficult to

handle and avoid damage. The 1⁄2—inch GWB is usually specified.

(9) Closely check door and frame and the other special

lined items for proper labels and compliance with requirements.

(10) Is the lead liner in the door and frame the same and

specified thickness as the wall its hung in?

(11) Check edges of prefinished door and all surfaces of

unfinished materials for proper fit, alignment, and damage.

13A-03 ERECTION

a. General

Construction of x-ray shielded rooms requires close

attention to contract requirements. The work will be performed

in strict accordance with the following:

(1) Contract drawings and specifications.

(2) Approved manufacturer*s recommendations.

(3) NCRP Reports 33, 34, and 35.

b. Construction of X-Ray Shielded Rooms

(1) Lead shielding under 3MM thick will be installed in a

single layer.

(a) Check for minimum 1-1/2 inch lap at all joints

(b) Check for minimum specified thickness.

(2) Lead shielding that is more than 3MM thick will be

installed in two or more layers.

(a) Check for minimum 1-1/2 inch lap at all joints.

(b) Check for minimum specified thickness.

(3) Vertical wall shieldings will be erected on lead

strips prior to the installation of floor linings in the

shielded room.

(a) Check to see that lead strips project approximately 3

inches into the shielded room area.

(b) Check door sill lead shielding for extending 1 foot

beyond each door jamb and 1 foot into shielded room area.

(c) Check for coat of asphalt paint on top surface of the

sheet lead prior to application of concrete surface.

(d) Check to see that traffic and other work is not

performed in the area until lead floor lining is protected from

damage.
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13A-3

(4) Check for continuity of shielding at all built—in

feature of walls, columns, outlet and junction boxes, ducts,

conduits, and other wall penetrations.

(5) Lead—lined blocks installation

(a) Check for use of staggered block joints.

(b) Check for 1 inch tight lead laps, without soldering or

burring.

(c) Check to see that no mortar is placed between the lead

laps.

(6) Lead-lined panel installation. Use pilot holes drilled

to receive lead-headed nails, to prevent distortion of butt

jointed panels.

(a) Check to see that all joints are placed over supports.

(b) Check to see that all joints and covers are lapped or

covered with 2 inch wide lap strips, or the joints are backed

with 1-1/2 inch wide strips.

(c) Check finish molding strips for same finish as the

panels.

(7) Lead—lined lath installation. Use pilot holes, as

necessary, to prevent deformation of the fasteners and to

prevent distortion of the lath.

(a) Check to see that lath is applied with long edges at

right angles to supports and with lead linings placed next to

the supports.

(b) Check to see if lath end joints are placed over

supports, and staggered in alternate courses.

(c) Check to see that wall joints do not coincide with the

ceiling joints.

(d) Check over lap of the lead extensions on adjacent

sheets to provide an efficient lead lap.

(e) Check lath applied with long edges parallel to

supports to see if it has blocking to support end joints.

(f) Check external corners for reinforcing by use of

corner beads.

(g) Check securing of lath to wood supports with leadheaded nails 7 inches on centers.

(h) Check to see if nail heads are driven up flush with

lath surface.

(i) For metal supports - check to see that lath is

attached to wood furring strips, which are screwed or bolted to

the metal supports at right angles.

(8) Lead-lined gypsum wallboard. Use drilled pilot holes

for fasteners. Install the wallboards vertically, parallel with

the supports and with the lead lining next to the supports.

Provide blocking at all end joints.
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13A-4

(a) Check for use of 1-1/2 inch wide joint strips where

joints will occur.

(b) Check for 1-3/4 inch X 1-3/4 inch corner joint lead

strips.

(c) Check edges of wallboards for butt joints for

fastening with lead-headed nails at approximately 8 inches on

centers at joints, and 12 inches on centers at intermediate

supports.

(d) For metal studs - check for use of 1 inch long screws.

(e) Check screw heads for 1⁄2 inch diameter lead disc

covering, cemented to the surface of the wallboard, and made

flush with the surface of the wallboard.

(f) If plastic is not used - check for finish ply of

wallboard fastened with laminating adhesives. Nailing will not

be permitted on the finished ply.

(9) Suspended lead-lined plastered ceilings. See contract

drawings for erection details.

(a) Check insulated lath and continuous ceiling bars for

specified support by steel hangers from the overhead structure.

(b) Check to see that lead side of lath faces up.

(c) Check to see that lead in the ceiling will lap lead in

the wall by not less than 1-1/2 inches.

(10) Lead door thresholds. Install in accordance with

approved shop drawings, and constructed as detailed on the

contract drawings.

Check to see that lead surfaces in contact with concrete

is painted with a coat of asphalt paint or latex material.

(11) Operator*s lead-lined protection screen. Locate and

construct the screen in accordance with the drawings.

Check to see that details are complied with both in

materials and installation methods.

(12) Lead-lined doors will have a clearance of 1/16 inch

at sides and top, a minimum adequate clearance at bottom, lock

edge beveled 1/8 inch, and hardware adjusted as required.

Check that warps or twist of lead door does not exceed 1/4

inch in any face dimension of door, including full diagonal,

after door has been hung and finished.

(13) Viewing windows installed in doors. Secure windows

with hardwood strips of same species as face veneer of door.

Check to see if stops are glued to the door on corridor

side and fastened with prescribed screws or finish nails on room

side.
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13A-5

(14) Check that no line-of-sight through lead louvers

exists in installed doors. Fasten louvers with cadmium—plated or

chromium-plated screws.

Check fastenings to insure that lead lining of door was

not penetrated. Use lead lined plugs on one side for through

bolting of door closer.

(15) Film cassette transfer cabinets in lead—lined

partitions will have the entire cabinet, doors, and integral

wall flanges lined with sheet lead of the same thickness as the

partition.

13A-04 VERIFICATION

a. Survey Test

The contractor is required to hire a qualified expert to

make the required radiation protection survey. Check for:

(1) Approved written survey procedures.

(2) Qualification of the expert.

(3) Defective areas which do not meet standard for which

the room is to be used.

(4) CE approval of corrective action proposed for

defective areas.

(5) Resurvey of areas affected by corrective work.

(6) The written report of survey.

b. Certification

The acceptable report of survey for each room will certify

the protection provided to areas outside the room against

radiation exposure

c. Designations

(1) Check for the permanently posted plague in each room

which will contain specific information on thickness of the lead

shielding.

(2) Verify this information to be correct as built.

(3) Information required may vary with the function of the

room; check your specifications.

(4) Where the lead thickness within a room is different,

each surface area will require its separate plaque with the

as—built thicknesses noted.
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i

CHAPTER 13B

PRE-ENGINEERED BUILDINGS

INDEX

Para. Title Page

13B-01 GENERAL 13B-1

a. Coordination of the Work 13B-1

b. Verification of Dimensions 13B-1

13B-02 MATERIALS 13B-1

a. Submittals 13B-1

b. Manufacturer*s

Representative 13B-2

c. Delivery and Storage 13B-2

13B-03 ERECTION

a. Foundations and Services 13B-2

b. Electrical and Mechanical 13B-2

13B-04 TESTING AND CHECKOUT

PROCEDURES 13B-3
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13B-1

CHAPTER 13B

PRE-ENGINEERED BUILDINGS

13B-01 GENERAL

a. Coordination of the Work

(1) This chapter covers the installation of pre—engineered

buildings. Most such buildings require placement of foundations

and ground level slabs on grade. Some designs require basements

and/or crawl spaces.

(2) The placement of the foundations and slabs will

require close coordination between site grading, placement of

exterior and under the structure utilities, including vapor

barrier, and under the slab drainage if specified.

(3) Testing of the water lines, drain lines, sewers, and

gas lines will have to be accomplished prior to being covered by

the foundation and slabs.

(4) Electrical lines and communication lines will either

have to be coordinated with the placement of the foundation or

the slabs.

(5) Seismic considerations required by a design and the

seismic zone will have to be incorporated in the foundations and

slabs. This will include seismic reinforcing steel in masonry

and concrete, flexible joints where branch lines leave main

drain lines under ground and seismic penetrations through

foundation walls.

b. Verification of Dimensions

It is of the utmost importance that the foundations and

slabs fit the pre-engineered building, and that such items

contain the required hold down bolts or fastening plates. The

contractor shall verify all dimensions and coordinate its

dimensions with the approved shop drawings and contract

drawings. The contracting officer will be advised of any

discrepancy before Contractor performs any work.

13B-02 Materials

a. Submittals

(1) Shop drawings shall consist of the complete details

necessary to join together the foundations, slabs and preengineered structure. The shop drawings will provide a complete

list of equipment and materials, including manufacturer*s

descriptive and technical literature. The shop drawings will

provide the erection sequence, tie down arrangement, and joining

together details.

(2) Shop drawings will show electrical, mechanical,

structural, and architectural features included in the factory

constructed units and how these units will be joined to the

field installed components.
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13B-2

b. Manufacturer*s Representative

Check requirements for manufacturer*s representative

supervising the unloading, storage, and erection of the preengineered structure. Metal building guide specification does

not require a manufacturer*s representative.

c. Delivery and Storage

Equipment, parts, and units when delivered will be stored

with protection from the weather, humidity, temperature

variations, dirt, dust, or other contaminants Deliveries should

be scheduled to minimize job site storage whenever possible.

13B-03 ERECTION

a. Foundations and Services

(1) Check Civil, Structural, Mechanical, and Electrical

plans against approved shop drawings to insure proper

orientation of building, that building will fit foundation and

prepared slabs, and that all utilities required to be concealed

are installed prior to foundation or slab placement.

(2) Check anchor bolt and other tie down location, size,

and projections. Protect such tie down devices from damage from

construction equipment.

(3) Study erection procedures. Insure that manufactured

units and parts can be trucked to either erection location or to

storage as required. Coordinate underground work, deliveries,

and erection to avoid delay or unsafe working procedures.

(4) Work closely with CQC representative and the

manufacturer*s representative to insure that parts and portions

of the structure and utilities are fitted together without

bending or overstressing the parts or connections.

(5) Check connection points for completeness of joining,

required method of joining, and to make sure that all components

are present at the joining.

(6) Check exposed details of joined areas to insure that

required tolerances are met, that covers are provided as

specified, and that meeting planes are aligned, smooth and not

damaged as a result of shipping, storage, or erection.

b. Electrical and Mechanical

(1) Check shop drawings and contract drawings to insure

that all required services, utilities, and equipment are

provided and in the required location. Advise your supervisor if

errors or omissions are encountered.

(2) Determine if field run electrical and mechanical runs

are required to be installed prior to or after the preengineered units have been placed.

(3) Coordinate mechanical and electrical work with

structural and architectural work to insure that such items are

concealed and supported as required.
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13B-3

(4) Test utilities before concealment.

(5) Provide seismic bracing for electrical and mechanical

equipment as required by the contract documents and the seismic

zone.

(6) Check specified materials in exposed area to insure

proper finishes.

(7) Check all outlets, conduits, pipes, and fixtures for

firm attachment, required height, slope, and insulation

required. height, slope, and insulation if

(8) Check all equipment and fixtures for ease of

operating.

13B-04 TESTING AND CHECK OUT PROCEDURES

a. Check all joined together units for good fit, cover

plates, joining strips, or caulking as scarified. Check contract

requirements for wall end floor coverings such as wallpaper and

carpets.

b. Insure that using personnel are provided specified

training. Document the names and positions of user personnel

trained

c. Insure posting of operating instructions and obtaining

maintenance manuals for furnished or installed equipment.

d. Conduct specified acceptance tests on electrical and

mechanical equipment. Obtain test results.

a. Operate all doors, windows, and movable partitions.

Check for ease of operation, full opening and adjustment of

hardware. Require correction or adjustment of all items not

performing correctly.
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1 Dec 92

i

CHAPTER 13C

SOLAR ENERGY SYSTEMS

INDEX

Para. Title Page

13C-01 GENERAL REQUIREMENTS 13C-1

13C-02 MATERIALS 13C-1

a. Submittals 13C-1

b. Delivery and Storage 13C-2

13C-03 ERECTION and TESTING 13C-2

a. Installation 13C-2

b. Cleaning of Pipe 13C-4

c. Testing 13C-5

(l) Factory Tests 13C-5

(2) Field Tests 13C-5

(3) Balancing and Adjusting 13C-5

(4) Performance 13C-5
EP 415-1-261

1 Dec 92

13C-1

CHAPTER 13C

SOLAR ENERGY SYSTEMS

13C-01 GENERAL REQUIREMENTS

a. This chapter rovers the installation and testing of

solar energy systems consisting of the following:

(1) Solar Energy System for Domestic Hot Water Heating

(Liquid Collectors)

(2) Solar Energy System. for Domestic Hot Water Heating

and Spate Healing (Air Collectors).

(3) Solar Energy System for Domestic Hot Water Heating and

Space Heating (Liquid Collectors).

(4) Solar assistant Heat Pump System for Domestic Hot

Water Heating and Space Heating (Liquid Collectors).

(5) Solar Energy System with absorption chiller cooling,

Domestic Hot Water Heating, and Spare Heating (Liquid

Collectors). 

(6) Heat Rejection System, Fan Coil.

(7) Heat Rejection System, Extended Surface Radiation.

(8) Heat Rejection System, Pipe immersed in open water

tank.

b. Work in this chapter will be coordinated with chapters 5A

for Structural, 5B for Welding, 15A-G for Mechanical, and 16A

and NEC-70 for Electrical.

c. The contract drawings indicate extent and general

arrangement of the solar energy system. Approved shop drawings

will provide necessary details for installation and erection of

the system. The contractor is responsible for coordination and

verification of dimensions. The contractor will inform the

Contracting Officer of any discrepancy prior to performing any

work.

d. Welders shall be performance qualified in accordance with

Section IX, ASME Boiler and Pressure Vessel Code. Each welder

shall place his identification symbol near each weld he makes,

as a permanent record. Structural members will be welded in

accordance with specification section: welding, Structural.

Welding and non destructive testing procedures are specified in

Specification Section: Welding Pressure Piping.

13C-02 MATERIALS

a. Submittals

(1) All materials or equipment are specified to comply

with requirements of UL, ARI, or ASME. Proof of such compliance

shall be submitted.

(2) Manufacturer*s certificate of compliance shall be

submitted by contractor on construction of collector,

performance data for collector and 30 day degradation test data.
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13C-2

(3) Shop drawings will consist of illustrations,

schedules, performance charts, instructions, brochures,

diagrams, and drawings necessary for the installation of solar

equipment, associated equipment, and for piping, wiring, and

related foundations. Shop drawings shall include details of

storage device, air handling equipment, heat transfer equipment,

liquid circulating equipment, and controls and instrumentation.

Drawings will indicate clearances required for maintenance and

operation.

(4) Spare parts data will be provided for each different

item of materials and equipment specified.

(5) Operating and Maintenance Instructions will be

provided for system start-up and operation and maintenance.

(6) Performance Test reports in booklet form will be

provided. Each test report shall indicate the final position of

the controls.

b. Delivery and Storage

All equipment placed in storage will be protected from

weather, humidity, temperature variation, dirt, dust, or other

contaminants

13C-03 ERECTION AND TESTING

a. Installation

(1) All work shall be installed as specified and indicated

and shall comply with the applicable sections of HUD 4930.2 and

NBSIR-76-1187 or NBSIR-78-1526, except as otherwise noted.

(2) Absorption water chillers shall be installed in

accordance with Chapter 15G.

(3) Air Supply Distribution System shall be installed in

accordance with Chapter 15B.

(4) Ductwork shall be sealed in accordance with Table 1-1

in SMACNA Low Pressure Duct Construction Standards.

(5) Automatic control equipment shall be installed at the

location shown under the supervision of the control manufacturer

and in accordance with the manufacturer*s instructions.

(6) Thermal Insulation shall be installed in accordance

with Chapter 15C.

(7) Vibration isolation shall be provided for fans and air

handling units in accordance with specification section: Air

Supply and Distribution System (for A/C System)

(8) Check solar collector array for meeting approved shop

drawings. Check to see that each solar collector will withstand

the minimum indicated wind and snow load.

(9) Check piping for solar collector array for specified

size, type of material, use of fittings to make turns and

connections, specified support, automatic pressure and

temperature relief valve specified. Check adjustment of valve

for proper opening pressure and temperature.
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13C-3

(10) Insulate unprotected fluid-carrying lines and

components in accordance with Chapter 15C.

(11) Cover plates for flat plate solar collectors shall be

completely replaceable from the front of the collector without

disturbing the piping or adjacent collectors.

(12) Protective cover plates shall be reinforced fiber

glass, reinforce safety glass, acrylic or polycarbonate and

shall withstand hail or similar impact loads.

(13) Check heating, air supply distribution and heat

transfer systems to see that they are in accordance with

approved shop drawings, plans and specifications. Advise

supervisor of any deviation in equipment or installation.

(14) Check piping, valves, and accessories for meeting

contract requirements and for type of service intended.

(15) Check expansion tank and liquid storage tanks for

size and arrangement against approved shop drawings, plans, and

specifications. Check for specified lining in liquid storage

tank.

(16) Check for specified insulation with smoothing coat of

finishing cement for tanks located inside of buildings.

(17) Check for specified insulation protective covering

for underground tanks.

(18) Check for specified cathodic protection system for

steel water tank. See Chapter 13D and 16B.

(19) Check hot water storage heater tank against approved

shop drawings and contract plans and specifications. Provide

insolation for interior tanks and insulation protective covering

for underground tanks with cathodic protection as indicated.

(20) Exact location of automatic control devices will be

as recommended by the control manufacture — see shop drawings.

(21) Dampers shall be sized and fabricated by the

automatic control manufacturer, compare with shop drawings.

(22) Instrumentation for monitoring solar system

performance shell be mounted so as to be easily readable.

(23) Check approved sequence of automatic controls,

including shut off controls on high and low limits.

(24) Solar system*s automatic controls will be integrated

with building*s automatic control system and the EVAC systems.

(25) Check specifications for painting and finishing

requirements. Repair factory finished coatings where possible.

Provide field painting of surfaces that were prime coated only

at the factory. See Section Painting, General, of the Contract

Specifications.

(26) Cutting or other weakening of the building structure

to facilitate pipe installation will not be permitted without

written approval.
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13C-4

(27) Horizontal supply mains shall be pitched up or down

in the direction of flow as indicated. The grade shall be not

less than one (1) inch in 40 feet.

(28) Tin antimony solder (95-5) shall be used throughout

the collector loop and in the whole system when a silicone heat

transfer fluid is used.

(29) Welding electrodes shall be stored and dried in

accordance with AWS D1.1 or as recommended by the manufacturer.

Electrodes that have been wetted or that have lost any of their

coating shall not be used.

(30) Dielectric unions shall be provided between ferrous

and non ferrous piping to prevent galvanic corrosion.

(31) Swing joints or offsets shall be provided on all

branch connections, mains, and risers to provide for expansion

and contraction of the pipe.

(32) Check branch line for pitch, as indicated.

Connections shall be made to insure unrestricted circulation,

eliminate air pockets and permit drainage of the system.

(33) Supply and return lines shall provide for expansion

by changes in direction of run of pipe, by expansion loops, or

by expansion joints as indicated.

(34) Check for strainers at the inlet of each pump, heat

exchanger, heating coil, and cooling coil.

(35) Check that valves are installed where shown.

(36) Check valve stems to see that they have been

installed either horizontal or above.

b. Cleaning of Pipe

(l) Prior to flushing piping, all metering devices and

orifices shall be removed. Temporary by-passes shall be provided

for all solar collectors, coils, heat exchangers end equipment.

(2) Pipes shall be cleaned free of scale and thoroughly

flushed of all foreign matter.

(3) Strainers and valves shall be thoroughly cleaned.

(4) After the hydrostatic pressure tests have been made

and prior to operating tests, piping shall be cleaned again by

filling the system with clean water and an alkaline detergent.

The solution shall be circulated at the indicated flow rate for

a period of 48 hours. The system will be drained and flushed

thoroughly with fresh water.

(5) The system shall be drained and dried before filling

with silicone fluid.

(6) Fill system with specified fluid and necessary

inhibitors added.

(7) The initial cleaning and final filling shall be

supervised by a technically qualified representative of a

reputable water treatment organization.
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13C-5

c. Testing

(1) Factory Tests:

Check shop drawing submittals to determine if required

factory tests were made and recorded.

(2) Field tests shall be as follows:

(a) Piping — after cleaning, water piping shall be

hydrostatically tested at a pressure equal to 1 1⁄2 times the

total operating pressure for a period sufficient for inspection

of every joint in the system and in no case less than 2 hours.

No loss of pressure will be allowed.

Leaks found during testing shall be repaired by replacing

pipe or fittings. Caulking of joints will not be permitted.

Concealed pipes shall be tested in place before being

concealed.

The system will be drained and dried before filling with

silicone fluid.

(3) Balancing and adjusting - shall be in accordance with

Specification Section: TESTING ADJUSTING AND BALANCING OF HVAC

SYSTEMS.

Adjust flow through each collector by measuring either the

pressure drop or the temperature rise across the collector.

Temperature measurement shall be made by means of platinum

resistance or thermocouple measuring devices.

Pressures shall be measured through inlet and outlet

pressure taps with U-tube manometers.

Balancing valves shall be adjusted and set for the

indicated flow through the collectors.

(4) Performance

(a) After completion of pressure testing, cleaning,

balancing and adjusting, and installation of all systems and

prior to acceptance, tests shall be conducted to demonstrate

that system and all components are operating in compliance with

contract performance requirements.

(b) The tests shall be conducted by a competent

experienced engineer and shall cover a period of not less than

the specified days for each system.
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i

CHAPTER 13D

LIQUID AND GAS STORAGE TANKS

INDEX

Para. Title Page

13D-01 GENERAL 13D-1

a. Definition 13D-1

b. Approvals 13D-1

c. Storage and Handling 13D-1

d. Coordination of Work 13D-1

13D-02 BULK STORAGE TANKS 13D-1

a. Above Ground Tanks 13D-1

b. Underground Tanks 13D-3

13D-03 PUMPS (Excluding Water Pumps) 13D-4

a. General 13D-4

b. Positive Displacement Pumps 13D-5

c. Centrifugal Pumps 13D-5

d. Deep Well Turbine Pumps 13D-5

13D-04 AIRCRAFT FUELING SYSTEM 13D-5

a. General 13D-5

b. Fuel Piping 13D-6

c. Valves 13D-7

d. Strainers 13D-7

e. Gauges 13D-7

f. Filter Separators 13D-7

g. Mechanical Equipment 13D-8

h. Operations and Testing 13D-8

13D-05 SEWAGE TREATMENT PLANTS 13D-8

a. Sewage Bar Screens 13D-8

and Shredder

b. Grit Chamber 13D-9

c. Settling Chambers

(Sedimentation Tanks; 13D-9

d. Dosing Chambers 13D-10

e. Trickling Filter 13D-10

f. Distributors 13D-10

g. Sludge Digester 13D-11

13D-06 WATER DISTRIBUTION 13D-12

a. Pumps 13D-12

b. Water Tanks and Stand Pipes 11D-13

c. Chlorine and Nypochlorite

Feeding Machines 13D-13

13D-07 GENERATING UNITS 13D-13

13D-08 INCINERATORS 13D-15

13D-09 FOOD SERVICE AND HOSPITAL

EQUIPMENT 13D-16
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13D-1

CHAPTER 13D

LIQUID AND GAS STORAGE TANKS

13D-01 GENERAL

a. Definition

This chapter covers material, equipment, and good

workmanship practices for installation of liquid and gas storage

tanks.

b. Approvals

(1) Review ENG Form 4268, Submittal Register, and insure

that all material, equipment, and shop drawings are approved

prior to preparatory inspections and prior to either fabrication

or installation of foundation, tanks and associated equipment.

(2) Obtain any helpful manufacturer*s information.

c. Storage and Handling

(1) Insure that storage yard is placed in an area that

will not require movement of stored materials for Installation

of utility lines or other structures. Storage yard should be

adequate in size and location for both storing, sorting, and

retrieval of materials for erection.

(2) Insure that all materials are safely and properly

stored to prevent damage.

(3) Reject damaged materiel and equipment. Have such items

removed from the site.

(4) In handling heavy items use proper size construction

equipment to lift the loads being handled. Use proper size

slings, clamps, and chocking devices when lifting or moving

materials.

(5) provide necessary storage yard drainage, dunnage, and

working room for both equipment and personnel.

d. Coordination of Work

Continually check for interferences between structural,

electrical, and mechanical features, especially utilities in the

underground areas adjacent to the erection area.

13D-02 BULK STORAGE TANKS

a. Above Ground Tanks

(1) Determine that fabrication is in accordance with API

standards (for Petroleum Products).

(2) Verify compliance with approved shop drawings.

(3) Examine foundation details.

(4) Observe installation of sand base (oiled sand for Air

Force projects)
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13D-2

(5) Check thoroughly all welds for compliance with design

and workmanship. Check specifications for required weld

sampling. Reject welds not meeting these requirements. Check

specifications for destruct and non-destruct testing

requirements for welds.

(6) Examine certified mill reports for steel.

(7) Inspect interior of tank, sump, and pipes for

cleanliness.

(8) Refer to Chapter 5B for welding.

(9) Determine orientation of tanks.

(10) Measure plate thickness.

(11) Insure nameplates or stamps on tanks.

(12) Witness testing of the bottom and top plate welds.

Prior to testing, see that welded joint is well soaped.

(13) Insist that approved construction sequence is rigidly

followed.

(14) Note tank foundation prior to assembly and welding of

the bottom plates.

(15) Verify that tank foundation is not damaged during

erection of tank.

(16) Assure that radiographic inspection is made and

records substantiate the results.

(17) Inspect tank openings and fittings for location,

size, type, and reinforcement.

(18) Make sure that rim seals provide firm and continuous

contact between seal ring and tank shell at all times and under

all conditions, from partial to full tank capacity, without

binding or excessive wear.

(19) Insist that weatherhoods are provided over rim seals.

(20) Be certain that Zinc-coated or galvanized materials

are not permitted where there is a possibility of their coming

into contact with the fuels.

(21) Ensure that emergency venting requirements in API 650

are met.

(22) Electrical Grounding.

(a) Determine that electrical grounding has been

installed.

(b) Require testing by an electrical inspector after

grounding is complete.

(c) Check gasketed pipeline joint for electrical bonding

of adjacent pipe.
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13D-3

(d) Check insulated pipe flanges to insure complete

electrical separation.

(23) Insure that gage pipe column is plumb from top of

tank to bottom.

(24) Float-operated liquid level guage should be checked

for easy and accurate operation from an empty to a full tank.

Cable and tape should be installed level and plumb to avoid

friction or binding in protective pipe, pulleys, and guage-well

cover ferrule.

(25) Tanks should be calibrated and a certified guage

table prepared, as specified. Witness the calibration

operations. In the industry, calibration and strapping are

synonymous.

(26) Stairways, platforms, ladders, and safety guages

should be examined for compliance with approved design and for

conformance to safety regulations.

(27) Provide adequate ventilation and lighting during

inside work.

(28) All required tests should be made as specified and

witnessed by the inspector. A complete record of each test

should be maintained.

(29) Check for requirement for dike to contain leaks and

spills. Insure that containment area is built to required

dimensions, and that joints of dike materials are constructed to

prevent leakage to adjacent areas.

(30) Check for access ramps or steps over dike wells for

access to storage tanks.

(31) Check for restoration work requirement to restore

area outside of dike area after construction is complete. The

work will be done in accordance with contract specifications.

b. Underground Tanks

(1) Check anchoring in locations subject to high ground

water.

(2) Check shop drawings. Verify foundation bolt layout

check bolts for proper length and diameter.

(3) See that tanks have been constructed in accordance

with applicable standards and approved shop drawings.

(4) Ensure that pressure tests are performed. Check to see

if vacuum test on the interstitialspace is require to be

performed.

(5) Examine tank openings and fittings for location, size,

type, and reinforcing.

(6) Inspect shop applied coating on tanks. Witness holiday

test of coating. Repair coating and re-test to confirm quality

of repair. Check certified reports or inspection reports

provided by factory for compliance with contract specifications

and approved shop drawings.
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13D-4

(7) Field-applied coatings on tanks.

(a) Observe removal of shop protective paint coating for

conformance with specification requirements.

(b) Observe preparation and cleaning of tank surfaces to

be coated.

(c) Require application of primer immediately after

cleaning.

(d) Check application of enamel while primer is still

“live”.

(e) Determine the needs for re-priming, or for primer

removal and reapplication.

(f) Check use of manufacturer*s recommendations.

(g) Verify results of holiday testing and repairs to

coating.

(h) Witness handling of coated tank to avoid damage.

(8) Check type of fuel resistant gaskets{Buna-N or cork).

(9) Examine coating of tie—down straps.

(10) See that all appurtenances are installed inside of

tank. See that leak detection connections are installed on dual

wall tanks.

(11) Witness cleaning of interior of tank.

(12) Witness tank calibration.

(13) Observe the use of flexible connectors or piping to

tanks.

(14) See that tank slopes to low point or sump.

(15) Check specification requirements for installation of

cathodic protection for tank and piping to tank. See section on

cathodic protection.

(16) Check specification requirements for backfilling

around tank and piping. Check to see that tank manhole is to the

proper elevation. Clean out manhole after backfilling tank area.

Check for paved area or gravel area around manhole of tank and

tank area in general.

(17) Check to see that tank vent is installed to correct

height and installed as shown on drawings.

(18) Check to see that fill line to tank is to given grade

and protected from damage.

13D-03 PUMPS (Excluding water pumps)

a. General

(1) Determine that certified test curves are furnished for

each type of pump. Determine that shop drawings are approved.
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13D-5

(2) See that operation, maintenance, and installation

instructions are furnished.

(3) Note type of bearings. Check type of seal. Determine

lubrication requirement and water cooling requirement.

(4) Verify adjustment of stuffing box glands and leakage

of seals.

(5) Observe the direction of rotation.

(6) Pumps to motor alignment can be thrown out of

allowable tolerance at couplings during bolting down of base

plate or attaching pipe to the pump. Check coupling alignment

after pump is set and piping is attached. If coupling is out of

tolerance, the motor should be reset to eliminate the out of

tolerance measurements at the coupling.

(7) Examine guard device over couplings.

(8) Note electric motor drivers under operations.

b. Positive Displacement Pump

Check by—pass or leak-off protection in the event of a

closed discharge.

c. Centrifugal Pump

(1) Check type of casing and material.

(2) Check inherent self-priming features.

(3) Check facilities on top of casings.

d. Deep Well Turbine Pump

(1) Obtain and record the impeller clearance settings as

made by the pump manufacturer*s service engineer.

(2) Check pumps for non-reversing ratchet or restrictor.

(3) Verify overhead clearance and openings in slab above

for removal of pumps.

(4) Insure minimum submergence setting.

(5) See that vents are installed at the high point of all

pumps.

(6) Note bowl serial number to assure correct assembly

when field assembled. Inspect bowl alignment.

(7) Examine the check-valves installed between gate—valve

and pump.

(8) Determine that pump setting is level and plumb.

13D-04 AIRCRAFT FUELING SYSTEM

a. General
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13D-6

(1) Insure provisions to avoid injury and damage to work

in the proximity of hangars, parking aprons, and runways.

(2) Follow coordination between contractor and the air

base.

(3) Avoid substitution for approved materials. Require all

materials be submitted for approval.

(4) See that every effort is made to furnish an

uncontaminated system.

(5) Check cleanliness of existing system prior to

connecting a new installation.

(6) Evaluate effect of welding operations on existing

system prior to commencement of work because of the extreme

hazard involved.

(7) Inspect painted identification marking of fuel system.

b. Fuel piping

(1) Determine size, material, thickness, coating, and

painting of pipe.

(2) Refer to chapter for Welding.

(3) Examine storage of piping and materials to prevent

contamination.

(4) Check blanking ends of piping.

(5) Check for anchoring and expansion provisions.

(6) Require pneumatic testing with dry air.

(7) Inspect painted identification marking of fuel system.

(8) Note installation of valve numbering system.

(9) Require gasket material that is suitable for use with

petroleum products.

(10) Observe types of pipe sleeves for pipe passing

through concrete or masonry construction.

(11) Witness holiday tests of pipe coating.

(12) Compare pipe joint compound with type of product

approved.

(13) Check to make sure that there are pressure relief

valves or other means included to provide pressure relief

between closed valves.

(14) Examine encasement or protective sleeves where lines

pass under structures, railroad tracks and paved areas.

(15) Assure that the fittings and tools used for coupling

hose to track or railway cars are non-sparking materials.
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1 Dec 92

13D-7

(16) Determine that fill connections are identified to

indicate the type of fuel handled.

(17) Inspect the slope or pitch of the pipe.

(18) Look at low spots for drains and at high points for

air releases.

(19) See that unloading couplings are below tank car or

truck unloading connections.

c. Valves

(1) Check to determine lubrication or non—lubrication.

(2) Check type of material and pressure rating.

(3) Check valve boxes and extensions.

(4) Check for special valves.

(5) Check timing for POL Valves and sequence of operation.

d. Strainers

(1) Check for proper mesh size and non-corrosive basket

construction.

(2) Strainers should not be placed in line before pig* is

blown through lines and line has been blown clean.

(3) Strainers should be cleaned prior to acceptance from

the contractor.

e. Gauges

(1) Inspect to see that scale range is as per contract

requirement.

(2) Inspect size and construction.

(3) Inspect tank gauge and pump control.

(4) Inspect to see that loss liquid level pump control is

set at same level as minimum submergence level of pump.

f. Filter Separators

(1) Check to see that filter separator has been approved.

(2) Examine type of filtering media for approval.

(3) Insure filtering media replacement after operations

and tests.

(4) Insure that equipment is installed so that no

dismantling is necessary to replace filtering media cartridge or

strainers.

(5) Check requirement for spare filter media cartridges.

Turn spares over to using agency at end of contract.
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13D-8

(6) Check water dump valve operations by slugging the

filter with water.

(7) Secure, review, and maintain custody of the results of

all tests performed.

g. Mechanical Equipment

(1) Check insulated joint on railroad track.

(2) Check covers of hydrant outlet pits for good balance

and fit.

h. Operations and Testing

(1) Verify availability, in sufficient quantity of each

product.

(2) Check cleanliness of products delivered from existing

facilities for entry into the new system.

(3) Check use of the Government furnished tank trucks,

meters, hoses, filter media, hose, cart, etc.

(4) Do not permit intermixing of fuel, in a dual fuel

installation. Check requirement for a set of testing equipment

for each fuel system.

(5) Require test reports and certification that system

cleanliness standards have been met prior to turn over of a

facility to the using agency.

(6) Witness all testing and see that a test data log is

prepared by the contractor. A copy of this test data should be

included in the job files.

13D-05 SEWAGE TREATMENT PLANTS

a. Sewage Bar Screens and Shredder

(1) See that bars are parallel to one another, equally

spaced, and in the same place of travel as the rakes.

(2) Observe the adjustment of teeth on rakes for proper

mating with screen along entire travel. Reject rakes with

damaged teeth.

(3) Determine that manufacturer*s representative adjusts

tension of sprocket chains.

(4) Notice rake wiper for efficient cleaning of rakes.

(5) Examine shock absorber for elimination of excessive

wiper shock and smooth operation.

(6) See that complete assembly is set in concrete so that

no water is bypassed between concrete and equipment.

(7) Require contractor to furnish competent engineer to

instruct government representatives in operations and

maintenance.
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13D-9

(8) Witness operational tests for equipment performance

required by specifications.

(9) Obtain special tools, if required.

b. Grit Chamber

(1) Check elevator and level of proportional weir.

(2) Check rake travel to see that it is parallel with

floor of chamber.

(3) Check rake clearance for agreement with approved shop

drawings.

(4) Check sprocket chain tension and adjusting mechanism.

(5) Conduct operational test as required.

c. Settling Chambers (Sedimentation Tanks)

(1) Rectangular and circular sedimentation tanks.

(a) Assure that all embedded items are installed and are

properly located.

(b) Examine elevation of concrete baffles and scum

troughs.

(c) Observe and record all recommendations and settings

made by manufacturer*s representative supervising installation

of equipment.

(d) Evaluate adjustable weirs for elevation, level and

range of travel.

(a) Note adjusting mechanism of chain drive for easy

operation and for sufficient range to procure proper tension in

chain.

(f) Inspect scum pipes for level and elevation.

(g) Require lubrication with recommended lubricants prior

to initial start-up.

(h) View sprocket-wheel bearings for cleanliness, freedom

from binding, and smoothness of bearing surface.

(i) Check sprocket teeth for defects and for meshing

accurately with chain.

(j) See that shafting is level, plumb, and free from

rotation.

(k) Check chain for damaged links.

(2) Rectangular Sedimentation Tanks.

(a) Examine skimming run supports for level.

(b) See that angle track is level and aligned with forward

sprocket.

(3) Circular Sedimentation Tanks.
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13D-10

(a) Observe whether top of tank is level.

(b) Inspect skimmer arm, blade, and receptacle for rigid

support and assembly. Verify blade clearance.

d. Dosing Chamber

(1) Check weirs for proper elevation.

(2) Check all siphon placement dimensions and position.

(3) Observe adjustment and operation of weir plates or

stop planks.

(4) Verify location of trap opening pipe so that sewage

does not discharge directly into it.

(5) Observe setting of bell with respect to top of main

trap pipe.

(6) Assure that invert of vent and overflow pipe is above

the maximum discharge level of the siphon.

(7) During preliminary testing of tank, check maximum and

minimum discharge levels and the level at which the siphon stops

operating (minimum drawdown level)

(8) Conduct operating tests as required.

(9) Contractor must furnish competent engineer, or

superintendent, as necessary, to provide proper installation and

adjustments, to conduct tests, and to instruct government

representatives in proper operation.

e. Trickling Filter

(1) Check filter media for size and specified material.

(2) Insure that media material is protected from

contamination is stockpiled prior to placement in filter.

(3) Reject filter media that has been contaminated with

nonremovable materials such as oils, grease, soil, etc.

(4) Check placing of filter material.

(5) Assure against contamination after finished placement

of filter media.

(6) Check underdrains, for uniform bearing over the entire

bottom of each block. See that cross joints are staggered in

adjacent rows.

(7) Check air ducts for blockages.

(8) Check that blocks in drainage channel are not moved by

placement of filter media.

f. Distributors

(1) Fixed Nozzle.

(a) Check stability and caulking in joint of piping laid

within filter.
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13D-11

(b) Note spray nozzles for effective and uniform

distribution of sewage over entire filter bed.

(c) Assure furnishing of spare nozzles.

(d) Perform operating tests as required.

(2) Rotary.

(a) Assure uniform distribution of sewage over entire

filter bed.

(b) Examine distribution arm flushing valve for tightness

and freedom of operation.

(c) Replace nozzles that do not show uniform flow

characteristics.

(d) Assure that distribution arms are level guyed.

(e) Inspect seal for operation and tightness.

(f) Witness operation of arms at minimum head for starting

and for operation. Complete cycle through all heads to maximum.

See that motion of arms is parallel to surface of media.

g. Sludge Digester

1) Check all embedded items for proper location.

(2) Evaluate all cover seals for gas tightness.

(3) Check overall inside diameter of tank of floating

cover digesters for roundness and clearances.

(4) Examine cover rollers for clean bearings, ease of

greasing operations, and alignment of rollers and guides.

(5) Inspect heating system piping for tightness,

materials, and secure fastening.

(6) Assure that elevation of all cover rests are the same

on floating cover digesters.

(7) Check sludge draw-off piping for location of rigid

support.

(8) Assure that all heating system lines, gas lines, feed

pipes, and supernatant lines are flushed prior to operation.

(9) Assure that all debris is cleaned from interior of

structure.

(10) Check center post installation for plumbness and

rigidity.

(11) Examine sludge mixes and scum breaker for operating

ease and settings.

(12) Witness and record tests and adjustments made by

manufacturer*s representatives.

(13) Refer to Chapter 5B for welding.
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13D-12

(14) See that all manholes and openings through covers are

gas-tight.

(15) Note all sensing locations for thermometers and

controls.

(16) Verify that speed of mixer is set by manufacturer*s

representative or contractor.

(17) Observe setting of gas pressure regulating valve.

(18) Check the use of flexible hose with double unions, in

cold water connection to heating system.

(19) Obtain any special tools required.

(20) Perform operating tests as required.

(21) Require contractor to furnish competent engineer for

instructional purposes.

13D-06 WATER DISTRIBUTION

a. Pumps

(1) Be familiar with all pump manufacturer*s

recommendations and with Hydraulic Institute*s standards. Assure

that installation is in accordance with same.

(2) Assure that adequate foundation is provided.

(3) Verify the use of a direct drive pump when such is

specified.

(4) See that pump can be dismantled without disturbing

pipe connection or the alignment of pump.

(5) Assure that bronze parts are used where specified.

(6) Check freedom of movement of impeller and shaft.

(7) Assure that water-seal is provided with proper type

and size of packing.

(8) Inspect for necessary air cocks, drain plugs, guages,

and relief valves.

(9) Determine whether a gasoline engine is specified.

Check out same. (Use check list for Generator Units, included in

this chapter).

(10) Check controls to see that they function as

specified.

(11) Assure that all gears, couplings, projecting set

screws, keys, and other rotating or reciprocating parts are

fully enclosed or properly guarded.

(12) Assure that all instruction books, tools, and pumps

characteristic curves have been obtained from contractor.

(13) Examine Hydraulic Institute*s standard and NEPA

Standard N5.20 or American Standard B58.1. See that tests are

made in accordance with these requirements.
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13D-13

b. Water Tanks and Stand Pipes

(1) Check foundation construction against plans,

specifications, and shop drawings. Be sure to compare approved

shop drawings for foundation with fabricated column base plates

and anchor bolt layout.

(2) Closely compare steel erection with approved shop

drawings. Check the erection of steel with Chapter 5A Structural

steel and Chapter 5B Welding.

(3) Examine the layout of valve chamber to see that there

is adequate room for later maintenance of all parts.

(4) Make sure all required checks, gates, altitude valves,

and pressure guages are installed.

(5) Affirm that the results of the hydrostatic test are

satisfactory.

(6) Check the installation of such items as cathodic

protection, lighting and grounding.

(7) Determine whether there is a complete shop coat

coverage and that the tank receives the specified finish paint.

(8) Determine the PPM of chlorine in the system during and

after the disinfection period. Prior to chlorination, internal

brass parts, such as those in altitude valves, should be removed

and later replaced after the chlorine has been flushed from the

line.

c. Chlorine and Hypochlorite Feeding Machines

(1) Work to be performed in accordance with the

manufacturer*s recommendations, and to conform with plans and

specifications.

(2) Assure the workmen are skilled in this type of work.

(3) See that controls, gauges, meters, valves, injectors,

and reliefs are installed as required.

(4) Check for proper piping installation. Know where

emergency shut off valves are located on the chlorine supply

lines and tanks.

(5) Make sure that all special tools, operating

instructions, and manuals are provided.

(6) Perform operational tests as required.

13D-07 GENERATING UNITS

a. See that contractor has verified all dimensions.

b. See Chapter 15A for checking pipe and fittings, Chapter

16A for electrical features, and Chapter 5B for welding.

c. Determine that skilled workmen are being employed.

d. Assure easy access to all parts of the engine.
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13D-14

e. Examine fuel handling and storage facilities.

(1) Observe tank installation.

(2) Check manhole construction; observe for water—tight

cover, and for the height of manhole cover.

f. Assure necessary access doors in equipment.

g. Check the water level.

h. Check for excessive vibration.

i. Observe adjustment of V belt drives.

j. When operating the engine, check for excessive smoke,

overheating, etc. at this time also check to insure that

adequate ventilation is present in the test areas.

k. Check day tank installation.

(1) Check mounting and method of supporting.

(2) Determine that high level cutoff switch is properly

installed.

l. Assure that approved tanks are installed as specified.

(1) Assure that tanks are kept clean during installation.

(2) Check cleaning operation and its results.

(3) Examine priming and painting applications.

(4) Holiday test the tanks as necessary to assure a

complete prime and paint job.

(5) Check voltage of holiday detector.

(6) Continually watch for abrasions.

(7) Carefully watch backfill operation, check compaction

and watch for any possible damage to tank or piping.

(8) See that all bare places on exterior of tank are

repaired with hot enamel.

m. Check the installation, anchorage, and support of all

piping. This includes the exhaust piping and muffler.

n. Make sure that all pipes, valves, fittings, pumps,

etc., for the fuel and lubricant systems are shipped to the job

with ends closed. Check when installed to assure cleanliness,

and continue to guard against the entrance of dirt and foreign

matter into the equipment.

o. Assure the acid cleaning, the neutralization, and the

drying of the interior of the fuel piping systems.

p. Note the requirement for expansion joints.

(1) Check type furnished.

(2) Check method of installation.
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13D-15

(3) Check for misalignments.

(4) Follow manufacturer*s instructions to determine range

of movement for installing expansion joints.

q. Mufflers.

(1) Check type furnished and specified.

(2) Check method of mounting.

(3) Check treatment for rust resistance.

(4) Check noise level.

(5) Check drain hole.

r. Be alert for the requirements concerning auxiliary

equipment such as silencer, special controls, trickle charges,

filters, instrument board, static exciter, voltage regulator,

auxiliary compartment, special tools, operating instructions and

manuals.

s. See that required tests are made.

(1) Check safety circuit.

(2) Check governor.

(3) Check fly wheel.

(4) Check accessibility of brush rigging.

(5) Performance.

(6) Controls and interlocks.

13D-08 INCINERATORS

a. Make sure that construction is in exact accordance with

approved shop drawings. Check dimensions very carefully.

b. Check construction and thickness of fire brick in

furnace and flue connections. Watch for:

(1) Width of joints.

(2) Wall thickness.

(3) Handle of arches and circular linings.

(4) Size of baffle.

(5) Bricks laid on edge in hearths and floors.

(6) Installation of expansion joints.

(7) Bracing.

c. Check casting and bonding of refractory casting when

same is used.

d. See that insulating brick is installed in specific

location.
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13D-16

e. See Chapter 4 for Installation of exterior wall brick.

f. Assure that there is at least a 2" separation between

exterior walls and fire brick lining of chimney. Check plans and

specifications to see if different dimension is required for the

separation for your specific contract.

g. Check chimney for:

(1) Cleanout door and frame.

(2) Concrete protective cap.

(3) Spark screen.

h. Assure the installation of a safety rail around

charging throats and guillotine.

i. Check the installation for items such as:

(1) Dampers.

(2) Auxiliary burners.

(3) Test pipes.

(4) Instruments.

j. Determine if other equipment such as can-wash or

forced-draft is specified and check same.

k. Require that all necessary operating tools; spare

parts, operating instructions, manuals, and training have been

provided.

l. See that unit is dried out in accordance with

requirements.

m. Assure that operating tests are conducted and that

results have been recorded. Obtain copies of all test records

and certification that unit was properly constructed and is

operating satisfactorily.

13D-09 FOOD SERVICE AND HOSPITAL EQUIPMENT

a. Require an equipment layout if there is any question of

items fitting into place.

b. Require the installation of all trimmings, steam traps

and fittings necessary for proper operation.

c. See that the equipment manufacturer*s name plate is in

a conspicuous location.

d. Install back flow preventers when equipment has a water

supply.

e. Determine that motors of equipment are suitable for

voltage supplied.

f. Check the quality of workmanship in the fabricated

equipment.
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13D-17

g. Check welds for smooth, ground off finish, and ensure

freedom from imperfections and color differences.

h. Check for the substitution of spot welds where full

welds are needed or specified.

i. Check the type of material used in fabrication and the

type and quality of finish.

j. Check for burrs, projections, and fins.

k. Inspect for exposed screws, rivets, or bolt heads.

l. Check for ferrous fastenings where stainless types are

specified.

m. All exposed piping is to be chromium-plated brass.

n. Completely check out the plumbing for equipment, using

Chapter 15.

o. Check all dimensions and capacities of equipment.

p. Check equipment for specified controls.

q. Input for any breaks in coated metal, and make sure the

metal is properly treated and protected against corrosion.

r. Determine that equipment with waste or drain surfaces

is pitched to drain,

a. Inspect counter tops for:

(1) Defects.

(2) Corners being rounded, bullnosed, and equal in finish

of the counter top.

(3) Closure at walls.

(4) Bracing.

t. Compare all guages of metals with guages approved on

shop drawings.

u. Determine that all equipment is easy to clean.

v. Check equipment drawers for corrosion-resisting steel

sides, roller bearings, and the amount of play.

w. Check size of drawer to see that they have the

specified stop.

x. Check sliding doors for construction, size, type, and

ease of operation.

y. Check all hardware for type of material and finish.

z. Inspect sinks for:

(1) Specified fixtures and trim.

(2) Overflow fittings.
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13D-18

(3) Special features required.

aa. Examine all hoods for:

(1) Corrosion resisting steel construction.

(2) Freedom from vibration.

(3) Method of hanging.

(4) Grease filters.

(5) Method of connecting to duct.

ab. Determine that each piece of equipment is continually

protected and that it is cleaned prior to turn over to the using

agency.

ac. Require an instruction book with each piece of

equipment.

ad. Require special tools be furnished, if specified.

ae. Require operational tests for each piece of equipment.

Make a record of your findings.

af. When specified, assure that an experienced engineer

from the manufacturer*s plant is present to supervise the

equipment installation and testing.
EP 415-1-261

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i

CHAPTER 14A

ELEVATORS

INDEX

Para. Title Page

14A-01 GENERAL 14A-1

a. Coordination of Work 14A-1

b. Layout 14A-l

14A-02 MATERIAL 14A-1

a. Shop Drawings 14A-1

b. Spare Parts Data 14A-2

c. Operating and Maintenance

Instructions 14A-2

d. Storage and Handling 14A-2

14A-03 INSTALLATION AND TESTING OF ELECTRICAL

AND HYDRAULIC ELEVATORS 14A-2
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14A-1

CHAPTER 14A

ELEVATORS

14A-01 GENERAL

a. Coordination of Work

(1) This chapter covers the installation and testing of

Electric Elevators and Hydraulic Elevators. See Chapter 16A and

NEC 70—ARTICLE-620, for Electrical; Chapter 5A for Structural

Steel; and Chapter 5B for Welding.

(2) The contract drawings indicate general layout and

components of the elevators. Approved shop drawings will provide

necessary information for installation of the particular

elevator selected for the project.

(3) Elevator installation is a speciality trade. Elevator

installation mechanics must have a minimum of two years

experience on type of elevator specified. Close coordination is

required between contractor*s CQC organization and the

supervisor installing the elevator.

(4) Checks should be made to detect and avoid any conflict

between the elevator layout and the structure. Conduits and

pipes will not be run through the elevator shaft.

(5) In cases of hydraulic elevators, the installation must

be started early enough in the construction period so that

installation may be made of the hydraulic casing.

(6) 3-Phase inspections and meetings will be held with CQC

representative and elevator installer representative to assure

that quality work designed into the project is being obtained.

(7) When structural or load bearing members are to be

field welded, welding and qualification of welders shall be as

specified in section: Welding, Structural.

b. Layout

(1) The contractor must provide elevator equipment room

layout drawings which must be reviewed and approved prior to

installation of equipment.

(2) Check layout of elevator equipment room for space to

maintain and repair the electrical and mechanical equipment.

14A-02 MATERIALS

a. Shop Drawings

(1) Shop drawings will provide necessary erection details.

They will include a complete list of equipment and materials,

including illustrations, schedules, manufacturer*s descriptive

literature, performance charts, catalog cuts, installation

instruction, brochures, diagrams, fabrication instructions,

dimensioned layouts in plan and elevation showing the

arrangement of the elevator equipment.

(2) Compare the shop drawings closely with the contract

requirements contained in the plans and specifications.
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14A-2

(3) Become familiar with the shop drawing and contract

requirements prior to each phase in particular for the

preparatory meeting and initial inspection. Refresh your memory

by referring to these documents as follow—on inspections are

made.

b. Spare Parts Data

Prior to beneficial occupancy (B.O.) the contractor shall

provide a complete list of parts and supplies, with the current

unit prices and source of supply. This information will be

turned over at time of B.O.

c. Operating and Maintenance Instructions

The contractor will furnish complete copies of operating

instructions, maintenance instructions, operator training for

using agency personnel, and will post where directed, framed

instructions and wiring and control diagrams showing the

complete layout of the entire system. Upon completion of testing

he will provide test results in booklet form, showing all field

tests performed to adjust each component, and all field tests

performed to prove compliance with the specified performance

criteria.

d. Storage and Handling

(1) Insure that materials are new, handled safely and

carefully to prevent damages and are the source as approved.

(2) Reject damaged and nonconforming materials. Have

damaged coatings repaired.

(3) Check for storage off the ground. Assure weather tight

storage to protect finished materials, equipment, and panels.

14A-03 INSTALLATION AND TESTING OF ELECTRICAL AND HYDRAULIC

ELEVATORS

a. See that structural steel framing and guide rails are

plumb and secured as required.

b. See that contractor has checked equipment dimensions

against the space available, and checked to see if shaft is

plumb.

c. Compare the features of the delivered equipment with

the approved shop drawings.

d. Check for required accessories such as fan, telephone,

light fixtures, convenience outlets, wrenches, direction-light

jewels, etc.

e. Provide steel casing larger than diameter of hydraulic

elevator*s cylinder. The casing shall be accurately positioned,

plumbed, and set to accept the cylinder. Prior to setting

cylinder in casing, the entire outside surface of the cylinder

shall be protected from corrosion by the application

of double-wrapped layers of isolation material recommend by the

manufacturer. The area between the casing and the cylinder wall

shall be filled with dry sand after the cylinder has been

accurately located. Seal top of casing. The work of boring the

well and setting the cylinder shall be coordinated with

construction of concrete pit.
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14A-3

f. Verify that ferrous metal meets salt-spray fog test,

and that stainless steel panels are used where specified.

g. Make sure that protection guards are provided for

moving parts, this includes shafts, keys, setscrews, belts,

sprockets, and chains.

h. Check contract installation requirements against the

manufacturer*s recommendations. Call to your supervisor*s

attention any differences.

i. Check anchor bolts and conduits for proper location.

j. Check elevator mechanics and welders qualifications.

k. Carefully check all installations for stability,

specified connections, anchorage, etc.

l. Determine the type of lubrication required, and examine

equipment for same.

m. See that spare parts data is provided for each item of

equipment.

n. Operate elevator to determine responsiveness. See that

manufacturer*s name plate is in a conspicuous location. Check

all control lights, both inside the cab and at elevator

landings.

o. Check all safety features. Determine if contract

requires a break-in period, operated by the contractor.

p. Installation or hoisting or lifting machinery may

require that construction of certain floor and/or wall areas be

deferred until installation is completed.

q. Guard open shaftways until doors are provided.

r. Inspect hoisting cables after installation for possible

damage during the construction operation. For hydraulic

elevators also inspect the hydraulic lifting device after

installation.

s. Assure that required tests are performed in compliance

with ASME AID.1 and that all data is recorded. Obtain copies of

all tests with certification that the elevator are properly

installed and are in proper operating condition.

t. Check certification by elevator inspector per AR

420—15. See that the safety certification is mounted in the cab

and under glass.

u. Check contract requirements for homing of elevator

after last call. Check specified door opening time. Check

sequence required when a multi-elevator installation is made.
EP 415-1-261

1 Dec 92

i

CHAPTER 14B

HOISTS AND CRANES

INDEX

Para. Title Page

14B-01 GENERAL 14B-1

a. Coordination of Work 14B-1

b. Verification of Dimensions 14B-1

14B-02 MATERIALS 14B-1

a. Submittals 14B-1

b. Manufacturer*s

Representative 14B-1

c. Operator Training

Instructions 14B-1

d. Delivery and Storage 14B-2

14B-03 ERECTION AND TESTING 14B-2

a. Structural 14B-2

b. Mechanical Alignment 14B-2

c. Electrical Alignment 14B-3

d. Testing 14B-3
EP 415-1-261

1 Dec 92

14B-1

CHAPTER 14B

HOISTS AND CRANES

14B-01 GENERAL

a. Coordination of Work

(1) This chapter covers the installation and testing of

Hoists and Cranes. See Chapter 16A and NEC70-Article-620, for

Electrical; Chapter 5A for Structural Steel; and Chapter 5B for

Welding.

(2) The contract drawings indicate general layout and

components of the cranes and hoists. Approved shop drawings will

provide necessary information for installation of the particular

hoist or crane selected for the project.

(3) Hoists and crane installation is a specialty trade.

Major assemblies of the crane shall be shop assembled as

completely as possible. Welders, welding operators and welding

procedures shall be qualified or prequalified in accordance with

AWSD1.1. Close coordination is required between the contractor*s

QC representative, the crane and hoist contractor, and the

manufacturer.

b. Verification of Dimensions

The contractor shall verify all dimensions in the field

and shall advise the contracting officer of any discrepancy

before performing any work.

14B-02 MATERIALS

a. Submittals

(1) Shop drawings shall consist of a complete list of

equipment and materials, including manufacturer*s descriptive

and technical literature, performance charts and curves, catalog

cuts, and installation instructions. Shop drawings shall also

contain complete wiring and schematic diagrams and coordination

details for proper function of unit.

(2) Spare parts data shall be furnished for each different

item of material and equipment specified.

(3) Operations and Maintenance manuals and instructions

will be provided.

(4) Performance Test Reports will be submitted, upon

completion and testing of the installed system, in booklet form

to prove compliance with the specified performance criteria.

b. Manufacturer*s Representative

The manufacturer*s representative shall supervise the

installation, adjusting, and testing of the cranes and hoists.

c. Operator Training Instructions

A field training course shall be provided for designated

operating staff members. The course will cover all items

contained in the Operations and Maintenance Instructions.
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14B-2

d. Delivery and Storage

Equipment when delivered will be stored with protection

from the weather, humidity, temperature variations, dirt, dust,

or other contaminants

14B-03 ERECTION AND TESTING

a. Structural

(1) Check TM 5-809-10 to determine seismic considerations

for your construction site. Review Chapter 13, Seismic Design of

Buildings. Tell your supervisor if lateral restraints or hold

down clamps are required but not provided for.

(2) Structural bolted connections shall be made with ASTM

A325 bolts. A490 bolts or galvanized bolts shall not be used.

(3) The bridge rail shall be fastened to the top cover

plate with welded clips. Bridge rail joints shall be bolted

using standard joint bars. Rail joints shall be staggered. A

positive stop shall be provided at the bridge rail ends to

prevent creep.

(4) Provide structural trolley stops on the bridge to

engage the trolley wheels, and locate to permit maximum trolley

travel. Bumpers shall be the spring or hydraulic type for the

bridge or trolley.

(5) Compare the name plate capacity of equipment with

specified requirements.

(6) Check track for:

(a) Size of members.

(b) Method of supporting and anchoring.

(c) Stability and minimum sway.

(d) Being level and parallel.

(e) End-of-track stops or bumpers.

(f) The way wheels ride on track.

(7) Confirm that clearances are provided for required

operation.

(8) Check welding and bolted connections of members.

(9) Insure that erection procedures for crane will not

cause internal stresses, forced or improvised fits,

misalignments, nicks of high strength structural steel

components, stress-raising welds, and rough burrs.

(10) After crane is erected any damaged paint surfaces

shall be cleaned and repainted.

b. Mechanical Alignment

All motors, couplings, brakes, gear boxes, and drive

components shall be aligned when reinstalled, in accordance with

the manufacturer*s tolerances.
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14B-3

c. Electrical Alignment

(1) The control system shall be aligned in accordance with

the manufacturer*s instructions. Alignment data shall include

the following:

(a) Timer settings

(b) Resistor tap settings

(c) Pot settings

(d) Test point voltages

(e) Supply voltages

(f) Motor voltages

(g) Motor currents

(h) Test conditions, such as ambient temperature, motor

load, date performed, and person performing the alignment.

(2) A copy of the final alignment data shall be stored in

control panel door.

d. Testing

(1) Check ease of operating equipment.

(2) Determine that all the various speeds can he obtained.

(3) Check if all safety devices such as lift switches,

brakes, etc., have been furnished, connected, and function as

designed.

(4) See that specified tests are performed and recorded.

(5) The contractor shall provide all personnel necessary

to conduct the tests including but not limited to crane

operators, riggers, rigging gear, and test weights. Tests will

be performed in the presence of the Government representatives.

(6) Test sequence shall be in accordance to specified

procedure.

(7) Test data shall be recorded on appropriate test record

forms for retention for the life of the crane. Recorded values

shall be compared with design specifications or manufacturer*s

recommended values.

(8) Equipment monitoring. During load test, check for

improper operation or poor condition of safety devices,

electrical components, mechanical equipment and structural

assemblies. Report all defects to test supervisor immediately.

(9) Check specifications for specific tests to be

conducted.
EP 415-1-261

1 Dec 92

i

CHAPTER 14C

MATERIAL HANDLING SYSTEM

INDEX

Para. Title Page

14C-01 GENERAL 14C-1

a. Coordination of Work 14C-1

b. Verification of Dimensions 14C-1

14C-02 MATERIALS 14C-1

a. Submittals

b. Manufacturer*s 14C-1

Representative 14C-2

c. Delivery and Storage 14C-2

14C-03 ERECTION AND TESTING 14C-2

a. Erection 14C-2

b. Testing 14C-3
EP 415-1-261

1 Dec 92

14C-1

CHAPTER 14C

MATERIAL HANDLING SYSTEM

14C-01 GENERAL

a. Coordination of the Work

(1) This chapter covers the installation and testing of

freight handling equipment, prefabricated chutes, conveyors,

gravity rollers, power belts, and other devices for transfer of

bulk or package materials. System includes associated

components, hardware, control, and safety equipment.

(2) The installation of a material handling system

requires close coordination between structural, mechanical, and

electrical work. The CQC representative must insure that the

material handling equipment is designed to fit into the space

available; that it is delivered in time so as not to hold up the

construction work, and that the necessary walls, columns, or

roof areas are left open to allow entry into the structure of

the material handling equipment.

(3) Shop drawing reviews must include determination if

space is available for future maintenance, operation, and

subsequent replacement of worn equipment. Location of anchor

bolts, and connections for utilities must be checked and assured

prior to placement.

(4) Seismic considerations required by the design and the

seismic zone must be incorporated into the work. Carefully check

contract requirements and shop drawings for the requirement for

seismic bracing, supports, snubbers, and springs.

b. Verification of Dimensions

(1) Verify opening sizes and locations, anchor bolt size

and location, foundation pads, equipment isolation and vibration

elimination means. Check shop drawing requirements against

contract drawings. Advise your supervisor if errors are

detected.

(2) Verify structural clearances such as overhead beams

and girders, clear span between columns, and wall spacing.

(3) Coordinate electrical and mechanical work to insure

needed equipment clearances.

(4) Some automated material handling equipment will

require close tolerance of concrete floors, so that the

equipment can service the storage bins without tilting or

leaning of the automated material handling equipment.

14C-02 Materials

a. Submittals

(1) Shop drawings shall consist of a complete list of

equipment and materials, including manufacturer*s descriptive

and technical literature, performance charts and curves, catalog

cuts, and installation instructions. Shop drawings shall also

contain complete structural, electrical, and mechanical layouts,
EP 415-1-261

1 Dec 92

14C-2

schematic diagrams, and coordination details for installation of

the components and system.

(2) Spare parts data shall be furnished for each different

item of material and equipment specified.

(3) Systems operating and maintenance manuals and

instructions will be provided.

(4) Performance test reports will be submitted, upon

completion and testing of the installed system, in booklet form,

to prove compliance with the specified performance criteria.

b. Manufacturer*s representative

Check requirements for manufacturer*s representative to

supervise installation, adjusting, and testing of the material

handling system.

c. Delivery and Storage

Equipment, plates, and units when delivered will be stored

with protection from the weather, humidity, temperature

variations, dirt, dust, or other contaminants. Deliveries should

be scheduled to minimize job site storage whenever possible.

14C-03 Erection and Testing

a. Erection

(1) Check TM 5-809-10 to determine seismic considerations

for your construction site, Tell your supervisor if required

reinforcing or restraints are not provided for in the contract

for the structure and the material handling system.

(2) Check shop drawings and contract drawings to insure

proper orientation of the equipment and utilities servicing the

equipment.

(3) Check anchor bolt layout, foundations, vibration

eliminator and restraints.

(4) Install equipment in accordance with installation

sequence shown in shop drawings and contract drawings.

(5) Compare the name plate capacity of the equipment with

the specified equipment capacity. Inform your supervisor if

variation in capacity is found.

(6) Insure that erection procedures for material handling

equipment will not cause internal stresses, forced or improvised

fits, misalignment, or damage to either the building or the

equipment.

(7) After equipment is erected any damaged paint surfaces

shall be cleaned and repainted.

(8) All motors, couplings, brakes, gear boxes, and drive

components shall be aligned when installed at the site, in

accordance with the manufacturer*s tolerances, for mechanical

alignment.
EP 415-1-261

1 Dec 92

14C-3

(9) The material handling system shall be electrically

aligned in accordance with the manufacturer*s instructions.

Alignment data shall include all timer settings, test point

voltages, supply voltages, motor voltages, motor currents, and

test conditions such as ambient temperature, motor load, date

performed, and person performing the alignment. Obtain a copy of

the final alignment data.

b. Testing

(l) Check ease of operating equipment.

(2) Determine that all the various speeds can be obtained.

(3) Check if all safety devices have been furnished,

installed, and are operating properly.

(4) See that specified tests are performed and recorded.

(5) The contractor shall provide all personnel necessary

to conduct the tests. Tests will be held in the presence of the

Government representative.

(6) Test data shall be recorded and evaluated by

manufacturer*s representative. Verification will be given that

units are installed and operate in the manner designed. Obtain

copies of all test reports and data.

(7) Recorded values shall be compared with design

specification or manufacturer*s recommended values. Inform your

supervisor any improper values obtained during testing.

(8) During operating and load tests check for improper

operation or poor condition of safety devices, electrical

components, mechanical equipment, and structural assemblies.

Report all defects to test supervisor immediately.

(9) Check specifications for specific tests to be

conducted.
EP 415-1-261

1 Dec 92

i

CHAPTER 15A

PIPING SYSTEMS

INDEX

Para. Title Page

15A-01 GENERAL 15A-1

a. Coordination of Work 15A-1

b. Layout 15A-1

15A-02 MATERIALS 15A-1

a. Submittals 15A-1

b. Storage and Handling 15A-2

c. Water Pipe and Fittings 15A-2

d. Fuel Gas Pipe and Fittings 15A-2

e. Drainage Pipe and Fittings 15A-3

f. Heating Pipe and Fittings 15A-3

g. Refrigeration and Air

Conditioning Pipe and

Fittings 15A-3

h. Fire Sprinkler Pipe and

Fittings 15A-3

15A-03 INSTALLATION 15A-4

a. General 15A-4

b. Pipe Connections - Screwed 15A-5

c. Pipe Connections

Mechanical 15A-6

d. Pipe Connections Hub &

Hubless Types 15A-6

e. Pipe Connections

Soldered 15A-7

f. Pipe Connections - Solvent

Cement (Adhesive) 15A-7

g. Pipe Connections - Welded 15A-7

h. Fittings and Valves 15A-8

i. Pipelines 15A-8

15A-04 TESTING 15A-10

a. Preparation 15A-10

b. Performing Tests 15A-11

15A-05 CLEANING ADJUSTING

AND OPERATION 15A-12

a. Cleaning 15A-12

b. Adjusting 15A-12

c. Operations 15A-13
EP 415-1-261

1 Dec 92

15A-1

CHAPTER 15A

PIPING SYSTEMS

15A-01 General

a. Coordination of Work

(1) This chapter covers piping for the water, gas,

drainage, heating, fire sprinkler and refrigeration/air

conditioning systems, and condensate (drainage) pipelines.

Refrigerator/air conditioning piping includes refrigerant,

condenser and chilled water pipelines.

(2) Drawings indicate general layout. Pipe and equipment

space and schedule for installation must be coordinated between

the various subcontractors doing the work.

(3) Check and eliminate interferences between electrical,

mechanical, architectural and structural features, especially in

equipment rooms, and above ceilings.

b. Layout

(1) The contractor will provide equipment and mechanical

room layout drawings which must be reviewed and approved.

(2) Pipe sleeve layout drawings will be useful. Check for

clearances and proper sleeve sizes to include the pipe

insulation thicknesses.

(3) Check layout for space to operate valves.

(4) Check layout for space to maintain and repair piping,

especially at equipment spaces.

(5) Check for sufficient space for required swing joints

at branch connections.

(6) Check space for anchors and expansion loops.

(7) Check space for support of hangers for piping.

(8) Check space for slope in pipe lines. Remember that all

piping systems carrying liquids must be drainable.

(9) Pipe lines should not pass thru footings; locate

beneath footings before the footings are placed.

(10) Check equipment dimension to assure all equipment can

be removed and replaced thru the doorways provided, once

ceiling/roof is installed.

15A-02 Materials

a. Submittals

(1) These usually include information on compliance with

specifications using labels, listings or certificates. Shop

drawings are required for layout of mechanical rooms and should

include the special support for heavy piping and fittings.
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15A-2

(2) The mechanical specialist will check submittals for

compliance with requirements.

(3) After determining that the submittal is in compliance,

use its descriptive information to check the material at

delivery. You will use the layout drawings to check actual

installation.

b. Storage and Handling

(l) Insure that materials are handled safely and carefully

to prevent damage.

(a) Reject damaged materials.

(b) Have damaged coatings repaired.

(2) Insure proper handling for coated pipe; use wide belt

slings.

(3) Check for storage off of the ground and weather tight

storage when required.

(4) Store pipe and fittings to eliminate entry of dirt,

etc.

(5) Refrigerant pipe is cleaned and capped at the factory.

The pipe must remain capped in storage.

(6) Check for piping that is factory cleaned and purged

with inert gas and capped. Check for gas tight capping.

c. Water Pipe and Fittings

(1) There are about 23 different pipe materials which can

be selected for above ground cold water pipelines. Many are

plastic materials. Plastic pipes cannot be used in water systems

for buildings greater than two stories in height.

(2) Plastic type pipe cannot extend through the roof or

through fire rated walls or floors.

(3) There are almost as many selections for above ground

hot water pipelines. Check your specifications.

(4) Seamless copper water tube must be hard drawn: Type M

above ground and Type L below ground.

d. Fuel Gas Pine and Fittings

comply with the Fuel Gas Code as given in National Fire

Protection Association (NFPA) Standard No. V54.

(2) Check for permitted pipe options; either all or only

steel, aluminum alloy, metal tubing and plastic materials may be

specified.

(3) Check for specific materials required in insulating

couplings.

(4) Aluminum alloy tubing and pipe is not permitted

underground or at exterior locations.

(5) Plastic pipe is not permitted in or under the building

and is permitted only underground outside of the building.
EP 415-1-261

1 Dec 92

15A-3

(6) Check the specifications for ambient temperature

limitations to the use of plastic pipe.

e. Drainage Pipe and Fittings

These consist of the waste system, the stormdrains and

rainwater conductors and the condensate drainage pipelines from

air conditioning and refrigeration units.

(1) There are many optional pipe materials and use is

dependent on locations in the building and in the drainage

system.

(2) Suggest you use the pipe material submittal for

identification or the pipe material table in the specifications.

(3) Check for drainage pattern type fittings as they are

required in the wet pipe portion of the waste system.

(4) Hubless cast iron pipe cannot be used underground and

may not be permitted in crawl spaces.

(5) Check for use of proper pipe and fittings in corrosive

waste and vent systems.

f. Heating Pipe and Fittings

(1) Check for use of black steel pipe or copper tubing for

low temperature hot water pipelines.

(2) Steam piping must be black steel: vent piping must be

the same type.

(3) Check for use of Schedule 40, black steel, in high

temperature pipelines of 2 inches and larger.

(4) Use welded joints for high temperature water pipelines

over 3/4 inch diameter.

g. Refrigeration and Air Conditioning Pipe and Fittings

(1) Check the steel pipe or the copper or steel tubing and

fittings for intended service. Refrigerant service rating is

required for lines carrying a refrigerant.

(2) Check for galvanized steel pipe or hard drawn copper

tubing for condenser water lines, except lines 4—inches and

larger require black steel which must be coated and wrapped for

underground use.

(3) Chilled water. Check the type of piping specified for

chilled water lines.

(4) The drainage lines for condensate water are usually

given in the plumbing section of the specifications.

h. Fire Sprinkler Pipe and Fittings

(1) Insure that materials are in accordance with approved

submittals.
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15A-4

(2) The type system is designed to use a specific water

supply and distribution for specific occupancy. More information

can be found in National Fire Protection Association (NFPA)

Standard No. 13.

(3) Contractor*s working plans shall be approved and shall

be used when installing the system.

15A-03 INSTALLATION

a. General

(1) Laying underground pipe lines is covered in Chapter

2C, Volume 1 of the Construction Inspector*s Guide.

(2) Installation of exposed pipelines inside the building

should follow building lines. The building structure cannot be

cut or otherwise weakened for pipelines without written

approval.

(3) Check for required slope in horizontal runs; liquid

systems must be drainable.

(4) Check for drains at low points.

(5) Check for air cocks at high points.

(6) Check for required access to drains, air cocks and

valves.

(7) Check for contact between dissimilar metals such as

copper to iron or steel. Isolation (separation) will be

required. Dissimilar pipe must be coupled with a dielectric

connection.

(8) Are hangers proper style, size and at required

intervals? Are ferrous hangers coated where used against copper

pipe? Size hangers to encompass the pipe insulation.

(9) Are pipelines restrained from lateral movement at

trapeze.

(10) Wall or floor supports must also restrain the

pipeline from lateral movement.

(11) Check for support needs at each floor but not more

than 15 foot intervals. Support is not necessary at the floor

slab on grade hangers with “U” bolts or other type clips.

(12) Check for extra hangers or supports required at

fittings and devices. A hanger is usually required within one

foot of each change of direction.

(13) Suspended heavy pipelines must have proper support

without overloading support points. This should be covered in

the preparatory inspection by the contractor*s quality control

representative. Be aware of:

(a) Excess loads on steel bar joints or beams.

(b) A hanger load or multiple hangers at the same location

with more than 100 pounds of load.
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15A-5

(c) Check with your supervisor where you have a suspicious

condition and he will request a structural evaluation.

(14) Check for required anchors and expansion loops or

joints, especially on long pipelines. Also check for guides at

the expansion points.

(15) Check for union or flanged connections at equipment

and elsewhere in order to break and repair or replace piping,

etc.

(16) Check for proper size pipe sleeves. Sleeves shall be

large enough for the pipe insulation thickness when required.

(17) Pipe sleeves through waterproofing must have a

clamping device to hold the flashing.

(18) Sleeves must protrude above finished floor surfaces

in wet areas. Space between pipe and sleeve must be sealed.

(19) Check for proper fireproofing of openings between

pipes and fire-rated construction.

(20) Check that escutcheons are used around pipes

penetrating finished surfaces.

(21) Use soft drawn copper tubing, as permitted, when not

using fittings.

(22) Steel pipe bending with proper equipment is permitted

in sizes to 4-inch diameter. Bend radius must be at least 6

times pipe diameter.

b. Pipe Connections — Screwed

(1) Examine the threading operation for:

(a) Square cut pipe

(b) Proper reaming before threading

(c) Sharp cutters so that threads are not shaved

(d) Tapered threads - not running threads

(e) Thread run - not more than three threads should be

exposed after connection is tight. The specifications may have a

threading table you can refer to.

(f) Use of cutting oil - pipe shall be cleaned of oil and

metal “filings”. This is critical for refrigerant lines.

(g) Protect floor surfaces — Use a sand box or other

adequate protection under the threading/cutting operation.

(h) Plastic pipe and metallic tubing will not be threaded.

(2) Examine screwed pipe connections for:

(a) Use of approved thread lubricant or tape applied to

male threads only. Some piping may not permit use of tape at

screwed joints check for requirements
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15A-6

(b) Tighten connection, but do not overtighten to strain

the fittings.

(3) Be alert for distorted valves. See that wrenches are

used on the end of valves being screwed onto the pipes in order

to prevent damage to the valve bore. If it is necessary to put

wrench on the opposite end of valve from the end being screwed

onto pipe, use a nipple that has been screwed into the valve.

(4) Do not screw pipes against the web of globe valves, or

against the underside of seat rings of gate valves.

(5) Use threaded connections to angle stops at plumbing

fixtures.

c. Pipe Connections — Mechanical

(1) Check proper alignment of flanges, couplings and

gaskets.

(2) Check the gasket material, it must be compatible with

the liquid or gas in the pipeline.

(3) Gaskets with high temperature water shall be metallic

asbestos type.

(4) Do not use the drift pin or spud wrench handle to

align flanges.

(5) Mechanical couplings and fittings must be compatible

and manufactured by the same concern.

(6) Mechanical couplings are usually permitted on ferrous

metal pipelines in the building for domestic hot and cold water

systems.

d. Pipe Connections - Hub and Hubless Types

(1) Check for proper rubber gasket installation in the hub

or bell. Spigot end must be pushed “home into the hub.

(2) When molten lead is used to make the joint, check for:

- Jute compacted into base of joint to seal the end, and

center the spigot end in the hub.

- Depth of joint.

- Pouring the molten lead joint in a continuous operation.

- Caulking the lead with proper size irons.

- Caulking each joint at least three times around.

(3) Hubless joint uses a rubber sleeve with stainless

steel band; the assembly must be approved by the Cast Iron Soil

Pipe Institute (CISPI).

(4) Check for proper torque wrench set to 5 foot—pounds

for tightening the stainless steel band in hubless joints.
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15A-7

e. Pipe Connections — Soldered

(1) Surfaces of the fitting and pipe must be cleaned to

bright metal with an abrasive material before the joint is made.

(2) The 50/50 solder is half tin/half lead and can be used

in drainage, waste and vent (DWV) pipelines. It is also known as

soft solder.

(3) Silver solder is 95/5, 95 percent tin — 5 percent

antimony, and must be used in all other pipelines.

(4) Core solder is not permitted.

(5) Joint must be well heated before solder is applied.

Approximately 400F for soft solder and 1150F for silver solder.

(6) Check for use of a multiflame torch for uniformly

heating joints where 2 1⁄2 inch diameter and larger pipe are

soldered.

f. Pipe Connections — Solvent Cement (Adhesive)

(1) For plastic pipe connections use compatible materials.

(2) Use in accordance with the pipe manufacturer*s

instructions.

(3) Do not join different kinds of plastic pipe together.

(4) Only heat—fusion connection is used to join

polyethylene pipe, tubing or fittings.

g. Pipe Connections - Welded

(1) Check for use of welding fittings.

(2) Making fittings by notching or mitering pipe is not

permitted.

(3) Check for the approved welding procedures before

welding begins.

(4) Check for the individual welder certification in the

type welding each welder must perform.

(5) Welders must stamp each weld with an assigned symbol

so that the individual*s weld can always be identified. Painted

stamps are not permanent and may not be used to identify welds.

(6) Check welding of refrigerant pipe as the fittings and

pipe must be filled with inert gas such as nitrogen, during

welding. This prevents the formation of scale inside the pipe.

(7) welding for fire sprinkler systems must be performed

in a shop and in accordance with NFPA 13 requirements. Jobsite

welding is not permitted.
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15A-8

(8) Check Chapter 5B, Volume 3 of the “Construction

Inspector*s Guide” for additional information on welding.

h. Fittings and Valves

(1) Check riser diagrams and floor plans on drawings for

proper valve locations.

(2) Are valves proper type?

(3) Valves must be oriented with stems in horizontal

position or above. Only the horizontal position is allowed for

refrigerant pipelines.

(4) Check and globe valves have an arrow cast in housing

to indicate direction of flow. Check these valves for proper

orientation in the pipeline flow.

(5) Check for access to all valves. Are access locations

marked on ceiling panels.

(6) Use dielectric connectors where required at locations

where different metals connect together in the pipeline.

i. Pipelines

(1) Water pipelines.

(a) Are air chambers installed at fixtures?

(b) Are water hammer arrestors shown instead of air

chambers? Check your riser diagrams on the drawings for

locations and sizes of these arrestors.

(c) Are valves located as shown?

(d) Does the water service have a gate valve and drain at

its point of building entry?

(e) Check for use of a backflow prevention device in each

branch waterline connected to another system. Also check for the

correct type device, especially where toxic fluids are involved.

(f) Check for a vacuum breaker at each fitting or fixture

with hose connection. The vacuum breaker will prevent backsiphonage.

(2) Fuel gas pipelines.

(a) Avoid installation under buildings. Fuel gas service

should be installed above grade on the outside. Do not install

service pipeline in the trench with other utilities.

(b) Do not permit soldered joints. Use pressure- threaded

joints for copper pipe.

(c) When piping is to be embedded in concrete, check for

special requirements such as:

- Should be acceptable to the gas service company

- Check concrete mix for compatibility with pipe material.

Certain additives and aggregates may not be compatible.
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15A-9

(d) Don*t embed gas pipelines in solid walls and

partitions.

(e) Check for protective coating on underground metallic

pipelines.

(f) Where piping must be buried under the building it

should be encased in a gas tight conduit for its full length of

run. Space between the pipe and conduit must be safely vented to

the atmosphere. Check your details.

(g) Check for pipe slope and drains at low points.

(h) Check for required pipeline bonding and grounding in

accordance with the National Electric Code.

(i) Check for shutoff valves as required.

(3) Drainage lines.

(a) Hubless cast-iron pipelines require support next to

each joint.

(b) Hub type pipelines require support at 10 feet

intervals and within 3 feet of each fitting.

(c) Check for required expansion joint at floors in

plastic pipeline risers.

(d) Install cleanouts so they are flush with finish

surfaces. Close each cleanout with a brass plug installed with

graphite thread lubricant.

(e) Check the elevation of each floor drain before

finished floor is placed to assure drainage slope.

(f) Check floor drain for type specified. Does it require

a special item such as a sediment basket, a backwater valve or a

self-priming valve?

(g) On roof drains check for the clamping ring to hold the

metal flashing and for the cast iron strainer.

(4) Heating pipelines.

(a) Check for slope of at least 1 inch in 10 feet.

(b) Reducing fittings on horizontal lines must be

eccentric type with bottom of pipelines flat for positive

drainage flow.

(c) Check for proper branch line take off from the high

temperature pipeline supply and return. Should be from the upper

half of pipeline, at a 45 degree angle in direction of flow.

(d) Check for special piping from high temperature

waterline air vents to funnel drain.

(5) Refrigeration and air conditioning pipelines.

(a) Refrigerant steel pipeline joints shall be welded.

(b) Refrigerant tubing of copper or steel shall have

brazed joints.
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15A-10

(6) Fire sprinkler pipelines.

(a) The approved shop drawings will be your guide in

checking the fire sprinkler system layout and pipe sizes.

(b) Check for possible conflict between final sprinkler

head location and user items which would interrupt flow coverage

or cause damage to the system.

(c) Review Chapter 3 of the National Fire Protection

Association Standard 13 for supports, hangers, slope and

drainage.

(d) Do not allow paint on sprinkler heads. Check heads for

proper temperature rating indicated by color code or stamped

numbers.

(a) Where required, outside connection shall be the size

indicated and shall mate with fire department hose.

(f) Check for required sprinklers in concealed spaces.

(g) Check for special protection against freezing,

corrosion and earthquakes, and for sprinkler head clearance from

heat sources.

(h) Check electric power and alarm for:

- Electric power correction ahead of the main switch.

- Alarm tie-in with fire department, as required.

- Effective location of the local alarm.

15A-04 TESTING

a. Preparation

Testing is the responsibility of the contractor unless

stated as a Government responsibility in the specifications.

Check with supervisor for recommended presence of user personnel

during certain testing such as sprinkler, etc. The system or

portion of the system will be prepared for testing by the

craftsman who installed the pipeline. The contractor*s quality

control representative will be responsible for verifying the

extent of test, the method and results which will be reported.

The following items must be checked:

(1) Determine extent of test.

(2) Is pipeline isolated at limits of the test with valves

closed and the plugs and caps tightly in place?

(3) Are pipeline valves open within the test area?

(4) Are pipelines adequately blocked and anchored for

pressure tests? Pipelines should be in the permanent, fixed

position before the test is permitted.

(5) Will joints be exposed for the visual or soap test

requirements?

(6) When testing pipeline to be concealed, does extent of

test include all of the affected pipeline.
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15A-11

(7) For a pressure test, have diaphrams or other internal

parts of valves, regulations, etc. which may be damaged by the

pressure been removed?

(8) Review the test method to be used.

(9) Inspect the test instruments and apparatus for proper

type, calibration and operation.

(10) When flushing to clean the pipeline, check to

determine that coils for heating, air conditioning and

refrigerant lines are bypassed to prevent flushing—water from

passing through coils.

b. performing Tests

(1) Water pipelines.

(a) Pneumatic or hydrostatic test shall be used.

(b) Check ambient temperature at beginning and end of test

period for temperature differential and the correction factor

for the final gauge reading.

(c) For the hydrostatic test, was the tested segment

vented to ensure it was completely filled with water?

(2) Fuel gas pipelines.

(a) An air pressure test, similar to the waterline test,

is usually made. Do not use oxygen.

(b) Refer to National Fire Protection Association (NFPA)

Bulletin 565 test requirements for nitrous oxide and oxygen

system test requirements.

(c) Check the gas system for leakage immediately when

beginning the test using fuel gas.

(3) Gravity drainage lines.

(a) Is the test stack high enough to provide the 10 foot

head for all of the tested line.

(b) Check each joint for leakage.

(c) The final smoke or peppermint test is made with all

fixtures attached.

(4) Heating pipelines.

(a) Hydrostatic pressure testing is required. Usually 45

psig for four hours for low temperature waterlines.

(b) High pressure waterlines are tested at 1 1⁄2 times

design pressure.

(5) Refrigeration and Air Conditioning pipelines.

(a) Pneumatic pressure test used on refrigerant pipelines

using dry nitrogen. Check each joint with soap solution.

(b) Refrigerant pipelines also are charged with

refrigerant gas and joints checked for leaks with a halide

torch.
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15A-12

(c) Refrigerant pipelines also require an evacuation test.

Check the specifications for details.

(d) Check the hydrostatic pressure test on water pipelines

for use of appropriate pressure and time requirements.

(6) Fire Sprinkler pipelines.

(a) Refer to Chapter 1, NEPA 13 for specific test

requirements.

(b) Assure that feeder piping has been flushed before

testing.

(c) Check for approved contractor*s test procedure and

adequate monitoring of the tests by contractor*s quality control

person.

(d) Check the adequacy of contractor*s required material

and test certificates to be submitted after completion of tests.

(e) Test blanks used in the system during testing shall be

approved type and each blank shall be numbered and accounted for

at activation of the system.

15A-05 CLEANING ADJUSTING AND OPERATION

a. Cleaning

(1) Pipelines constructed with properly stored and

protected pipe should need very little cleaning.

(2) Close ends of unfinished lines during work stoppages.

(3) On occassion, craftsmen temporarily place tools or

other items in the end of pipes. This habit must be stopped.

(4) Check the specification for flushing requirements.

Flushing may be ordered for dirty pipelines.

(5) The completed potable water system must be sterilized

by chlorination. This process, as given in the specification, is

required reading.

(6) Heating pipelines must be cleaned with a chemical

solution after successful completion of the pressure tests.

Check for proper solution, temperature and time.

(7) Fire sprinkler systems must be flushed and disinfected

after testing.

b. Adjusting

(l) When beginning the operating phase each piping system

must be closely inspected for necessary adjustment and proper

operation.

(2) Adjust flow and flush valves.

(3) Check air cocks for leakage, clean and adjust as

required.
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15A-13

(4) Condenser and chilled water pipelines must be balanced

after testing.

(5) Check for heating system approved balancing procedure.

This must be performed by a qualified engineer.

c. Operation

(1) Specifications require that user personnel be

instructed in proper system operation. Make a note of the

identification of these personnel for the record.

(2) Check the posted operating instructions. Are posting

requirements met? Do they include the required diagrams, layouts

end specific written instructions?

(3) Are pipelines coded as required?

(4) Check for required spare parts.
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1 Dec 92

i

CHAPTER 15B

DUCTWORK

INDEX

Para. Title Page

15B-01 GENERAL 15B-1

15B-02 SHOP DRAWINGS 15B-1

15B-03 DUCTWORK 15B-1

a. Fabrication 15B-1

b. Erection 15B-2

c. Diffusers, Registers,

and Grilles 15B-2

d. Insulation 15B-3

e. Balancing and Testing 15B-3
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15B-1

CHAPTER 15B

DUCTWORK

15B-01 GENERAL

This chapter covers ductwork for air conditioning,

heating, ventilating, and exhaust systems. The QA Rep must

closely coordinate this chapter with chapter 15C, 15E, 15F, and

15G. It is important that the QA Rep have a thorough knowledge

of the job plans, specifications, and potential obstructions in

the area in which the ductwork is to be installed, including

locations of fire rated walls that the duct must penetrate.

15B-02 SHOP DRAWINGS

a. It is the QAR*s responsibility to determine that all

ductwork is approved well in advance of its actual need on the

job.

b. Check all ductwork delivered to the site for

conformance with approved shop drawings.

15B-03 DUCTWORK

a. Fabrication (See SMACNA Duct Manual appropriate to

material and service requirements)

(1) Inspect for type, thickness and shape of sheet

material, and fiber glass boards used for ductwork.

(2) Check workmanship and observe lock seams and breaks in

ductwork for cracks of sheet metal ducts. Check fiber glass

ducts for broken, or damaged edges, joints, and seams.

(3) Inspect all joint connections for correct type and

adequately sealed to prevent movement and air loss.

(4) Make sure that the joints are neatly finished and that

the duct is smooth on the inside. Any laps should be made in the

directions of the flow of air. Internal insulation will be

securely fastened and coated as specified.

(5) Provide adequate bracing and reinforcement of the

larger ducts.

(6) Compare the radius of curved duct with the

specification requirements.

(7) Slope ratio of transitions should be ) Provide turning

vanes and extractors to eliminate abrupt turns of air which

cause appreciable turbulence.

(9) Check the need for and construction of splitter

dampers. Make sure the operating mechanism is accessible; and if

exposed in a finished room, the mechanism is to be chromium

plated.

(10) Make sure that fire and/or smoke dampers are provided

in ducts as required in accord with NEPA, and SMACNA fire damper

guide. Check for fire-safety switch on return air ducts of

circulation system.
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15B-2

(11) Check duct for the required test holes and covers.

(12) Check the fabrication of flexible connections.

(13) Make sure that equipment serviced by the ductwork is

fully accessible for maintenance, repairs, oiling, cleaning, and

for filter changing.

b. Erection

(1) Examine all fabricated ducts, rejecting any which are

not smooth or any which are damaged.

(2) Examine duct hangers for specified material,

thickness, and spacing.

(3) Check specification requirements for the need for

stiffeners for wide ducts. Also check for need of trapeze

hangers under wide ducts.

(4) Provide approved flexible connections between ducts

and for fan units.

(5) Check rigidity and tightness of such field installed

items as dampers and defectors.

(6) Provide access doors at all fire dampers, automatic

dampers, coils, filters, heaters, thermostats, or at any item

that requires servicing. Doors are to be airtight, securely

fastened and accessible, and able to be fully opened. Refer to

SMACNA and Specifications for size of access doors required.

(7) Inspect goose necks and rain hoods for method of

fastening, flashing and bracing. Goose necks are to be turned

away from the prevailing wind. Check specifications for screens

on open end of goose necks.

(8) Provide proper size sleeves where insulated duct

passes through wall openings.

(9) When obstructions cannot be avoided, the duct area

should never be decreased more than 10 percent, and then a

streamlined collar should be used. Larger obstructions require

an increase in the duct size in order to maintain as nearly

uniform velocity as possible.

(10) Before insulating metal duct, test duct for air

tightness.

(11) All ducts, plenums and casings must be thoroughly

cleaned of debris and blown free of small particles and dust

before supply outlets are installed.

(12) Inspect duct break away collar at fire dampers for

meeting SMACNA requirements.

c. Diffusers. Registers, and Grilles

(1) Insure that the contractor furnishes a schedule

showing all air inlets and outlets.

(2) Inspect diffusers and registers for accessible volume

control operator.
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15B-3

(3) Examine specification and installation for integral

anti-smudge rings for diffusers.

(4) Check for loose or bent vanes.

(5) Inspect each item for fit, and see that gaskets are

provided when required.

(6) Inspect for the proper operation of registers,

dampers, and grille directional-controls.

d. Insulation

Insulation for metal ductwork is covered in Chapter 15C

entitled, Mechanical Insulation. Chapter 15C covers pipe

insulation, equipment insulation, and ductwork insulation.

e. Balancing and Testing

Balancing and Testing of air supplies is covered in

Chapter 15F entitled, Ventilating, Air Supply and Distribution

Systems.
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i

CHAPTER 15C

MECHANICAL INSULATION

INDEX

Para. Title Page

15C-01 GENERAL 15C-1

15C-02 IDENTIFICATION OF MATERIAL 15C-1

15C-03 SHOP DRAWINGS 15C-1

15C-04 SURFACE BURNING

CHARACTERISTICS 15C-1

15C-05 MECHANICAL INSULATION 15C-1

a. Ductwork Insulation 15C-1

b. Pipe Insulation 15C-2

15C-06 DUCTS NOT REQUIRING INSULATION 15C-3

15C-07 INSULATION FOR RECTANGULAR AND

ROUND DUCTS 15C-3

15C-08 INSULATION FOR HOT EQUIPMENT 15C-3

15C-09 INSULATION FOR COLD EQUIPMENT 15C-4

15C-10 ABOVE GROUND PIPE INSULATION 15C-4

15C-11 PIPING EXPOSED TO WEATHER 15C-4

15C-12 BELOW GROUND PIPE INSULATION 15C-5
EP 415-1-261

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15C-1

CHAPTER 15C

MECHANICAL INSULATION

15C-01 GENERAL

This chapter covers field-applied insulation. Factory

applied insulation is specified under the equipment, duct, or

piping to be installed, as detailed in the specification.

15C-02 IDENTIFICATION OF MATERIAL

All packages or standard container of insulation, jacket

material, cements, adhesives, and coatings delivered for use,

and all samples shall have a manufacturer*s stamp or label

attached giving the name of the manufacturer, brand, and a

description of the material.

15C-03 SHOP DRAWINGS

a. It is the inspector*s responsibility to determine that

all insulation related materials are approved well in advance of

their actual need on the job.

b. After approval of materials and prior to insulating any

pipe the contractor will submit for approval sample insulation

boards, or approved standards, showing his proposed methods of

mechanical insulation, including cut-a—way sections, insulation,

coverings, and finish of completed work. Approved sample boards

will be maintained by the contractor at the jobsite for the

duration of the work.

15C-04 SURFACE BURNING CHARACTERISTICS

a. Check underwriters labels and test certificate of all

insulating materials and accessories for not exceeding a flame

spread rating of 25 or a smoke developed rating of 50, as

determined by ASTM E 84.

b. Check specification for limitations on surface burning

characteristic.

15C-05 MECHANICAL INSULATION

a. Ductwork insulation

(1) Distinguish between areas requiring flexible type

insulation and those requiring rigid or semi-rigid type

insulation.

(2) Check the type and thickness of insulation and

requirements for vapor barrier.

(3) Check the method of fastening insulation to exterior

or interior of duct.

(a) If metal pins are used, check the type and spacing.

(b) If wire is used, see that corners of insulation are

protected from possible damage.

(c) Verify adhesive materials are correct, and area

specified receives proper coverage.
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15C-2

(4) Make a careful check for breaks in insulation and

vapor barriers.

(5) See that materials are fire—retardant or

noncombustible as required by the specifications.

(6) When equipment casings are required to be insulated,

check for proper application. See that application is firm.

(7) Where insulation is subject to mechanical damage,

check for protection requirements.

(8) Check for continuity of insulation through walls and

floor, if required.

(9) Check for proper sealing of insulation to diffusers,

grills, and fire dampers.

b. Pipe Insulation

(1) Determine whether the material on the job has been

approved for the particular piping being installed. Make sure

insulations, vapor barriers, adhesives and sealers are

noncombustible or fire retardant as specified.

(2) Note that heated water piping is insulated differently

from chilled water piping and from combination chilled and

heated water piping.

(3) Check thickness of insulation and of vapor barrier.

(4) Determine that insulation jackets which are exposed to

view are paintable.

(5) Examine the requirements for the insulation of

flangers, fittings, and valves, and assure compliance with the

requirements.

(6) Check the lap and the sealing at joints.

(7) Be very careful to see that there are no breaks in the

vapor barrier. Watch for later damages during construction.

(8) Check specification requirements for extending through

sleeves in walls, floors, and ceilings; chilled water lines

inside cabinets of fan coil units should be covered as required

to prevent condensate dripping on floor.

(9) Make sure that pipe hangers are installed over

insulation. Metal shields to be provided between hanger ring and

insulation. High density insulation inserts shall be installed

with a length equal to length of metal shield.

(10) Check for the neat termination and seal of insulation

at the end of insulation.

(11) Know the special requirements for insulation and

jacketing of piping exposed to weather.

(12) Check the installation, the width, and the spacing of

the bands used on pipe jacketing.

(13) In chilled-water and hot—water combination piping

check for vapor seal requirement on boiler piping.
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15C-3

15C-06 DUCTS NOT REQUIRING INSULATION

a. Site—erected casings and plenums constructed of factory

insulated sheet metal panels.

b. Ducts shown to be acoustically lined, provided

sufficient thickness of liner is specified.

c. Supply and return ducts in air conditioned or heated

spaces, unless otherwise shown.

d. Return ducts in ceiling spaces when roofing is

insulated. Ceiling space shall be defined as those spaces

between the ceiling and bottom of floor deck or roof deck inside

the heated space insulated envelope.

e. Supply and Return Ducts made out of faced fiber glass

insulating board. Check on sealing joints between individual

duct sections, thickness, and connections.

15C-07 INSULATION FOR RECTANGULAR AND ROUND DUCTS

a. Check flexible type insulation used on concealed ducts

for specified minimum density, usually 3/4 pcf for rectangular

ducts.

b. Check rigid type insulations used on exposed ducts for

specified minimum density, usually 3 pcf for rectangular ducts.

c. Check for flexible type insulation specified for round

duct, usually a minimum density 3/4 pcf.

d. Check for specified vapor barrier jacket on exposed

insulation, either factory applied or field applied.

e. Check specification for requirement for factory applied

or field applied vapor barrier on insulation on concealed duct.

f. Check rigid fiber glass duct installation method to

insure accessibility for maintenance of coils, vanes, and fan

motors used in the HVAC duct system.

15C-08 INSULATION FOR HOT EQUIPMENT

a. Check specification to determine if insulation is

required to be rigid block or semi-rigid board.

b. Check for specified type of material and thickness of

insulation being installed.

c. Form or fabricate insulation to fit equipment.

d. On round equipment insulation edges will be beveled to

insure tight joints.

e. Check joints for being tightly butted, being filled

with mineral fiber, or insulation cement.

f. Check specifications and manufacturers recommendation

on spacing of bands. Spacing will not be less than 12 inches on

centers.
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15C-4

g. Check for excessive use of wires in lieu of bands.

Check for insulation corner protectors under wires.

h. Check hot ducts and equipment for specified finish

i. Check for continuity of insulation thru walls and

floors.

15C-09 INSULATION FOR COLD EQUIPMENT

a. Check dual temperature equipment, which operates at 60F

or below at any time, for insulation as specified for cold

equipment. Check specification for pump insulation. It may vary

from flexible, rigid, or semi-rigid type insulation. Check all

other equipment for specified insulation..

b. Check insulation for thickness specified.

c. Check installation of vapor barrier.

d. Check drain pans under pumps for insulation underneath.

a. Check cold duct and equipment insulation. finish, in

accordance with specifications.

15C-10 ABOVE GROUND PIPE INSULATION

a. Check contract specifications to determine type of

insulation required on pipelines within the structure.

(1) Normally, domestic hot water, steam, condensate, hot

water heating, heated oil, and water defrost lines are insulated

as hot pipelines.

(2) Normally domestic cold water, interior roof drains,

refrigerant suction lines, chilled water and dual temperature

water line, air-conditioner condensate drain pipelines, exposed

to weather drainage piping, and piping which operates at 60F or

below at any time, are insulated as cold pipelines.

b. Check exterior piping for being insulated as required

by specifications for piping exposed to weather.

c. Check specifications for areas which are to receive

factory-applied vapor barrier jackets, field applied aluminum

jackets, and field applied vapor barrier.

15C-ll PIPING EXPOSED TO WEATHER

a. Check to see that pipe is insulated and jacketed for

applicable service. Note that vapor barrier is not normally

specified for hot pipelines.

b. Check to see if specified jacket is aluminum.

c. Check to see if jacket is required to be factory

applied or field applied.

(1) Check to see if aluminum jacket laps not less than 2

inches at all joints.

(2) Check banding requirements for the jacket.
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15C-5

(3) Check to see that horizontal joints are lapped

downward to shed water, and that vertical joints are sealed with

a water proof coating.

(4) Check specifications for special treatment of flanges,

couplings, unions, valves, fittings and anchors.

15C-12 BELOW GROUND PIPE INSULATION

a. Check all below ground domestic hot water heating,

heating hot water to 200F, dual temperature water, and chilled

water piping for specified insulation. Generally the insulation

is 1 1/2—inch thick cellular glass.

b. Cellular glass insulation.

(1) Check to see that bore surfaces of insulation are

coated with a thin application of high strength gypsum cement,

as recommended by manufacturer.

(2) Check to see that insulation joints are

(a) Staggered, one-half overlapping the next opposite half

section.

(b) All joints are tightly butted and seated with bedding

compound.

(c) Insulation secured with 2 stainless steel bands per

section of insulation.

(d) Insulation termites at anchor blocks.

(e) Insulation is continuous thru sleeves and manhole.

(f) Backfill around and three inches above the insulation

to be free of stones larger than 1/4 in any dimension.

(g) Insulation extends two inches inside of building*s

interior and tightly butted, scaled, and vapor barrier coated to

interior piping.

(h) Check for special insulation requirements for flanges,

couplings, unions, valves and fittings.

c. Check finish of insulation for 2 coats of mastic with

glass cloth or tape embedded between coats. Check for proper

overlap at all joints.

(1) Check wet film thickness of both coats of mastic to

meet specifications requirements.

(2) Check termination points to see that mastic and cloth

or tape covers the end of of the insulation and extends along

the base pipe as required by the specifications.
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i

CHAPTER 15D

PLUMBING SYSTEMS

INDEX

Para. Title Page

15D-01 GENERAL 15D-1

15D-02 FIXTURES AND MATERIALS 15D-1

a. Three Phase Inspections 15D-1

b. Storage and Handling 15D-1

15D-03 COORDINATION OF WORK 15D-l

15D-04 INSTALLATION 15D-1

a. General 15D-1

b. Protection 15D-2

15D-05 PIPELINES, DRAINS, VENT STACKS

AND INSULATION 15D-2

15D-06 CLEANING, ADJUSTING,

AND OPERATING 15D-2

a. Cleaning 15D-2

b. Adjusting and Operating 15D-2
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15D-1

CHAPTER 15D

PLUMBING SYSTEMS

15D-01 GENERAL

Definition. This chapter covers plumbing fixtures,

materials, and good workmanship practices for plumbing systems.

15D-02 FIXTURES AND MATERIALS

a. Three Phase Inspections

Insure that all plumbing fixtures and materials have been

submitted and approved prior to the Preparatory Inspections,

fabrication, and installation. Obtain and review manufacturer s

installation information. During subsequent Initial Inspections

with contractor*s CQC representative, check to see that contract

requirements and manufacturer*s recommendations were complied

with during installation. Follow-up Inspections will be made as

the installation of the plumbing systems progress throughout the

facility under construction or renovation.

b. Storage and Handling

Insure that all materials and equipment are handled

carefully, properly stored and protected to prevent damage.

(1) Reject damaged materials and equipment. Have them

removed from the site.

(2) Inspect the plumbing fixtures upon arrival at the job

site for conformance with contract requirements. Require

adequate storage and protection from damage before and after

installation. Insure that fixtures are installed in compliance

with contract requirements and good plumbing practice.

(3) Withhold inventory payment for improperly stored and

protected materials.

15D-03 COORDINATION OF WORK

Continually check for interferences between electrical,

mechanical, architectural, and structural features especially in

toilet and shower room walls, floors, and pipe chases.

15D-04 INSTALLATION

a. General

(1) Know how the plumbing system fits into the total job

and where the specific items are to be installed. Prior to

installing plumbing fixtures check to insure that all testing of

water supply lines, vents, and drains have been completed.

(2) Check size, spacing, elevation, and location of wall

and floor stub outs to receive plumbing equipment. Do not allow

plumbing fixtures to be stained, or supply lines to be

undersized. Insure that the stub outs are corrected as necessary

prior to setting plumbing fixtures.

(3) Check location and firmness of the installation of

specified equipment supports, holders, and tie down flanges.
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15D-2

(4) Check setting or attaching plumbing fixtures, for

required seals, traps, grouting, and caulking. Check each

fixture for alignment, height, anchorage and for plumbness.

(5) Check for use of chrome plating on exposed piping,

valves, escutcheons, cover plates, and drains.

(6) Check for surge arrestors on lines having quick

closing valves. Check for positioning of access opening to allow

maintenance of surge arrestors and operation of control and shut

off valves. Check for individual shut off valves at each piece

of plumbing equipment.

(7) Check for connection of cold water piping to the right

hand side of showers, lavatories, and sinks. Also make sure cold

water is provided to toilets and urinals.

(8) Check for specified trim, materials, screws, and

bolts.

b. Protection

(1) Keep trash and debris out of fixtures and drains.

Check fixtures for damage during installation.

(2) Cover and protect fixtures after installation to

prevent future breakage, staining, or other damage.

(3) Check workmanship on all bolting, grouting, caulking,

shimming, and leveling after work in toilet and bath area after

the work has been completed. All fixtures, whether wall or floor

mounted, must be firmly attached in place to prevent damage to

the fixtures and to the seals of the fixtures. Check to see that

all materials and fixtures are sanitary anti-siphon units.

15D-05 PIPELINES. DRAINS. VENT STACKS, AND INSULATION

See Section 15A for water pipelines, fittings, valves,

vents and drain lines. See Section 15C for insulation of pipe

lines.

15D-06 CLEANING, ADJUSTING, AND OPERATING

a. Cleaning

(1) Inspect all surfaces for damage or stains. Replace or

clean as necessary. Clean equipment before running water thru

it.

(2) See that all grease, paint, plaster, spackle, spots

and debris are removed. See that anchorage and seals are firm.

See that equipment is still undamaged. Accept only properly

working, and undamaged equipment.

b. Adjusting and Operating

(1) Flush, turn on, or otherwise run water thru system.

Check flow, water levels, quietness of operation, and shut off

capability. Check flow thru both fixtures and drains. Correct as

necessary.

(2) Reject equipment that is damaged, does not properly

operate, is not properly installed, and is not in new condition.
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i

CHAPTER 15E

HEATING SYSTEMS

INDEX

Para. Title Page

15E-01 GENERAL 15E-1

15E-02 MATERIALS AND EQUIPMENT 15E-1

a. General 15E-1

b. Boilers, Furnaces, and

Accessory Equipment 15E-2

c. Fuel Burning Equipment 15E-2

d. Draft Fans 15E-3

e. Oil Storage Tank 15E-3

f. Circulating, Condensate and

Vacuum Return Pumps 15E-3

g. Miscellaneous Fittings and

Equipment 15E-3

15E-03 INSPECTION 15E-4

a. Planning 15E-4

b. Piping 15E-4

c. Pipe Insulation 15E-5

d. Hot-Water Systems 15E-6

e. High-Temperature

Hot Water 15E-6

f. Steam Systems 15E-6

g. Hot Air Heating 15E-6

h. Heating and Ventilating

Units 15E-7

i. Unit Heaters 15E-7

j. Controls 15E-7

k. Boilers and Boiler Plants 15E-7

l. Smoke Connections 15E-13

m. Fuel Storage and Conveying 15E-13

n. Painting 15E-14

o. Testing 15E-14

p. Operating Instructions and

Guaranties 15E-14
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15E-1

CHAPTER 15E

HEATING SYSTEMS

15E-01 GENERAL

a. This chapter covers material, equipment, and good

workmanship practices for the installation of heating systems.

b. The QA Rep should strive to obtain systems in

accordance with the contract requirements that are safe,

adequate, and neat, and which function properly with a minimum

of routine maintenance.

c. In combination heating-cooling systems designed for

year- round automatic air conditioning, coordinate material of

this section with Section 15F, VENTILATING, AIR SUPPLY AND

DISTRIBUTION SYSTEMS, 15G REFRIGERATION AND AIR CONDITIONING,

AND SECTION 15C MECHANICAL INSULATION.

15E-02 MATERIALS AND EQUIPMENT

a. General

(1) Make sure that each piece of material and each item of

equipment has been approved well in advance of its need. When

the material and equipment arrive on the job, inspect them very

carefully, comparing them with the approved shop drawing and

samples. Check and record nameplate data on all equipment.

(2) Determine that there is adequate space in the room for

proper functioning and maintenance of all the equipment.

(3) Reject all damaged materials and equipment and have

them removed from the site.

(4) Check the electrical features of equipment and

coordinate with the mechanical features.

(5) Determine that provisions have been made for access

panels.

(6) Check the required controls and valves for compliance

with contract requirements.

(7) Check specification provisions for necessary spare

parts and tools for all of the equipment.

(8) See that operations and maintenance instructions are

with equipment and are posted on the wall upon completion of

installation.

(9) Require proper storage and protection of all materials

and equipment.

(10) Check the noise level of all equipment.

(11) Verify requirements for the installation of flexible

pipe connections and vibration eliminators for equipment.

(12) Check the installation of all equipment for

compliance with manufacturer*s recommendations.
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15E-2

b. Boilers, Furnaces, and Accessory Equipment

(1) Examine pressure boilers for conformance with the ASME

Code.

(2) Check for all necessary connections on the boiler.

(3) Check cast iron boilers, if field assembled, for

tightness of joints.

(a) All joints shall be sealed.

(b) Reject cracked section.

(4) Inspect refractory furnaces built up on the job for

materials and workmanship.

(a) Require expansion joints to be provided. Piping on

both sides of expansion joints should be properly guided.

(b) Insure packing to prevent gas or air leakage.

(c) Reject all cracked, chipped or otherwise damaged brick

and tile.

(d) Check plastic refractories for placement, thorough

ramming, and consistency.

(a) Require refractories to be kept dry.

(f) Inspect for use of refractory mortar in construction

of combustion chamber.

(g) Check for air circulation under the combustion chamber

floors.

(5) Inspect the application of insulation after all joints

are tightly sealed. Check material, thickness, and finish.

(6) Observe accessory equipment operation such as

feedwater controllers, dampers, pressure and draft gages, flow

and pressure recorders, soot blowers, water columns and boiler

blowdown. Check the pressurestat differential.

(7) Check requirement for expansion joint in floor around

boiler.

c. Fuel Burning Equipment

(1) Coal, Hand-Fired. Verify installation of grates and

operation of dumping mechanism.

(2) Coal, Stoker-Fired. Confirm capacity and operation of

feeder, grates, and ash removal.

(3) Oil burners. Check:

(a) Size and type of burner tips

(b) Location of electrodes to insure spark in oil spray

cone

(c) Position of gas or oil pilot
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15E-3

(d) Clearances for removal of burner from furnace.

(e) Burner adjustments.

(f) Carbon dioxide in flue gas.

(4) Inspect gas burners for cleanliness, adjustments,

position of pilot flame, and sensing element. Check regulator

and controls.

(a) Blow out gas line before connecting to burner or

regulator.

(b) Install regulator in vertical position.

(c) Pipe gas vents to the outdoors.

d. Draft Fans

(1) Check fans and drivers for anchorage, alignment, and

rotation.

(2) Check accessibility of lubrication fittings.

(3) Inspect dampers for operation in compliance with

contract requirements.

(4) Inspect bearings for smoothness and overheating.

(5) Check vibration and vibration absorbing mounts.

(6) Inspect insulation application to induced draft fan.

(7) Examine safety control interlocks and sic-flow

switches.

e. Oil Storage Tank

(1) Check for Underwriter*s approval.

(2) Check tank capacity and calibration.

(3) See that tanks have the required openings and the

means for proper anchorage.

(4) Check for tank heaters, when required.

(5) Examine paint coating and examine holiday testing.

(6) Check manufacturers instructions for proper

installation.

f. Circulating, Condensate and Vacuum Return Pumps

Inspect for capacity and for method of mounting.

g. Miscellaneous Fittings and Equipment

Inspect drips, traps, valves, coils, elements, convectors,

radiators, etc., as they are brought on the job, to make sure

that they are of the correct capacity and that they have been

approved.
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15E-4

15E-03 INSPECTION

a. Planning

(1) Check the availability of codes, reference data and

manufacturer*s recommendations.

(2) Check with contractor for his detail layouts of

equipment and piping which are normally made to coordinate work

of the various trades.

(3) Compare nameplate data, piping markings, etc., with

requirements.

(4) provide the proper spacing of equipment to make sure

that there is adequate room fur piping, ductwork, accessibility

for maintenance and that walls behind ductwork can be finished

without duct removal. Check for adequate clearance for removal

of air filters and strainers.

(5) verify how the heating system fits into the total job.

(6) Be sure that sleeves of the correct size and material

are properly located in floors and walls before they are built.

(7) In spite of all attempts to insure that sleeves,

inserts, boxes, and so on, are all in place before concrete is

placed, oversights occur, and it becomes necessary to cut

concrete. Any such operation should be approved by the

supervisor before it is begun. A cut in concrete wall should be

made from both sides of the wall to avoid spalling of the far

surface.

h. Piping

(1) Compare piping workmanship with the check list of

paragraph 15A-03.

(2) Check storage and handling against paragraph 15A-02b.

(3) Inspect for the required type and size of pipe.

(4) Examine the cutting of construction to install piping.

(5) Require provisions for expansion and contraction, and

proper anchorage of pipe.

(6) Check the installation of mechanical expansion joints.

Do not remove spacers until expansion joints are ready to be

installed.

(7) Verify that the pitch of the horizontal runs are

correct.

(8) Check the position of branch connections.

(9) Be sure that required valves are installed in the

correct positions.

(10) Check the method and procedure of jointing pipes.
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15E-5

(a) On threaded joints, check for the use of tapered

threads. See that graphite and oil, or an equivalent, are

applied to the threads.

(b) On welded joints, check for compliance with approved

welding procedures, inspect for defective welds; check type of

material of the welding rod; make sure welders have been

qualified and are stamping their welds. See Chapter 5 and

Chapter 15A for welding inspection guidance.

(11) See that piping is properly aligned and that there is

no strain on joints or on adjacent equipment.

(12) See that proper grade and alignment are maintained

and that proper fittings are provided to eliminate air pockets

and restrictions.

(13) Check for air valves at all high points and at the

ends of mains. Check for drips and traps at low points. Examine

the lines to make sure that condensate cannot accumulate in the

lines.

(14) Inspect for required floor, wall, and ceiling plates.

Check for type, size, material, and finish.

(15) Watch for the use and proper installation of

eccentric fittings.

(16) See that interconnecting piping between boilers

conforms to shop drawings and ASME Code. Watch for adequate

valves and other special fittings. Cutoff valves shall be

provided to isolate each boiler from the steam header.

(17) Be sure that lift fittings are provided where the

gravity flow of vacuum returns is interrupted by a change to a

higher elevation.

(18) Clean all supply and return lines before putting them

into operation. Check whether contractor has cleaned all traps

and strainers after pipe cleaning and before system operation.

(19) Check safety valve discharge pipe for number of ells

(restriction).

(20) Check bent pipe for kinks, wrinkles or other

malformations.

c. Pipe Insulation

(1) Know locations of pipes required to be insulated.

(2) See that insulation has been approved.

(3) Check width and type of material and the spacing of

bands.

(4) Be sure that all fittings except unions and flanges

are insulated.

(5) Be sure that insulation is being correctly installed.

See section 15C Mechanical Insulation.
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15E-6

(6) Check for continuity of insulation through walls and

floors.

(7) Check that proper thickness of insulation is being

applied.

(8) On chilled-water and hot-water combination piping and

boiler piping check for vapor seal requirement.

d. Hot Water Systems

(1) Note the installation of balancing valves or orifices

in the return connection of each radiator or heating device.

(2) See that contractor balances system as required by

plans or specifications.

(3) Insure that threaded openings are provided on

converters. See that safety devices and temperature controls are

furnished and are in working order. Check coil for tightness and

clearance for its removal. Note drain pipe to outside atmosphere

or floor drain from blow—off safety valves.

(4) Check for automatic and manual vents.

(5) Examine expansion tanks for size, conformance to code,

protective paint coating, insulation, water level gage, drain

and air charging valves.

a. High Temperature Not Water

(1) Check pumps for:

(a) Leveling, alignment, and stability on foundation

(b) Lubrication

(c) Seals for leaks

(d) Packing adjustment and type

(e) Pressure retention

(f) Correct rotation

(g) Seal coolant service installed.

(2) Insure that radiant heating coils are accurately

placed, firmly secured, and absolutely tight under a hydrostatic

test pressure of one and one-half times the operating pressure

prior to encasement in construction.

f. Steam Systems

(1) Know details of the type of system required.

(2) Check the operation of supply valves to radiator and

convector.

(3) Check radiator run-out for pitch.

g. Hot Air Heating

(1) Insure that contractor follows NFPA criteria for

installation of oil or gas equipment.
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15E-7

(2) Be sure that return air has free passage to heater

unit.

(3) Note damper setting balance of the flow of air.

(4) Check that flexible connections have been installed

between furnace and duct system.

h. Heating and Ventilating Units

(1) Require that all component parts operate

satisfactorily.

(2) Note access doors for tightness and clearance.

(3) Determine that noise level is within acceptable

limits.

(4) Check flexible pipe connections and/or vibration

eliminators.

(5) Check rotation.

i. Unit Heaters

Check:

(1) Air distribution

(2) Noise level

(3) Controls

(4) Clearances

(5) Rotation

j. Controls

Be sure that the controls are provided, as specified, that

they are properly hooked up, and that they will perform the

required operation.

k. Boilers and Boiler Plants

(1) General Requirements:

(a) Before rolling in, check the cleaning of ends of tubes

and the surfaces of tube holes in drums and headers. Check to

assure that new boilers exposed to weather are covered to

prevent corrosion.

(b) See that tube-rolling is done by experienced workmen

and that all precautions are taken to prevent either under or

over rolling. At this stage of erection request technical

assistance.

(c) Insure that the boiler inspector is notified when it

is time for the hydrostatic test. Obtain Certificate of

Inspection. Do not permit the installation of any baffles or the

setting of refractories until after the boiler has passed

inspection.
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15E-8

(d) Affirm that baffles of steel, refractory tile, or

monolithic construction are installed gas-tight but with

provision for expansion, and that they will resist dislodgment

by "puffs".

(e) Insure that boiling-out operations for the removal of

grease, oil, and other foreign matter are performed before

boiler is placed on-the-line.

(f) Insure that space is provided for tube removal and

cleaning and for general maintenance of all equipment.

(g) Check to assure that during periods of operation by

contractor chemical treatment and blowdown are provided to

prevent scale deposits and corrosion.

(2) Settings

(a) Be sure that all settings are constructed with

provision for expansion and contraction of both the refractories

and the pressure parts. See that expansion joints are sealed to

prevent passage of air or gases but are flexible enough to

maintain their seal under movement of the structure. Check the

entire setting for leaks.

(b) Check solid refractory walls for plumb, level courses

and dipped joints. Check grades of refractories used. Chipped,

cracked, wet or broken refractory materials will be rejected.

(c) Insure that refractory tile and setting casings are

constructed to prevent the escape of gases or the infiltration

of air, and that they are installed in accordance with the

recommendations of the manufacturer.

(d) Insist that all openings through setting walls are

accurately located and of proper size. Check temperature of

boiler setting surface against room temperature.

(a) Verify that pipe sleeves for draft gages are clean and

flush with interior face of wall.

(f) Inspect uptake damper for correct location, bearing

material, and freedom of operation when hot.

(3) Fuel Burning Equipment

(a) Correlate coal stokers with stationary grates for

accurate placement and support of the grate bars. See that

shaking and dumping mechanism will work freely under operating

temperatures.

(b) Evaluate traveling and moving grates for alignment of

running parts and guides, tightness of seals, and provision for

expansion and contraction.

(c) Note lubrication and protection of motors, gears, and

bearings.

(d) Examine all moving parts for operation under

temperatures encountered and for loads specified.

(e) Insure that grate design and coal sizing are suitable

for each other.
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15E-9

(f) See that stoker feeding mechanism is adjusted to

distribute the coat evenly over the grates.

(g) Verify that pulverizers are constructed and installed

as nearly dust-tight as possible. Be sure the equipment is

firmly secured to foundation. Check units for proper balance and

quiet operation at normal operating speeds.

(h) See if pulverizers are adjusted for proper coal

fineness. Notice whether heat is applied to the coal in the

pulverizer, or that temperatures are obtained prior to entrance

of coal to assure satisfactory dryness of coal.

(i) Insure that burners are adjusted for efficient

operation, minimum excess air, stable ignition at low rating,

and no impingement on furnace walls. Use a boiler test kit when

required.

(j) Evaluate the coal feeder for accurate and even

operation.

(k) Examine the installation of access and inspection

doors.

(l) View magnetic separators for location ahead of

pulverizers.

(m) All safety precautions are to be observed in the

installation of gas burners and piping. Arrangement of gas

valves should be in accordance with ASA Standard Z 21.33.

(n) Burners should be arranged to permit ready inspection

and servicing.

(o) Note location of pilot flame. Provision shall be made

to facilitate manual lighting of pilot flame. Hand torch and

receptacle should be provided for each boiler.

(p) See that mixing dampers or valves are adjusted to

proportion air and fuel for the most efficient combustion with

minimum excess air and stable operation of low rating, with no

impingement on furnace walls.

(q) Compare all dimensions of the combustion chamber

during construction for agreement with manufacturer*s approved

shop drawings. Check all materials of construction for

compliance with specifications and approved shop drawing. Take

physical samples of all tile, insulating plastic, firebrick,

etc., for future reference.

(r) Check type and capacity of heaters for grade of oil.

(s) Check relief of excess pressure in pumps.

(t) Test oil piping for leaks.

(4) Draft Fans and Ductwork

(a) See that induced draft fans are provided with cleanout

doors.

(b) Verify the operation of dampers at high flue gas

temperatures.
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15E-10

(5) Blow Down System

(a) Insist that work conforms to applicable codes.

(b) Observe location of vent and discharge lines.

(c) Require that piping provides for expansion and

contraction.

(6) Combustion Controls

(a) Inspect equipment for type, capacity, installation,

and operation.

(b) Be sure that operating devices are firmly secured to

floor, foundations, or other supports and that they operate

freely. They should have sufficient power to easily perform

their duties.

(c) Check the location and stability of sleeves in setting

walls, ducts or breechings for draft piping, thermometers and

gages.

(d) Pipe, tubing, and wiring should run neatly and

Parallel to the lines of building or structure. They should be

firmly secured and have proper pitch. See that draft piping is

provided with means for removing accumulations of ash and soot.

(e) Verify the operation of safety controls.

(f) Check that flame-sensing device is installed in

position to sense both pilot and main flame.

(g) Determine that instrument panels are firmly anchored

and set plumb. Be sure that wiring, tubing, and piping are

neatly arranged in rear of panel. See that nameplates,

indicating the function of each instrument, are mounted on the

face of the pane.

(h) Secure a written statement from manufacturer*s

representative to the effect that all equipment of the control

system is properly installed and in perfect operating condition

before acceptance.

(7) Economizers and Air Heaters

Check for tightness of tubes or plates and for evidence of

erosion or corrosion whether integral with the boiler or

separate units. Observe performance.

(8) Fly Ash Collectors

Check:

(a) Inspection and cleanout doors for location and

adequacy

(b) Dampers for free operation under all temperature

conditions.

(c) Discharge grates for leakage of either ash or air.
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(9) Boiler specialties

(a) Verify all trimmings such as water column, steam gage,

safety valves, blowoff valves, nonreturn valves, stop and check

feed valves and vent valves for type and size. Inspect for

installation and setting.

(b) Check that safety valve discharge piping is anchored

so that it does not impose a strain on valve.

(10) Soot Blowers

(a) Determine operating pressure of steam operated unite.

(b) Note materials of elements and bearings.

(c) See that wall boxes are accurately and firmly set and

that the operating heads are securely fastened. Insure that each

element operates freely and that it may be removed without

disturbing tubes or setting.

(d) Check clearance for the removal of soot blowers.

(e) Insure that drainage is provided to prevent moisture

from being blown into the furnace.

(11) Check for correct location and installation of test

holes in breechings and stacks to allow for periodic measurement

of fly ash and other particulate matter for air pollution

control.

(a) Inspect breechings for gage (thickness) of metal,

supports, and insulation.

(b) Examine cleanout doors for tightness, location, and

size.

(c) Check expansion joints for tightness and location.

(d) Check caulked joint at opening around breaching

entering masonry chimneys.

(e) Check guys, bracing or other supports.

(f) Reject damaged or unsuitable brick and radial block.

See that all courses are brought up together and bonded.

(g) In reinforcement operation inspect materials and

accuracy of placement. Observe especially the lapping of bars.

(h) Evaluate the material and the setting of embedded

items for securing ladders, platforms, cables, lights, doors, or

other equipment.

(i) Check openings and locations of test holes in

breaching. Check cleanout door for size and location.

(j) Check closing and latching of cleanout doors.

(k) See that firebrick lining covers the chimney area and

that weep holes are provided at bottom.

(l) Check continuous-pour type concrete chimneys for a

smooth, jointless exterior finish.
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(m) Determine if ladders are sturdy, securely anchored,

and provided with safety cages where required.

(n) Verify that metal vent cap, when required, is firmly

secured and coated for prevention of corrosion.

(o) Identify requirement for obstruction lights and

lightning protection. Check access to them for servicing.

(p) Insure that chimney is plumb, concentric, and has

uniform taper from top to bottom.

(12) Boiler Feedwater

Check:

(a) Type of water treatment for:

- Water available.

- Pressures and temperatures to be obtained in boiler.

- Materials and installation.

(b) Scales, proportioning devices, and mixing valves for

accuracy and operation.

(c) Installation of tanks and piping for types of material

and supports, workmanship, and conformance with contract

requirements.

(d) Pressure tanks for conformance with the applicable

codes and ASME stamp.

(e) Control apparatus for the installation and operation

of all components. Check should be done by the manufacturer*s

service engineer. Refer to job specifications for necessary

tests and reports required, and determine from service engineer

the sequence of testing.

(f) Open heaters for the installation of pans, trays,

plates, sprays, and other internal parts, as well as for the

setting of the control for water level in storage compartment.

Be sure that heater vent operates and that the heater reduces

the oxygen content in the water to the specified amounts before

acceptance. Checking should be done by manufacturer*s service

engineer.

(g) Closed heaters for compliance with code governing

unfired pressure vessels. Assure that clearance is provided for

the removal of tubes. Evaluate performance.

(h) Thermometers and gages for accuracy and operation.

(13) Turbines.

(a) Inspect equipment for the pressures and temperatures

to he applied. Compare with approved shop drawings.

(b) Examine all drains, drips, leakoffs, relief valves,

and other required safety devices for operation.

(c) Insure that turbines are firmly secured to foundation,

are accurately aligned with driven equipment, and operate

without vibration.
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15E-13

(d) Check that piping is installed to impose no strain on

turbine connections.

(e) Verify that provision is made for expansion when

aligning couplings.

(f) Be certain that field—assembled turbines are installed

by the manufacturer*s erectors only

(g) Reduction gears must mesh perfectly and operate

smoothly and without noise or vibration. Check dwelling after

turbines and gears are in perfect alignment.

(h) Evaluate the operation of governors.

(i) Check capacity and steam consumption under various

load conditions.

1. Smoke Connections

(1) Examine the size and construction of stacks and flues.

(2) Check the clearance space between stacks, flues, and

adjacent building materials.

(3) Inspect the method of supporting and anchoring all

smoke connections.

(4) See that cleanout is provided which will allow

cleaning of the entire smoke connection without dismantling.

m. Fuel Storage and Conveying

(1) Inspect overhead bunkers for capacity in conformance

with specifications. See that all gates are installed dust—

tight and that they operate freely. Note the sealing of spaces

around top of bunkers and elevators.

(2) Be sure that silos are erected plumb and concentric.

(3) See that courses in tile, brick or block silos are

carried up evenly, that horizontal joints are level, and that

reinforcement is welded and thoroughly embedded.

(4) Tight joints and reinforcement bands for concrete

stave silos must be pulled up tightly.

(5) Check continuous-pour type concrete silo for a smooth,

jointless exterior finish.

(6) Determine whether pneumatic conveyers are installed

with air and dust—tight joints.

(7) Examine materials and installation of mechanical coal

conveyers.

(8) Insure that screw flights do not ride on bottom of

trough.

(9) See that bucket, chain, and belt conveyor guides and

bearings are carefully aligned.
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15E-14

(10) Evaluate skip hoists for capacity and proper

installation, with particular attention to operation of the top

and bottom limit stops.

(11) Make sure that housings for all conveyors and

elevators are installed with dust-tight joints.

(12) Access doors and connections with chutes and

discharge gates should be tightly fitted.

(13) Observe that chutes are installed with sufficient

slope to insure free, gravity flow of coal.

(14) Check weighing lorries for capacity, accuracy of

weight, and ease of operation.

(15) Verify that vibrating feeders are accurately

positioned and adjusted for specified flow of coal.

(16) Be sure that coal crushers are securely anchored to

foundation or supports and that grids are adjusted to proper

coal size. Ascertain the direction of rotation.

(17) Check coal scales for accuracy of weight and for

operation of component parts.

(18) Track and Truck Hoppers — Insure provision for

removing water from pita. Inspect hopper grids for size opening

and materials.

(19) Note flow of coal of entire conveying system, from

unloading hoppers to boilers.

n. Painting

(1) See that equipment contains the correct finish. Watch

for abrasions.

(2) Watch for miscellaneous ferrous metal items that are

not primed.

(3) Require finish painting as specified.

(4) Identify all pipe runs as specified.

o. Testing

Witness that all required tests of heating equipment are

accurately recorded. See that tests are performed by

manufacturer*s representatives where required. Check tests and

verify that tests meet all requirements before acceptance.

Report unsatisfactory test results to the supervisor.

p. Operating Instructions and Guaranties

(1) See that equipment guaranties and instructions for the

operation of equipment are furnished.

(2) Notify supervisor of the readiness of the construction

for test and subsequent operation for instructing personnel.
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i

CHAPTER 15F

VENTILATING, AIR SUPPLY AND DISTRIBUTION SYSTEM

INDEX

Para. Title Page

15F-01 GENERAL 15F-1

15F-02 EQUIPMENT 15F-1

a. General 15F-1

b. Fans and Air Handling

Units 15F-1

c. Power Roof Ventilators 15F-2

d. Gravity Ventilators 15F-2

e. Dampers 15F-2

f. Filters 15F-2

g. Screens 15F-3

15F-03 DUCTWORK AND MECHANICAL

INSULATION 15F-3

15F-04 DIFFUSERS, REGISTERS,

AND GRILLES 15F-3

15F-05 BALANCING AND TESTING 15F-3

a. Cleaning and Adjusting 15F-3

b. Testing 15F-4
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15F-1

CHAPTER 15F

VENTILATING, AIR SUPPLY

AND DISTRIBUTION SYSTEMS

15F-01 GENERAL

Since the ventilating system is largely dependent upon

associated equipment, the QAR must closely coordinate this

chapter with Chapters 15B, 15C, 15E, and 15G. The same

importance of a thorough knowledge of job plans and

specifications applies.

15F-02 EQUIPMENT

a. General

(1) It is the QAR*s responsibility, in concert with the

quality control man, to determine that all equipment is approved

well in advance of its actual need on the job.

(2) Check all equipment delivered to the site for

conformance with approved shop drawings. Make sure the necessary

rating and test certificates have been furnished.

(3) Closely examine material for any damages. Minor

abrasions or rust spots must be cleaned and repainted to match

original paint in appearance and in quality. Reject other

damages.

(4) Be certain that approved vibration-isolators and

flexible connections will be furnished as specified.

(5) Examine the mounting of each piece of equipment for

secure installation.

(6) Check equipment for excess noise and vibration.

(7) Do not use dissimilar materials, especially screws,

fasteners and flashings with different equipment bases and

housing materials.

b. Fans and Air Handling Units

(1) Check rotation of fan before permanent power

connection is made.

(2) Check method of drive. If belt driven, check means

provided to adjust the motor.

(3) Check the type of motor enclosure.

(4) See that specified seals, sleeves and bearings are

provided, and when lubricating type bearings are allowed provide

accessibility for lubricating without dismantling fan or

disconnecting duct.

(5) Provide a fire-safety switch on return air ducts of

circulation systems.

(6) Check for pulley and belt alignment.

(7) See that adequate guards are provided for rotating

equipment and belts.
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(8) Check for installation of smoke detectors when

required.

c. Power Roof Ventilators

(l) Provide service accessibility.

(2) Flashing at curbs must be water-tight.

(3) Discharged air is not to be directed toward air

intakes.

(4) Check for required local disconnect switch.

d. Gravity Ventilators

(1) Examine installation for rigidity and

weathertightness.

(2) Make sure units are oiled and properly adjusted.

(3) Check the actual freedom of rotation of the blades.

e. Dampers

(1) Backdraft dampers should be installed for each exhaust

fan.

(2) Check the actual operation of the dampers. See that

dampers do not rattle and that felt strips are provided for

backdraft dampers.

(3) Assure that a separate frame is provided in openings

on which the dampers will be mounted.

(4) Check for correct installation of fire dampers in

accordance with SMACNA Fire Damper Guide.

f. Filters

(1) Make sure the proper type of filter is furnished and

installed.

(2) Check thickness and method of mounting and supporting.

(3) Provide proper amount of adhesive and washing tank for

viscous medium type filters.

(4) Inspect sealing strips.

(5) Provide accessibility for removal and replacement of

filters.

(6) Assure that air stream is distributed uniformly over

all filter areas.

(7) Observe electrostatic-type filters for operation of

warning lights and door interlocks. Check ionizers for loose

wires, sparking, and free access.

(8) Inspect automatic sprays for complete washing and

spray coverage.
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15F-3

(9) On traveling screen type filters note the operation of

screen and oil charge.

(10) On renewable roll media type filters inspect:

(a) Tracking of roll

(b) Media runout switch (c) Timer setting (d) Static

pressure control

(a) Tension on media

(11) See that clean filters are installed upon completion

of final tests.

(12) Check specifications regarding requirements for spare

filters. This requirement is sometimes expressed as a percentage

of the total of each kind required. Check on the transfer of the

spares to the operating agency.

g. Screens

(1) Provide bird or insect screens if required.

(2) Check fabric material and installation of dissimilar

materials.

(3) Check mesh size.

15F-03 DUCTWORK AND MECHANICAL INSULATION

See Section 15D for Ductwork. See Section 15C for

Mechanical Insulation.

15F-04 DIFFUSERS. REGISTERS. AND GRILLES

(a) See that the contractor furnishes a schedule showing

all air inlets and outlets.

(b) Inspect diffusers and registers for accessible volume

control operator.

(c) Examine specification and installation for integral

anti-smudge rings for diffusers.

(d) Check for loose or bent vanes.

(e) Inspect each item for fit, and see that sponge-rubber

gaskets are provided when required.

(f) Inspect for the proper operation of registers,

dampers, and grille directional-controls.

15F-05 BALANCING AND TESTING

General Check for any required certification of HVAC test

and balance subcontractor/agent, prior to their arrival at site.

a. Cleaning and Adjusting
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15F-4

(1) All ducts, plenums and casings must be thoroughly

cleaned of debris and blown free of small particles and dust

before supply outlets are installed.

(2) Clean equipment of oil, dust, dirt, and paint spots.

(3) Replace sectional throwaway filters after ductwork is

blown out and cleaned.

(4) Lubricate all bearings.

(5) Check tension on all belts and the adjustment of fan

pulleys.

(6) Check that all fan and belt guards are in place.

(7) Install temporary filters for tasting purposes.

b. Testing

(1) Before insulating duct test it for air tightness.

(2) Contractor must provide necessary equipment for

airflow measurements and coefficients for registers and

diffusers.

(3) Review contractor*s method for recording test data,

including comparison to the design air-flows.

(4) Test each outlet for the amount of air quantities

required.

(5) Final air-flows must be recorded after all adjustments

are made.

(6) If actual air flows result in objectional velocities

or distribution, notify your supervisor.

(7) Check all dampers for proper operation.
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i

CHAPTER 15G

REFRIGERATION AND AIR CONDITIONING

INDEX

Para. Title Page

15G-01 GENERAL 15G-01

15G-02 PIPING 15G-01

a. Refrigerator Piping 15G-01

b. Water Piping 15G-01

c. Installation 15G-01

d. Insulation 15G-02

15G-03 EQUIPMENT 15G-03

a. General 15G-03

b. Condensers 15G-04

c. Reciprocating Compressors 150-04

d. Centrifugal Compressors 15G-05

e. Receivers 15G-05

f. Water Chillers 15G-06

g. Evaporative Coolers 15G-06

h. Unit Coolers 15G-06

i. Refrigeration Specialties 15G-06

j. Package-Type

Air Conditioners 15G-07

k. Washers 15G-07

l. Humidifiers and

Dehumidifiers 15G-08

m. Absorption Refrigeration

Machine 15G-08

n. Cooling Towers and Ponds 15G-08

o. Pumps 15G-09

p. Insulation 15G-09

15G-04 CONTROLS 15G-10

15G-05 TESTING 15G-10

a. Submittals 15G-10

b. Procedures 15G-11

c. Types 15G-11

15G-06 PAINTING 15G-11

15G-07 OPERATING INSTRUCTIONS AND

GUARANTIES 15G-11
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15G-1

CHAPTER 15G

REFRIGERATION AND AIR CONDITIONING

15G-01 GENERAL

This chapter covers Refrigeration and Air Conditioning for

both the central and unitary type systems.

Since there is generally a duplication in the requirements

for piping and ductwork for this subject and for plumbing and

air handling, and since those areas have been covered in

previous chapters, it will be necessary for the inspector to be

very familiar with the piping area of Chapter 15A and the

ductwork section of Chapter 15C.

When the work appears to be beyond the scope of the

inspector, technical assistance should be requested promptly.

15G-02 PIPING

a. Refrigerator Piping

(1) Determine where copper or black steel will be used,

and the type required.

(2) Make sure the piping and fittings have been approved.

(3) Check the method of installing piping. See Section

15A.

(4) Make sure piping is stored as prescribed in

specifications.

b. Water Piping

(1) Check the type of piping required for chilled water

and condenser water systems. See Section 15A.

(2) Determine weight and class of piping.

(3) Make sure the specified and approved piping, fittings

and jointing materials are being used.

c. Installation

(1) Utilize paragraphs 15A-02 and 15A-03 as a check list

for fabricating and installing piping. Watch specifically for

workmanship, supports, and sleeves.

(2) Be especially careful to:

(a) Make sure the specified solder is used. Check

soldering of joints.

(b) See that internal valve parts are removed from valves,

and that valves are wet wrapped before soldering.

(c) See that joints are thoroughly cleaned before

soldering.

(d) Check on the removal of excess flux and acid after

joints are made.
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15G-2

(3) Make sure the proper type flexible connections are

installed in the required locations.

(4) See that unions or flanges are installed at all

equipment, at control valves, and at other points that will

facilitate maintenance.

(5) Check carefully for the proper slope of all lines.

Assure slope of refrigerant lines to provide movement of oil

through the system.

(6) Check installation for improper configuration of

piping. Make sure the installation conforms with the approved

drawing. If there is any question about the requirement for the

arrangement of piping and if there is no approved drawing,

obtain the drawing before allowing the contractor to proceed.

(7) Make sure air vents are installed at high points in

water lines and that drains are installed at low points.

(8) Do not allow gate valves to be installed where globe

valves are required.

(9) Be sure balancing cocks are installed as required to

permit proper balancing.

(10) Do not install swing check valves in vertical lines

with a downward flow of water.

(11) Check for the installation of such required items as

pressure gages, thermal elements, thermometer wells, etc.

(12) Provide adequate number and type of hangers. Hangers

on uninsulated copper pipe must be electrolytically coated or

made of solid compatible non ferrous metals.

(13) Check for the proper installation of oil traps and

double risers in refrigerant lines.

(14) Check valves for pressure setting and discharge

locations.

(15) Be sure that refrigerant system is evacuated prior to

charging and accomplished according to job specifications.

(16) Make sure the system is charged with the required

type and amount of refrigerant.

(17) See that the system is completely checked for leaks.

Dry nitrogen must be used for pressure tests.

(18) Double check to see that there are no unnecessary oil

traps.

(19) Vacuum should be broken by charging the system with

dry refrigerant for which the system is designed.

d. Insulation

(1) Determine whether the material on the job has been

approved for the particular piping being installed. Make sure

insulations, vapor barriers, adhesives and sealers are

noncombustible or fire retardant as specified. See Section 15C

Mechanical Insulation.
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15G-3

(2) Note that heating water piping is insulated

differently from both chilled water piping and combination

chilled and heated water piping.

(3) Check thickness of insulation and of vapor barrier

finish.

(4) Determine that insulation jackets which are exposed to

view are paintable.

(5) Examine the requirements for the insulation of

flanges, fittings, and valves, and assure compliance with the

specifications.

(6) Check the lap and the sealing at joints.

(7) Be very careful to see that there are no breaks in the

vapor barrier. Watch for later damages during construction.

(8) Check specification requirements for extending

insulation through sleeves in walls, floors, and ceilings;

chilled water lines inside cabinets of fan coil units should be

insulated as required to prevent condensate dripping on floor.

(9) Make sure that pipe hangers are installed over

insulation. Metal Shields to be provided between hanger ring and

insulation. High density insulation insert shall be installed

with a length equal to length of metal shield.

(10) Check for the neat termination and seal of insulation

at the end of insulation.

(11) Know the special requirements for insulation and

jacketing of piping exposed to weather.

(12) Check the installation, the width, and the spacing of

the bands used on pipe jacketing.

15G-03 EQUIPMENT

a. General

(1) All equipment should be checked to see that it is

approved before it is needed on the job. When equipment arrives

on the job, it should be checked against shop drawing. During

installation, the contractor*s work should be checked against

the contract plans and specifications, the approved shop

drawing, and the manufacturer*s recommendations.

(2) Be sure that no damaged equipment is installed.

(3) See that equipment is stored in a manner that will

insure that the equipment be like new when installed.

(4) Be sure that all refrigeration equipment is installed

strictly in accordance with the safety code for mechanical

refrigeration.

(5) Check on space requirements for equipment. Obtain an

equipment room layout drawing and make sure that adequate

clearances are provided for maintenance and operation.
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(6) Determine the need for access panels. A common error

is the failure to provide the means for pulling condenser and

chiller tubes.

(7) Make sure that all rotating parts, such as belts,

chains, sheaves, shaft couplings, etc. are covered to protect

personnel.

(8) Check the type of motors on equipment, the type of

motor starter, heaters in the motor starters, and voltage of

motor.

(9) Make sure all equipment is lubricated according to

manufacturer*s recommendations. This includes motor bearings.

b. Condensers

(1) See that air flow is not obstructed and that wind

deflectors are installed, if required, in air cooled condensers.

(2) Inspect water cooled condensers for leaks and proper

flow.

(3) Check evaporative condensers for:

(a) Spray coverage.

(b) Float valve operation without chatter.

(c) Water level.

(d) Fan rotation and speed.

(e) Pump suction strainer.

(f) Liquid discharge line carried full size to first

elbow, with a 12-inch to 18-inch drop to receiver.

(g) Mesh size of inlet screens.

(h) Pan, casing, eliminators, fan corrosion protection,

and complete drainage.

(i) Provision for and adjustment of constant bleeding.

(4) For all season air cooled condensers manufacturers

recommended installation should be adhered to. Check project

plans, specifications, and manufacturers recommended

installation to see if condenser flooding or air volume control

is required.

c. Reciprocating Compressors

Check for:

(1) Oil, suction, and discharge pressures.

(2) Shaft alignment on direct-driven machines.

(3) Operation of high pressurestat, low pressurestat, and

oil pressure failure switch.

(4) Proper level viscosity of oil.
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15G-5

(5) Installation of required gages.

(6) Amount, correct type, and dryness of refrigerant

charge.

(7) Pressure holding ability upon pump-down.

(8) Isolator deflection and compressor vibration.

(9) Suction strainer screen mesh, and removal of startup

belts.

(10) Unloader action.

(11) Compressor speed.

(12) Belt tension and alignment.

(13) Motor amperage under maximum load.

(14) Refrigerant flood back and oil foaming.

(15) Cylinder head overheating.

(16) Rotation.

(17) Automatic oil heater in crank case. Heater should

work during shutdown.

(18) Loops in refrigerant piping as loops will permit oil

to be trapped.

(19) Damage of equipment compressor — should not be run

during vacuum tests.

d. Centrifugal Compressors

Check for:

(1) Alignment of compressor, drive and gear box.

(2) Suction damper or inlet vane operation.

(3) Safety control circuit operation.

(4) Purge compressor operation.

(5) Float valve operation, if furnished.

(6) Oil pump and cooler operation.

(7) Noise and vibration.

(8) Required gages.

e. Receivers

Check for:

(1) Location, if installed on the outside of the building.

Do not place in direct rays of sun.

(2) Relief valves are adequate size.
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15G-6

(3) ASME Stamp.

(4) Drain, purge valve, liquid level indication, and shutoff valves.

f. Water Chillers

(1) Examine water drains, vents, and correct pass

arrangement in direct expansion type chillers.

(2) Inspect for freeze protection safety devices.

(3) Check strength of liquid bleed-off at bottom of

flooded chillers. Check adjustment of level control.

(4) Check tubes and shell in brine chiller for type of

material.

g. Evaporative Coolers

Inspect for adequate spray coverage, non sagging media,

water carry-through, correct water level in sump, and lack of

float valve “chatter.

h. Unit Coolers

Check:

(1) For corrosion—protected pan and casing.

(2) Water defrost units for spray coverage with no

carryover.

(3) Electric defrost units, for cycle timing in accordance

with the job conditions.

(4) Hot gas defrost, for suction pressures and refrigerant

charge in accordance with manufacturer*s recommendations.

(5) Drainage during defrost cycle.

(6) Cycle timing.

(7) That drain lines are properly trapped on the warm end.

i. Refrigeration Specialties

Check:

(1) Superheat setting of expansion valves and that bulb

and equalizer position is in accordance with the manufacturer*s

recommendations.

(2) Solenoid valve for vertical stem, correct direction of

refrigerant flow, and manual opener disengaged.

(3) Unobstructed view of sight glass.

(4) Operation of evaporator pressure regulator under light

load.

(5) Operation of hold-back value upon start-up.
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15G-7

(6) Float valves or switches mounted level and at a height

which will insure correct liquid level in the evapoess before

opening of refrigerant drier canisters.

(7) Airtightness before opening of refrigerant drier

canisters.

(8) Drier; if it is the replaceable type, piping will be

arranged to facilitate replacement — 3 valve bypass.

(9) Piping connections of liquid-suction heat exchanger.

(10) That direct expansion coils are installed as

recommended by manufacturer.

(11) That pans of fan-coil units are protected against

corrosion.

(12) That drain pans are installed under all units, or as

needed, to collect condensate.

j. Package-Type Air Conditioners

Check the following:

(1) High-pressure cutout setting.

(2) Compressor hold-down bolts (for shipping) removed.

(3) Drip pan should be watertight and connected to open

drain.

(4) Water regulator valve operation, if used.

(5) Installation of air filters and strainers.

(6) Operation of thermostat.

(7) Suction and discharge pressures of refrigeration

compressors.

k. Washers

(1) Check the following features of the spray-type air

washers:

(a) All nozzles discharging water spray.

(b) No water should carry over from eliminators.

(c) Eliminators must not rattle, and they must be

removable for maintenance.

(d) Float valve should not “chatter” on opening or

closing.

(2) Check the following features of the capillary—type

washers:

(a) Media should not sag in frames.

(b) Wetting of all media.

(c) Water level is at correct height.
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l. Humidifiers and Dehumidifiers

(1) Examine the humidifiers for supported coil and

corrosion-protected pan.

(2) Check refrigeration type dehumidifiers for frosting of

cooling coil and for water carry-over.

(3) Check absorption type dehumidifiers for the following:

(a) Solution level and temperature controls.

(b) No solution should carry over from eliminators.

(c) Regenerator duct must be drained of specified

material, and correctly sealed.

(d) Damper operation, cycle timing, evidence of “dusting”

of the desiccant, and regenerative temperatures.

m. Absorption Refrigeration Machine

Check the following:

(1) Cleanliness of all parts during erection.

(2) Proper materials.

(3) Access for removing tubes from absorber-evaporator and

generator-condenser.

(4) Control operation, especially high and low-limit

temperature cutouts or condenser water pump interlock.

(5) Operation of purge system.

(6) Unit to be fully charged with water and a nontoxic

absorber after installation.

(7) Services of a factory representative for charging,

testing, starting the plant, and providing instruction.

n. Cooling Towers and Ponds

(1) Check mechanical-draft cooling towers for unobstructed

air intake, fan rotation and speed, belt tension, stacked fill,

and weather protection of motor. (Do not allow open fan motors

when totally enclosed motors are specified.) Insure that

water—flow through outlet does not form a vortex which draws air

in with the water. Check operation of water temperature control

and drainage devices.

(2) Observe spray ponds for evenness of sprays and for

water drift.

(3) Insure provision for an adjustment of constant bleed.

(4) See that mist eliminators are installed when

specified.

(5) Insure the installation of over-flow and drain piping.
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15G-9

(6) See that the water is at adequate level after

operation, and that spray-pump operates.

(7) Check belt alignment and tension.

o. Pumps

(1) Assure that manufacturer*s name-plates, equipment,

serial numbers, or code stamps are not covered or hidden from

view after installation.

(2) Check for anchorage of pump in compliance with

contract.

(3) Check alignment of pump with motor and piping.

(4) Make sure that all gages and meters are provided.

(5) See that eccentric reducers, in lieu of concentric

reducers, are used in suction piping, and that the flat side is

turned up.

(6) Check for adequate support of piping around pump.

(7) Be sure check valve is installed in discharge piping.

(8) Check pump packing. Make sure adequate packing is

installed to allow gland take-up.

(9) Check for excess vibration and flexible piping

connections if required.

(10) Make sure that the pump motor is weatherproof when

specified, and that it is connected to rotate correctly.

(11) Recheck oil sumps after operation, if applicable.

p. Insulation

(1) Check for:

(a) Proper insulation of chilled water pumps.

(b) Insulated converters and expansion tanks.

(c) Insulated condensate drain pans of air handling units.

(d) Protective finish over such items as pumps, converters

tanks, fans, etc.

(2) Insure that all insulating materials have been

approved and that they are of the specified thickness.

(3) Check the method of attaching insulation to equipment.

(4) Make sure that specified reinforcing is provided in

adhesive plaster finish.

(5) See that corner angle beads are installed at the

specified corners.
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15G-10

(6) See that the adhesive finish coat has smooth, pleasing

finish.

(7) Check on the application of vapor barriers to see that

they effectively seal out all moisture.

15G-04 CONTROLS

a. Review all control installations with approved control

shop drawings, to assure that they are being installed in strict

conformance with the drawings.

b. See that dampers are mounted securely on rigid

supports, and that the correct bearings are provided on the

blade axles.

c. Note damper motors while fan is on, and check linkage

between damper and motor.

d. Examine valve operations for tight closing.

e. Examine electrical equipment for interlocking.

f. Check on the installation of all required alarm bells.

g. See that freeze—stats are installed as specified.

h. Check for proper electrical current and voltage in the

control system. Carefully check the operation of solenoid

valves.

i. Check that air compressor location will permit tank

drain operation, and check for cycle time with all operating

controls.

j. Verify clean elements in humidistats when the system is

started.

k. Evaluate pneumatic systems for air—tightness,

restrictions caused by flattening of the tubing, and cleanliness

of the system.

l. Inspect electronic systems for grounded shielded cable,

and location of amplifiers with respect to magnetic fields, such

as large transformers.

m. View graphic panels for damaged plastic, dirt between

plastic and back plate, lacing of control wires and access for

service to all controls.

n. Verify control instructions, including sequence of

operations, and control drawing furnished by the contractor when

conducting final acceptance test. Check each function of the

controls.

15G-05 TESTING

a. Submittals

Be sure the contractor obtains approval of test procedures

and other pertinent information prior to testing.
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15G-11

b. Procedures

(1) Make a record of all tests, including such information

as who attended, methods and procedures of test, results, and

conclusions. Check specifications to determine that contractor

is recording sufficient data to comply with requirements.

(2) Before tests are scheduled, see that contractor has

proper tools, equipment, and instruments, and gages should be

certified and pretested.

(3) See that equipment is thoroughly checked and prepared

for tests.

(4) Make sure strainers and filters are clean immediately

prior to test.

c. Types

(1) Check the testing of refrigerant piping. See that

specified pressure is put on the lines. Make sure all joints are

checked, and that leaks are detected, repaired, and retested

until found satisfactory. Isolate all items which may be damaged

by high pressure.

(2) See that hydrostatic test is performed on all water

piping. Carefully check to see if there is a loss in pressure

during the test.

(3) See that a performance test on the system is run for

the duration specified. Make sure needed corrections and

adjustments are made as determined during test. See that the

contractor records all data required for the performance test.

(4) After successful tests, install a new oil charge in

compressor. Change oil filters and socks, and provide new

cartridge in refrigerant drier. (Oil charge is not required for

factory sealed units)

15G-06 PAINTING

a. See that equipment is furnished with the correct

finish. Watch for abrasions.

b. Watch for miscellaneous ferrous metal items that are

not primed.

c. Require touching up, priming, and finish painting as

specified.

d. Apply asphaltic varnish on all hangers and other items

not to be painted.

e. Require piping identification on coding as specified.

15G-07 OPERATING INSTRUCTIONS AND GUARANTIES

a. See that equipment guaranties, schematic flow diagrams,

and instructions for the operation of equipment are furnished

and posted.

b. Arrange for future operating personnel to be instructed

on the operation of equipment. Make a record of instruction

periods, including any complications, instructing personnel, and

personnel instructed.
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i

CHAPTER 15H

FIRE PROTECTION SYSTEMS

INDEX

Para. Title Page

15H-01 GENERAL 15H-1

a. Definition 15H-1

b. Approvals 15H-1

c. Storage and Handling 15H-1

d. Coordination of Work 15H-1

15H-02 SPRINKLER SYSTEMS 15H-1

a. General 15H-1

b. Materials 15H-2

c. Water Supply 15H-2

d. Aboveground Piping 15H-2

e. Sprinkler Heads 15H-2

f. Drains 15H-3

g. Wet Pipe Systems 15H-3

h. Dry Pipe Systems 15H-3

i. Deluge Systems 15H-4

j. Sterilization 15H-4

k. Alarm Facilities 15H-4

l. Testing 15H-4

15H-03 PIPING, INSULATION,

 AND INTERIOR ELECTRICAL 15H-4
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15H-1

CHAPTER 15H

FIRE PROTECTION SYSTEMS

15H-01 GENERAL

a. Definition

This chapter covers materials, equipment, and good

workmanship practices for Fire Protection Systems.

b. Approvals

(1) Review Eng Form 4288, Submittal Register, and insure

that all material equipment, and shop drawings are approved prior

to preparatory inspection, and prior to either fabrication or

installation. Obtain any helpful manufacturer*s installation

information.

(2) Insure that seismic restraints are shown on shop

drawings.

c. Storage and Handling

(1) Insure that all materials and equipment are handled

carefully to prevent damage.

(a) Reject damaged material and equipment. Have such items

removed from the site.

(b) Have damaged coatings repaired.

(2) In handling heavy pipe use wide belt slings to avoid

damage to pipe coatings.

(3) Check storage facilities for adequate weather

protection, possible damage, and safety hazard.

(4) When outside storage is necessary, store materials and

equipment above ground.

d. Coordination of Work

Continually check for interferences between electrical,

mechanical, architectural, and structural features especially in

ceiling area and along walls where fire protection system is to be

installed.

15H-02 SPRINKLER SYSTEMS

a. General

(1) Assure that fire protection systems serving occupied

buildings are not shut off for repairs without advance notice

being given to proper authorities.

(2) Note valves and equipment proposed for location within

reach of flood waters. Call to the attention of your supervisor.

(3) Do not take water from fire mains for domestic use.

(4) Identify painting and coding requirements.
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15H-2

(5) Check that sprinkler heads are not painted.

b. Materials

(1) Coordinate fire department hose connections for use

with local fire department hose.

(2) Inspect pipe, fittings, and valves. Pipe that is

properly reamed is free from burrs and fins.

c. Water Supply

(1) Evaluate plan of work to minimize interruption of water

service.

(2) Insure that water line is located below local frost

line.

(3) Block off ends of supply lines terminating in building

or valve house.

(4) Be certain that pipe joints are left exposed until

final inspection and tests are made.

(5) See that turns in supply line are braced, blocked or

clamped.

d. Aboveground Piping

(1) Notice size of pipe. Check to insure all hangers are

tight.

(a) Run parallel to building lines, with slope to drain.

(b) See that branch piping is off top of main.

(c) Where impossible to obtain an even slope, plugs should

be provided at low points so that the entire system may be

drained. Check for inspection test connections required by NFPA.

(2) See that no cutting of structural members for support

or passage of pipe is allowed.

(3) Insure that holes through fire walls are provided with

sleeves and plates. Sleeves will be provided where pipe passes

through walls and floors.

(4) Check that installation of seismic restraints are

installed as approved.

e. Sprinkler Heads

(1) Be sure that heads in accordance with NFPA 13 are

installed in upright position with recommended clearance to roof

or ceiling surfaces.

(a) When in pendant position return bends will be used if

water is subject to sedimentation.

(b) Where subject to mechanical injury heads will be

provided with approved guards.

(c) All heads will be new and should not be painted.
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15H-3

(2) Determine sprinkler head temperature ratings as proper

for ambient temperatures anticipated in the area; e.g., near

heaters, skylights, etc.

Notify your supervisor in instances where sprinkler head

temperature ratings appear to be inconsistent with anticipated

ambient temperatures.

(3) Spare heads should be provided and arrangements made to

transfer them to the using service.

(4) Where sprinkler heads are shown to be installed in

special hazard areas, such as electronic shops, confirm that

installation will be in conformance with area usage.

f. Drains

See that valves or plugs are provided to insure drainage of

the entire system. Assure that discharger from all drain valves is

visible. They should be arranged so that wide open valve position

under normal pressure will not cause any water damage.

g. Wet Pipe Systems

(l) Insist that piping layout is in strict accordance with

approved drawings.

(2) Alarm check-valve assembly must conform with connection

diagram.

(3) Observe installation of water—flow indicators for

conformance with connection diagram.

(4) Confirm insulation and painting requirements.

(5) Check water flow alarm signal by using wet pipe type of

inspector*s test connection.

h. Dry Pipe Systems

(1) Determine that piping layout is in strict accordance

with approved drawings.

(2) Note dry pipe valve installation for conformance with

connection diagram.

(3) Inspect installation of air compressors. Air supply

line should include flexible connection and orifice plate. Check

motor controller operation. If compressor is equipped with an air

storage tank, assure that condensate water drain is provided at

bottom of tank.

(4) Examine locations and operation of condensate chambers;

i.e., drum drips.

(5) Check water flow alarm signal time and dry valve trip

test time by using the dry pipe type of inspector*s test

connection.

(6) Where dry pipe valve accelerators are provided, check

for proper operation.

i. Deluge Systems
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1 Dec 92

15H-4

(1) Confirm that piping layout is in strict accordance with

approved drawings.

(2) Examine installation of deluge valve assembly.

(3) Inspect and test releasing devices.

(4) Check tripping devices both manual and automatic. Check

provisions to insure against accidental water damage.

(5) Insure that contractor provided portable test units in

good working order.

j. Sterilization

Witness dosage, distribution, retention, and final flushout.

k. Alarm Facilities

(1) Check installations to insure that all alarm devices

have been provided and are in operating condition.

(2) Be sure that electric power for alarm signals is taken

from the house current supply line ahead of the main switch.

(3) Examine alarm system for tie-in with local fire

department.

(4) Check alarm to insure that it can be heard above normal

noise levels.

l. Testing

(1) Review test procedure for adequacy, and witness all

tests.

(2) Protect dry pipe valves against damage during the

tests.

(3) In testing extensions to existing system, insure that

self-indicating blanks are used. Remove upon completion of tests.

(4) Insure that all sprinkler contractor*s certificates

covering materials and tests are properly executed.

(5) Insure that flushing and hydrostatic tests are made in

accordance with the accepted tests specified in Standard 13 of the

National Fire Protection Association.

(6) Insure that all lines and controls are properly

painted, color coded, indentified, tagged, and with directional

flow markings.

(7) Check with supervisor to assure user/fire marshall is

present as needed durin the test.

15H-03 PIPING. INSULATION. AND INTERIOR ELECTRICAL

See Section 15A PIPING SYSTEMS, Section 15C MECHANICAL

INSULATION, and Section 16A INTERIOR ELECTRICAL.
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i

CHAPTER 16A

INTERIOR ELECTRICAL

INDEX

Para. Title Page

16A-01 GENERAL 16A-1

16A-02 GENERAL REQUIREMENTS 16A-1

16A-03 GROUNDING 16A-4

a. Drawings and

Specifications 16A-4

b. Visual Inspection 16A-4

c. Grounds to Metallic

Water-Piping System 16A-4

d. Bolted Connections 16A-4

e. Exothermic Welding

Connections 16A-4

f. Metallic Enclosures 16A-4

g. Incoming Service Conduit 16A-5

h. Grounding Connection 16A-5

i. Ground Rods 16A-5

j. System Neutral and

Equipment Grounds 16A-5

k. System Neutral 16A-5

l. Multiple Connections 16A-5

m. Grounding Resistance 16A-5

n. Electrical Continuity 16A-5

16A-04 WIRING METHODS 16A-5

a. Rigid Metal Conduit,

Intermediate Metal Conduit

(IMC), and Electrical

Metallic Tubing (EMT) 16A-5

b. Cable Systems 16A-9

c. Busway Systems 16A-9

d. Continuous Rigid Cable

Supports or Cable Trays 16A-10

e. Wireways 16A-10

f. Auxiliary Gutters 16A-10

g. Underfloor Duct Systems 16A-10

h. Movable Partitions 16A-11

i. Conductors 16A-11

16A-05 OUTLETS 16A-11

16A-06 DEVICE PLATES 16A-13

16A-07 RECEPTACLES 16A-13

16A-08 WALL SWITCHES 16A-13

16A-09 SERVICE EQUIPMENT 16A-13

16A-10 LOAD CENTER TYPE PANEL BOARDS 16A-14

16A-11 PANELBOARDS 16A-14
EP 415-1-261

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ii

(con*t) 

16A-12 CABINETS 16A-15

16A-13 FUSES 16A-15

16A-14 UNDERGROUND SERVICE CONDUITS 16A-14

16A-15 AERIAL SERVICE 16A-16

16A-16 MOTORS 16A-16

16A-17 MOTOR CONTROL 16A-17

16A-18 MOTOR DISCONNECT MEANS 16A-18

16A-19 LAMPS AND LIGHTING FIXTURES 16A-18

16A-20 EQUIPMENT CONNECTIONS 16A-19

16A-21 TRANSFORMER STATIONS 16A-19

a. Dry Type Transformers 16A-19

b. Transformer Taps 16A-19

c. Liquid—Filled Transformers 16A-19

d. Nameplate Data 16A-19

e. Accessories 16A-20

f. Bushings 16A-20

g. Insulating Liquid 16A-20

h. Grounding 16A-20

i. Ventilation 16A-20

16A-22 SWITCHGEAR 16A-20

16A-23 ENGINE GENERATOR SETS 16A-21

16A-24 ELEVATOR INSTALLATIONS 16A-22

16A-25 MISCELLANEOUS SYSTEMS 16A-22

16A-26 TESTS 16A-22

a. All Testing 16A-22

b. precautions 16A-23

c. Electrical Tests 16A-23

d. Records of Tests 16A-23

e. Description of Tests 16A-23

f. Megger Tests 16A-24

g. Method of Testing 16A-24
EP 415-1-261

1 Dec 92

16A-1

CHAPTER 16A

INTERIOR ELECTRICAL

16A-01 GENERAL

This guide has been prepared to assist the quality

assurance representative in obtaining the quality assurance of

interior electrical installation required by the contract

specifications. It is recognized that specialized technical

aspects of this subject may require the services of an electrical

engineer or technician. When the work appears to be beyond the

scope of the QAR, assistance should be requested promptly from the

immediate supervisor.

During the Preliminary Inspection of each phase of work,

make an inspection of materials prior to installation for

conformance with specification, plans, and approved shop drawings.

ENG Form 4288, Submittal Register, which lists approved materials

is essential to this inspection. Components for interior

electrical work will be inspected before they are installed and

energized. Initial Inspection and followup Inspections will follow

work as required by ER 1180-1-6.

16A-02 GENERAL REQUIREMENTS

a. It is the intent that the electrical installation shall

conform to the applicable rules of the current National Electrical

Code )NEC)*, except where expressly modified by the plans and

specifications. This requirement can be found in the general

section of the project specification for INTERIOR ELECTRICAL. The

appropriate edition of the code will be listed in APPLICABLE

PUBLICATIONS. A copy of the applicable NEC should be readily

available to the general inspector, and he should be readily

available to the QAR, and he should be prepared to use it as a

reference and an authority. However, the NEC is a minimum standard

intended to assure a safe installation. Frequently, Corps of

Engineers project specifications require a higher quality

installation than that which is required by the minimum standards

of the NEC. A substitution or change to the requirements of the

project specification proposed on the basis of being “Okay under

the Code” should not be casually accepted. NEC paragraph

references in the text of this guide are to assist the QAR in

using the Code and to lend authority to his demands for features

not spelled out in the project specification.

b. Watch job conditions at all times to assure that the

electrical work is done at the proper time in relation to other

parts of the building construction.

c. Determine the existence, extent, and classification of

hazardous locations as noted in the contract documentation. If

such locations exist, the installation therein should be strictly

in accord with appropriate sections of the NEC. Do not approve any

doubtful material or workmanship (NEC 500 - 503). Do not fail to

seek advice if needed.

*National Electrical Code (NFPA No. 70-84). Text references

are to the 1984 edition. Copies can be obtained from the national

Fire Protection Association at Batterymarch Park, Quincy, MA 02269

for $15.00.
EP 415-1-261

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16A-2

d. Inspect materials and equipment and approved shop

drawings. If materials are in accord with approved shop drawing

but appear to be contrary to specifications, inform your

supervisor.

e. Examine both contractor and government—furnished

equipment for damage in shipment. Promptly report defective

equipment to your supervisor and accept or reject such equipment,

as directed.

f. Shop inspection by a Government representative may have

been required for some equipment and material. Copies of reports

of such shop inspections should be on hand before acceptance of

material or equipment.

g. Storage of electrical equipment will be done per

manufacturers requirement and in dry locations, free of dirt,

dust, and corrosive fumes, with protection from physical damage.

Storage of switchgear, engine generator units, and

government—furnished equipment will usually require indoor

storage. Temporary heaters may be required or specified to keep

equipment free from effects of condensation. Equipment installed

during construction phases should be protected from dirt and

moisture. A requirement for this protection may be found in

special conditions of the contract (ALSO NEC 110—11.)

h. Require the contractor to furnish all layout drawings

required by the specifications. Electrical contract drawings

should be reviewed and compared with architectural, structural and

mechanical drawings for possible interferences. Examples of this

are:

(1) Are the wall switches located with proper respect to

door swing?

(2) Does location of wall outlets conflict with

installation of baseboard heating units, casework, cabinets or

lockers?

(3) Are there interferences with other building

construction, such as pipes, ducts, overhead doors, sliding doors,

accessibility, etc.? Especially check equipment room layout.

(4) Is relocation of ceiling lighting outlets required,

especially in utility and boiler rooms, to avoid interference with

mechanical equipment?

(5) Will transformers, bus duct or switchgear be subjected

to moisture from overhead floor inadequate?

(6) Have suspended ceilings been lowered, making lighting

fixture clearance from floor inadequate?

i. Temporary electric service will generally be required

during the construction period for lighting, power, and sometimes

heat. The contractor should make early arrangements for such

service to prevent construction delays; and temporary

installations will be located so as not to interfere with

operation of existing facilities or permanent construction.

The contractor should arrange for frequent inspection and

rehabilitation of temporary installation during the course of the

contract to keep it in good repair (NEC-305).
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16A-3

j. Adherence to the requirements of Corps of Engineers

Safety Manual, *EN 385-1-1, is a general provision requirement for

all Corps of Engineers administered projects.

(1) Temporary open wiring should be guarded or isolated by

elevation. Types NM in dry locations and/or NMC in damp locations

(Romex) are suitable for temporary wiring when guarded or isolated

by elevation (EM 385-1-1, paragraph 15D-01 and NEC 320, 336)

(2) Portable and extension cords shall be an Underwriter*s

Laboratory (UL) listed type for the usage. Hard service cords Type

S, SJ, SJO, SJT, SJTO, STO or ST are recommended for this service.

Types NM or NMC are not approved as portable cables or covers (NEC

400).

(3) Ground fault circuit protection for construction sites

is required on all 120 volt, single phase, 15 and 20 Amp

receptacles per NEC 305-4.

k. Use by the contractor of equipment and facilities

permanently incorporated in the structure should be carefully

watched to see that circuits and equipment are not overloaded and

that all work is left in essentially new condition. All protected

safety and working lamps used for temporary lighting shall be

removed when construction is completed, and new lamps shall be

installed in permanent light fixtures (Project Specification:

Lamps.)

l. ENG Form 4288, Submittal Register was prepared and

included in the contract specifications prior to bidding the work.

This list of required equipment will insure timely approval and

will alert the QAR if the contractor has not procured all

equipment. Generally, electrical construction materials and

equipment must be built and tested according to UL requirements.

Listed materials and equipment will bear the UL label. The

Electrical Constructions Materials Directory is available form UL

Inc., Publications Stock, 333 Pfingsten Road, Northbrook, IL

60062.

m. Check shop drawings for all equipment having electrical

connections to be sure that rough-in conduits and circuits are

correctly sized and located.

n. Manufacturer*s representatives are sometimes required to

assist field and contractor personnel in the installation,

assembly, testing and/or initial operation of electrical

equipment. When Government Furnished Equipment is involved, be

sure advance arrangements for such services are coordinated by

Resident Engineer and contractor so that the representative is on

hand when needed because usually the number of days are designated

in the contract and an overrun will result in an additional cost

to the Government. Maintain complete record of all adjustments and

tests made during installation and startup, and of any

peculiarities of the equipment which may be of use to those

responsible for its operation and maintenance. Turn copy of record

over to your supervisor for delivery to the using agency. Retain a

copy of all records for the job file.

o. The using agency should be required to witness tests.

The presence or absence of the using service personnel should be

noted on the test report.
EP 415-1-261

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16A-4

p. Fire ratings of structures shall not be compromised by

electrical installations (NEC 300-21).

16A-03 GROUNDING (NEC 250 and Project Specifications: Grounding)

a. Drawings and Specifications

Drawings and Specifications should be examined carefully to

determine the nature and extent of the grounding system and the

requirements for separate grounding of equipment and structures.

Automatic Data Processing (ADP) , Communications and Health Care

Facilities may have special or seperately derived grounding

requirements.

b. Visual Inspection

Visual inspection should be made of all ground-system

conductors, connections and electrodes as the work progresses.

Ground resistance test: The resistance of all electrodes must be

tested to assure resistance to ground of 25 OHMS or less (Job

specifications or NEC 250-84).

c. Grounds to Metallic Water-Piping System

Grounds to metallic water—piping system should be made on

the street side of the meter. Where this is impracticable, full

size jumper connections should be made around any piping system

elements which can be removed (NEC 250-112).

(1) Make sure that when the water piping system is used for

a ground, the water pipe is a metallic pipe and that no insulating

fitting has been interposed in the pipe between the ground wire

connection and earth. (NEC 250-81). An additional ground electrode

shall supplement the connection to the water pipe system (NEC 250-

81 or NEC 250-83).

(2) Where metallic water main is not available, driven

ground electrodes will be provided in conformance with

specifications (NEC 250-83, and Project Specifications: Ground

Rods).

(3) Interior metallic water piping shall always be grounded

(NEC 250—80(a)).

d. Bolted Connections

Bolted connections should be examined to make sure that

they are tight and that contact surfaces are cleaned and dry.

Contact surfaces will be metal-to-metal. Painted surfaces should

be cleaned to bare metal (NEC 250-75).

e. Exothermic Welding Connnections

Exothermic welding connections will be made in strict

accordance with the manufacturer*s instructions and will employ

the proper type and size of mold for the type and size of

connection made.

f. Metallic Enclosures

Metallic enclosures for ground wires shall be electrically

continuous from the point of attachment to cabinets or equipment

to the grounding electrode and shall be securely fastened to the

ground clamp or fitting (NEC 250-92(a)).
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16A-5

g. Incoming Service Conduit

Incoming service conduit must be grounded by logs, pressure

Connectors or clamps. Locknuts and bushings are not acceptable for

grounding service conduit (NEC 250-32, -71(a) and -72).

h. Grounding Connection

Ground clamps for connection to water pipe or grounding

electrode should be compatible with the pipe or electrode and UL

approved for the purpose (NEC 250-115)

i. Ground Rods

(1) Check size, length, and material of ground rods or

electrodes against contract drawings and specifications (NEC 250-

83, Project Specification: Grounding)

(2) If suitable water pipe is not available, and if ground

rods cannot be driven to a minimum depth of 8 feet, other means of

establishing a ground must be utilized (NEC 250—83 and C

250-84)

j. System Neutral and Equipment Grounds

Grounding electrode conductor should be joined to grounding

electrodes as shown on drawings (NEC 250-112). Some special

electronic facilities may require additional isolated grounding

electrodes and conductors (Project specification: Grounding.)

k. System Neutral

System neutral (Grounded circuit conductor) should be

grounded (connected to the grounding conductor) on supply side of

the service disconnecting means (main service switch(es). This

connection should be made within the service entrance equipment

enclosure (NEC 250-23; 250-50) (Project Specifications:

Grounding.)

l. Multiple Connections

The connecting of more than one grounding conductor to an

electode by a single clamp is prohibited, unless the clamp or

fitting is of a type of specifically designed and approved by the

Underwriters* Laboratory for such use (NEC 250-115).

m. Grounding Resistance

Grounding resistance should be verified by instrument

measurement (Job Specification or NEC 250-84.)

n. Electrical Continuity

Electrical continuity should be verified throughout system,

usually by visual inspection.

16A-04 WIRING METHODS (NEC 300)

a. Rigid Metal Conduit. Intermediate Metal Conduit (IMC) and

Electrical Metallic Tubing (EMT)
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16A-6

Check to determine requirements and limitations on use of

rigid conduit, IMC, or EMT and special finishing or coating

material (Steel with zinc coating or galvanizing is standard)

other materials may be allowed or required (Project

Specifications: Wiring Methods; NEC-345, 346, 347, and 348.)

(1) The project specifications generally require the

service entrance raceway to be rigid metal conduit (Project

Specification: Aerial Service.)

(2) Check size of installed conduit against plans and

specificatins and determine adequacy for number and size of

conductors to be installed. Refer to tables in NEC (Project

Specifications and NEC 345-7, 346-6, and 348-6 and Tables in

Chapter 9.)

(3) Check minimum size of conduit permitted by

specifications for both electrical system and communication system

(Project Specifications: Telephone and Sig. System Raceways and

NEC 345-6, 346-5, 347-11 and 348-5.)

(4) Check to be sure that all required conduits are in

place before on—grade slabs are placed. Check stub-up locations

against equipment shopdrawings.

(a) Generally, for slab-on-grade construction conduit must

be placed under the slab and must be rigid type. (Check plans and

specifications)

(b) Check project specifications for requirement that for

stub-ups, couplings be installed at finished floor level for free

standing equipment (Project Speficification: Conduits.)

(c) Exposed conduit should be installed so that bent

portion of stub-up will not extend above floor level.

(d) Be sure that all buried conduit has been surface

treated as required by specifications (Project Specification:

Conduit and Tubing Systems.)

(5) Inspect for damage and deformation of conduit systems

(Project Specifications: Changes in Direction and NEC 345-10, 356-

10, 347-13 and 348-9.)

(6) Is conduit system to be installed concealed or exposed?

Check project specification and plans.

(7) Check for the use of the proper type of conduit

fittings, i.e., concrete-tight, rain-tight cast fittings;

expansion joints (NEC 345-9, 346-9, and 347-6 and 348-8).

(8) Check for installation of sleeves for future work in

foundation walls and floors during correct stage of construction.

(9) Check maximum number of bends in any single conduit

run. Do not exceed:

(a) Electrical System -4 (90 Degree) bends, including those

bends located immediately at the outlet or fitting (NEC 345-11,

346-11, 347-14, 348-10.)

(b) Communication System - Check project specifications for

requirements. Generally, not more than 3 (90N ) bends.
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16A-7

(10) Make sure that all the conduit required for circuits

involving equipment furnished by other sections of the

specifications and approved shop drawings, as well as the

electrical sections, is installed prior to placing of concrete,

closing the walls, ceilings, etc.

(11) Check for bushings on ends of conduit. Bushings are

not usually required on EMT fittings, because EMT connectors

should have smooth internal surfaces (NEC 345-15, 346-8, 347-12).

(a) Check for use of insulating bushings and double lock

nuts (NEC 373-6(c).

(b) Check for use of double locknuts for circuits over 250

volts to ground (NEC 250-76b).

(c) See that locknuts, bushings, couplings, and connectors

are made up tight to insure ground continuity (NEC 250-92(b).

(12) See that field cuts of conduits and EMT are made

square, ends reamed or filed, and cleaned of oil and filings, (NEC

345-8, 346-7, 348-11: Project Specifications).

(13) Use of running threads is not permitted at couplings

(NEC 346—9).

(14) Correlate location of conduit terminations against

approved shop drawings, equipment and building plans.

(15) Tubing and conduit should be securely fastened in

place at intervals required. Means of support provided should be

in accord with specifications and NEC requirements (Project

Specifications, NEC 348-12, 348-12, 347-8, 346-12, 345-12.)

(16) Exposed conduit runs are to be installed parallel o

perpendicular to walls and structural members. Vertical conduit

runs should be plumb (Project Specifications: Conduit and Tubing

Systems.

(17) Conduit runs in wet areas shall be mounted so that

there is at least 1/4” air space between it and the wall or

support surface (NEC 300-6(c)).

(18) Minimum radius of bends of conduit should be in

accordance with table in the NEC (NEC 346-10, 348-9, 345-10). This

table is based on utilizing conductors with 600-volt insulation.

For cables with higher voltage ratings, and special cables such as

telephone cable, consult manufacturer*s recommendations for

minimum radius of bend.

(19) Check for supporting of vertical raceways at each

floor level of multi-story buildings (Project Specifications).

(20) Install galvanized pull-wires in empty conduits when

required by designs or specifications.

(21) Verify the use of corrosion-resistant materials in

areas where corrosive influences exist (NEC 300-6: Project

Specifications).

(22) Require means for prevention of entrance of foreign

matter in conduits during construction (Project Specifications).
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16A-8

(23) Use UL listed flexible conduit, standard or liquid

tight, for connections to motors installed on slide rails,

resilient mounts, those subject to vibration, and elsewhere as

specified (NEC 350, 351; Project Specifications). Minimum size is

1⁄2" except as allowed in NEC 350-3, and a bonding jumper may be

required.

(24) In areas classified as hazardous, be sure that

installation is strictly in accord with Project Specifications and

applicable NEC articles 500 through 517. All questions should be

referred to qualified personnel. For Class 1, Division 1 areas,

the following items should be carefully verified:

(a) Only threaded steel IMC or threaded rigid metallic

conduit, or MI cable with approved connectors can be used, (NEC

501-4(a) and threaded joints must be up wrench tight, (NEC 500-1),

unless a bonding jumper is installed.

(b) At least five full threads must be engaged at each

threaded joint (NEC 501-4(a). All field made threads must be

tapered (NEC 500-1)

(c) All fittings, fixtures, boxes, and enclosures must be

specifically involved. An Underwriter*s approval seal is generally

affixed to the equipment. If not, secure other firm verification

of approval.

(d) Explosion proof fittings, boxes and enclosures have

screw or ground joints at openings. Be sure that surface of ground

joints is clean, unscratched and smooth, so that the mating

surfaces make intimate contact throughout their area. Covers must

be tight and gaskets are not to be used.

(a) Be sure that all required seals are installed in the

correct location and that they are of the correct type (NEC 501-5

and 502-5) . Be sure seals are the correct type of the

application, vertical or horizontal.

(f) Check the mounting method of equipment to be sure that

no holes have been drilled into the interior chamber of an

explosion proof enclosure.

(g) Be sure that all flexible conduits bear the

Underwriter*s listing seal for the hazard involved.

(h) See that proper approved type sealing compound has been

installed in all sealing fittings. Follow manufacturer s

recommendations (NEC 501-5(c)2).

(25) Where rigid non-metallic conduits is installed under

the specification, it should be installed in accordance with NEC

347 and all special requirements of the Project Specifications.

(26) Provide conductor support in long vertical conduit

runs (NEC 300-19).

(27) Pull wires are provided and are of type specified.
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16A-9

b. Cable Systems

(1) Mineral, insulated metal sheathed cable, Type MI, will

be installed in accordance with Article 330 or the NEC and Project

Specification requirements.

(2) Metal clad cable Types MC and AC (commonly called "BX")

should be installed in accord with Project Specification

requirements and Articles 333 and 334 of the NEC. See that

insulating bushings or equivalent protection are provided between

the conductors and the armor at terminations.

(3) Non-metallic sheathed cables, Type NM and NMC commonly

called “Romex", should be installed in accord with Project

Specification and Article 336 of the NEC.

(a) Type NM cable must not be used when non-metallic

sheathed cable is installed in the cells of masonry block walls

which are exposed or which are subject to excessive moisture or

dampness. This includes exterior masonry walls. In dry,

noncorrosive locations, type MN may be used. NMC is applicable in

wet locations (NEC 336-3).

(b) See that nails will not be driven into cable.

Protecting plates may be required (NEC 300-4).

(c) See that ground wire is properly fastened at

terminating points and outlet boxes. Attach to each box of fitting

by securely fastening the wire to the intended screw or with an

approved grounding device (NEC 25C-114).

(d) See that cable is secured as required by the National

Electrical Code, within 12” or every cabinet, outlet box of

fitting and otherwise at intervals not exceeding 4 1⁄2 feet (NEC

336-5). See also NEC 370-7(c) for support of cable entering nonmetallic boxes.

(4) When authorized by the Project Specification, service

entrance cable. Types SE, and USE should be installed in accord

with NEC 338.

c. Busway Systems (NEC 364; Project Specifications.)

(1) Support busways at specified intervals (NEC 364-5;

Project Specifications.

(2) Install sway braces when needed to limit lateral

movement of busway (Project Specifications).

(3) Busway position, vertical or horizontal, will determine

whether plugs are installed on the sides or on top and bottom. If

plans do not indicate desired position, determination of

appropriate location should be made.

(4) Install busway runs securely in straight alignment,

parallel to floors and walls, with sufficient space either above

and below, or on both sides, to permit installation, operation and

servicing of bus plugs.

(5) Check to be sure that types of duct furnished are in

accord with specification. Check conductor metal, enclosure type,

duct type, wall flanges, and fire stops.

(6) Ground duct housing (NEC 250-33).
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16A-10

(7) Vertical riser sections up to 6 feet above the floor

must be unventilated type (NEC 364-6).

(8) Check plug-in features and tap off devices against

specification.

(9) Check on trolley busways, trolleys, brushes, contact

rollers, and flexible cables for no binding and good contact.

(10) Component sections to be legibly marked with voltage

and current ratings and manufacturer*s name (NEC 364-15).

(11) Installation and furnishing of busways usually require

that the contractor verify field dimensions. Be sure that timely

ordering of busway is not delayed.

(12) Provide for expansion as required by the manufacturer.

d. Continuous Rigid Cable Supports or Cable Trays

Cable trays are installed to support cables. Only certain

specified cables may be installed and loading of support is

limited. Cable trays should be installed in accordance with

Project Specification and NEC 318. Tray system with cable

installed must not downgrade fire barriers (NEC 318-5(g), 300-21).

e. Wireways

Wireways or inclosed troughs are installed to house and

protect wire and cable. In general, wires of the building wire

type, such as TW, may be installed in approved wireways. The

installation should be made in accordance with Project

Specification and NEC 362. particular attention should be paid to

NEC 362-5, which limits the number of conductors approved for

wireway installation.

f. Auxilliary Gutters

The gutters commonly used for interconnecting large panels

and switches fall under this article. Installation should comply

with NEC 374.

g. Underfloor Duct Systems (NEC 354, 356)

(1) Install underfloor raceways of steel construction

parallel with floor construction, and in straight alignment.

(2) Check to see that sufficient setting depth is available

for junction boxes. These are the deepest elements of underfloor

raceway systems.

(3) Check for tight joints between underfloor raceway

sections and at junction boxes to keep water out of raceway

systems (NEC 354-13, 356-9).

(4) Inserts of both the preset and after-set type will be

mechanically secured to the underfloor raceway and set level with

the floor (NEC 354-14, 356-10).

(5) Splices and tapes in underfloor raceway systems will

not be made in outlets at inserts, but only at junction boxes to

keep water out of raceway systems (NEC 354-13, 356-9).
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16A-11

(6) provide markers at ends of underfloor raceway runs, but

the plans and specifications may require more (NEC 354-9, 356-8)

(7) Install end caps at ends of all underfloor raceway

systems (NEC 354-10).

(8) Check tap-off locations to cabinets, panel boards, and

receptacles against drawings.

(9) Verify from shop drawings relative positions of

services in compartments. To be uniform throughout system.

(10) Check cross-sectional dimensions for adequate size

(NEC 354-5, 356-5; Project Specifications).

(11) Be sure that grounding continuity is maintained at all

connections in the system (NEC 250-75).

h. Movable Partition

Movable partitions, and similar enclosures unless

specifically listed as raceways, cannot be used as enclosures for

general wiring conductors. Instead raceways (such as conduit) must

he installed: or else cable (such as type MI) appropriate for the

application must be installed. See NEC restrictions for kitchen

vent hoods (NEC 410-9).

i. Conductors (NEC 310)

(l) Check type of insulation and jacket, conductor

material, conductor size and stranding in each circuit (Project

Specifications and NEC).

(2) Observe pulling of wires and cables to detect damage to

sheaths, jackets and insulation. This damage is usually caused

when runs are “paid out” in a debris-laden area and then stepped

on, or by raceways having sharp edges or contamination. Pullingeyes or cable-gripping devices will be required for large cables.

(3) Install all conductors of a circuit, including neutral,

in same raceway in conformance with NEC limitations (NEC 300-20;

215-4).

(4) Connections and joints will be clean and tight, with

listed pressure-type connectors, and made in junction and outlet

boxes, not in raceways (NEC 110-14, 300-15).

(5) Connectors, lugs and clamps used to connect copper and

aluminum conductors must be suitable for use with the conductor

material to prevent galvanic corrosion (NEC 110-14). Aluminum

conductors must be covered with antioxidant before connection.

(6) Use only white or natural grey identified conductors

for the grounded circuit conductor. Neutral (white or grey)

conductor of the wiring system will be insulated throughout (NEC

200-7). Conductors having white or grey identified coverings shall

only be used as the grounded circuit conductor except as allowed

in exceptions 1 thru 3 in NEC 200-7. Generally, use the same white

color for the entire system grounded conductors.
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16A-12

(7) When a grounding conductor for equipment is run with

circuit conductors it shall be bare, or green covered (NEC 250-

57(b)). Project specifications may require insulated conductors.

(8) Enforce color coding of conductors of branch circuits

when required by project specification.

(9) Branch-circuit conductors within 3” of a ballast within

the ballast compartment shall be recognized for use at

temperatures not lower than 90 degree C (194 degree F) (NEC 410-

31).

(10) Check that branch circuit wiring is not undersized.

Specification may require increased wire size when runs from panel

board to center of load equal or exceed 100 feet for 120 volt

circuits or 230 feet for 277 volt circuit.

(11) See that correct fixture wiring installation is made

(NEC 410-22 to 34).

16A-05 OUTLETS

Check for requirements of cast boxes in exposed work,

exterior work, wet locations, and hazardous locations (Project

Specifications)

b. Require hub-type cast boxes when specified (Project

Specifications)

c. Check size of junction and pull boxes (NEC 370-6, 18,

20).

d. Do not permit overcrowding of boxes with excessive

number of conductors (NEC 370-6).

e. Check identification requirements of power and control

conductors at terminals and in pull boxes and junction boxes.

Fenders should be tagged to indicate electrical characteristics,

circuit number, and panel designation (Project Specifications).

f. Check for boxes to be securely and rigidly supported

(NEC 370-13). (Project Specifications: Boxes and Supports.)

q. Fit concealed boxes into walls and ceilings. On

noncombustible construction, the front edge of box should be

within 1/4 inch of finished surface, and on combustible

construction flush with finished surface or project therefrom

(NEC 370-10)

h. Any masonry or dry wall work required for installation

of outlet, pull, of junction boxes is to be done by skilled

workmen. The masonry section of the specifications requires the

cutting of block for fitting installed items. Electrician should

not be permitted to chop away masonry or dry wall work.

Coordination is necessary between the electrical trade and masons

and carpenters to effect a suitable installation. (Project

Specifications).

i. Check for air space between box and wall or supporting

surface in wet locations where surface-type units are used (NEC

300-6).
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16A-13

j. Are outlets that are exposed to the weather a weatherproof type (NEC 370-5 and 300-6, Project Specification).

k. Pull and junction boxes shall have free access (NEC

370-19).

l. Floor outlets shall be of required type and properly

located.

m. Light outlets in mechanical and equipment rooms are

located to suit servicing and maintenance and extend below ducts.

16A-06 DEVICE PLATES

See that device plates are of specified material and finish

and that all surfaces are in contact with wall (Project

Specifications and NEC 410-56). On surface mounted boxes the

plates should be compatible with the box and without overhanging

corners. Also, NEC 380-0. Plates should be plumb and not dished or

bowed.

16A-07 RECEPTACLES

a. Check all receptacles to be sure that specified voltage,

ampere, color, slots, etc., are furnished. Also be sure that plug

is furnished if specified (Project Specifications).

b. Be sure that grounding continuity is maintained between

grounded metal box and receptacle and that bonding jumper is

installed when required or approved bonding type receptacle. Some

designs require ground wire from panel to receptacle (NEC

250—74).

16A-08 WALL SWITCHES

a. Check wall switches for proper ampere rating, voltage

rating, and type. Usually "A-C only” is required. AC only switches

are marked “AC” or "AC only" on yoke, never “AC/DC.” They can be

used for alternating current only (Project Specification and NEC

380-14).

b. Wall switches will be in hot leg of circuit, not in

neutral, and should be installed with the "on" position “up” (NEC

380-6)

c. Check for requirements of installing pilot lights on

switches (Project Specifications).

16A-09 SERVICE EQUIPMENT

a. Check to be sure that the proper type of enclosure is

furnished (such as drip-proof, totally enclosed, etc.) (Project

Specifications.)

b. Standard NEMA (KS-1) designations are used to describe

various enclosures for switches. The designations are as follows:

Type 1 — Indoor — General Purpose

Type 2 — Outdoor — Dusttight, Raintight and Sleet (Ice) 

Resistant
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16A-14

Type 4 - Indoor/Outdoor - Watertight and Dusttight

Type 5 - Indoor Dustproof

Type 7 - Class I, Groups A, B, C and/or D — Indoor

Hazardous Locations - Airbreak Equipment

Type 9 - Class II, Group(s) E, F and/or C - Indoor

Hazardous Locations - Airbreak Equipment

Type 12 - Indoor - Industrial Use, Dusttight and Driptight

with Knockouts “Weatherproof” is defined in the NEC as so

constructed or protected that exposure to the weather will not

interfere with successful operation (NEC 100) and raintight,

rainproof or watertight equipment can fulfill the requirements for

weatherproof.

c. Check whether fusible-type or circuit-breaker type of

service switch is required (Project Specifications)

d. Check that the service-switch enclosure is bonded to the

ground system (NEC 230-62, 63).

e. Check voltage rating and ampere rating of switch. Also

circuit breaker trip and fuse sizes and interrupting capacities

(Project Specifications and Plans)

f. Check ground fault protection of service equipment when

required by NEC 230-95, or Design.

g. Check meter location when specified.

16A-10 LOAD CENTER TYPE PANEL BOARDS

Load center type panelboards are sometimes authorized for

less critical applications compared to regular panelboards.

Compliance with Project Specifications, Federal Specifications,

and NEC 384-13 through 19 is required.

16A-11 PANELBOARDS

a. Be sure to inspect plug-in panel board devices to

determine tightness of fit.

b. Check loads on panels to be sure of approximate balance

among the phases. This is best done by use of clamp-on type

ammeters on feeders while panel is carrying its normal load

(operational test)

c. Be sure the panelboards typed directory is properly

filled out so that area and devices served can be quickly

identified (Project Specifications).

d. Circuit-breakers: switches, and fuses in panelboards

should be inspected to determine that they have correct number of

poles, proper voltage, current-rating, and proper interrupting

capacity. Refer to contract drawings and project specifications.

e. Check panelboards for inclusion of blanked-off spaces

for future circuit breaker installation. Space to be adequately

sized for the rating of future circuit breaker. Also see that

spare breakers required are in place in addition to blanked-off

spaces.
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16A-15

f. Check mounting height of top switch or curcuit breaker.

It should be less than six feet six inches.

16A-12 CABINETS (NEC 373; Project Specifications)

a. Check on size of gutter space. A minimum of 5 inches is

required for panelboards with thru feeders. Load centers should be

in accordance with NEC 373-6(a).

b. Telephone cabinets are to be checked for inclusion of

backboard painted with insulation varnish.

c. Compare size of telephone cabinets against contract

drawings.

d. Mounting is to be rigid and independent of the support

by conduits. In damp locations, there should be 1/4 inch minimum

air space at back of panel (NEC 373-2).

e. Connections to conduits are to be tight, assuring

electrical continuity (NEC 250-71 through 79)

f. Look for special features of construction and

installation for areas other than normal, such as hazardous, wet,

exposed to fumes, etc. (NEC 110-li).

g. Examine for galvanized metal construction.

h. Check mounting height of panelboard cabinets. Distance

from the highest position of top switch or circuit-breaker to

floor should not exceed 6 feet, 6 inches (Project Specifications)

16A-13 FUSES (NEC 240-6 and 8)

Inspect for the following:

a. Specified voltage rating.

b. Specified amperage and interrupting rating.

c. Non-renewable cartridge types for over 30 AMP capacity

(Project Specifications)

d. Are dual element time-delay fuses or current limiting

fuses with special “reject” holders required? (Project

Specifications)

16A-14 UNDERGROUND SERVICE CONDUITS (NEC 230-30 and 31)

a. Check detail requirements of plans and specifications

(Project Specifications).

b. Check requirement for painting or coating of conduits

(Project Specifications)

c. Check method and location of termination of conduit ends

and grounding (NEC 230-55).

d. Seal building ends of raceways entering from UG

distribution system (NEC 230-48).
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16A-16

16A-15 AERIAL SERVICE

a. Locate the splice between service drop and service

entrance (NEC 100) conductor at a level lower than the service

entrance fitting (head), and bend conductors to form a “drip loop”

at the entrance fitting. These precautions will prevent entrance

of water into the service equipment (NEC 230-24).

b. Support aerial service-drops on buildings, providing

required clearances from ground, building openings, and from roof

where service crosses roofs (NEC 230-24).

c. Service-drop cable type is to be in accordance with

specification requirements (NEC 230-22 and 23; Project

Specifications)

d. If connections are aluminum to copper, insure that the

type of connectors specified (usually tinned bronze) are utilized

and that anti-oxidant compound is properly applied, if specified.

16A-16 MOTORS

a. Check motors for conformance with NEMA classification

standards. NEMA classification is according to mechanical

protection and methods of cooling. Installation should be made in

accordance with project specifications. Dripproof and/or splashproof motors when specified shall be installed with ventilation

openings faced down to exclude moisture, dirt, etc.

b. Check motors to see that proper terminal connections are

made for the operating voltage. A connection table should be

securely attached to the motor by the manufacturer if several

alternate connections are possible.

c. Be sure motor revolves in direction correct for driven

device, Usually an arrow is placed on fans and pumps to show

correct directions of rotation. Motor rotation and speed must be

verified before connection to the load e.g. pumps, fans, etc.

d. Check reversing types of motors and multi—speed motors

to insure that direction of rotation and speed of motor

corresponds to setting of control.

e. Make ground connections of motor enclosure through

conduit system or by separate grounding conductor (NEC 430-141,

142)

f. Check motor against specifications and UL listings for

class of insulation, starting torque characteristics, class, and

design. Assure high efficiency motors are used where indicated.

g. Check motors for proper voltage. When 208V, three-phase

is specified, do not permit substitution of 230V, three phase and

vice versa. A 200 volt rating is the correct name plate rating for

application on 208 volt system. Proposed substitutions should be

referred to an electrical specialist.

h. Note conditions of windings; to be free from moisture

and dust. See that appropriate provisions are made to protect

equipment prior to turn-over of project.
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16A-17

i. Motors should be operated under connected load to

determine following operating characteristics:

(1) Voltage and current to detect possible overloaded

conditions

(2) Speed of motor

(3) Direction of rotation

(4) Overheating

(5) Vibration

(6) Abnormal sounds or odors

If connected load is not possible, refer to the Resident

Engineer. This normally can be done in conjunction with test

driven equipment.

j. Connect motors subject to vibration, and motors on

adjustable slide basis, with flexible conduit. Liquid-tight or

explosion-proof flexible conduit may be required by installation

conditions. Bonding jumpers may be required (Project

Specification; NEC 349, 350, 351, 501-4(a)).

k. Motors installed in hazardous locations are to bear an

Underwriters Laboratory nameplate, indicating the classification

of areas in. which the motor is listed for use.

1. Check lubrication requirements of motor prior to motor

operation (Manufacturers Instructions).

16A-17 MOTOR CONTROL

a. Check with the contractor to assure that all motor

controllers required by all sections of the specifications have

been ordered. Quite often, controllers are not ordered due to

disputes between subcontractors. The QAR should insure that the

prime contractor has made necessary arrangements to insure timely

procuring of motor controllers.

b. Check motor controllers for:

(1) Horsepower, voltage and current rating of least equal

to the rating of the motor which it controls.

(2) Automatic control devices such as thermostats, float or

pressure switches directly used as motor controllers, should be

adequately rated.

(3) Magnetic-coil voltage rating same as the controlcircuit voltage (may be different from the motor voltage)

(4) Selection of proper motor overload heaters; based on

the nameplate full-load current of the motor, ambient temperature

of controller location, temperature-rise limit of motor. Refer to

instruction sheet pasted on inside cover of motor controller.

Determine if automatic or manual reset is required for overload

protection (NEC 430-34) (Project Specifications.)
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16A-18

(5) Requirements for furnishing reduced voltage starters.

(Project Specifications.)

(6) Excessive humming or noise under operating conditions.

(7) Requirements for furnishing pilot circuit devices such

as “Hand — Off - Automatic” selector switches, pilot lights

(Project Specifications.

(8) Note three-phase motors are provided with the overload

element in each ungrounded conductor (NEC Table 430-37).

(9) Be sure control enclosure is as specified in Project

Specifications and is suitable for conditions of installation.

(10) Spare interlocks, if specified.

(11) Shipping blocking has been removed.

(12) Control and safety devices should be wired into the

“hot leg”, not the neutral leg of the control circuit. If motor is

connected to a grounded power supply, control power circuit should

also have a grounded conductor. The control power should be

disconnected from all power sources by its disconnect means

(NEC 430—74).

16A-18 MOTOR DISCONNECT MEANS

a. Disconnecting means that open all ungrounded conductors

will be provided for motor driven equipment installations. By

locking provisions or by being “in sight” the disconnect(s) will

provide protection for persons working on control, motor, and

driven equipment (NEC 430-101 thru 113).

b. Ratings of switches are to be checked against contract

specifications.

16A-19 LAMPS AND LIGHTING FIXTURES

Lighting fixtures should be examined for:

a. Chipped porcelain, cracked glass and plastics, bent

louvers, over-all finish, detachable sockets on RLM dome fixtures

(when specified) and “push type” sockets on open fluorescent

fixtures (when specified). (OCE standard fixture drawings.)

b. Required lamp type, wattage, and color characteristics.

c. Ballasts for fluorescent and mercury-vapor lamps

suitable for circuit voltage and of high power-factor type;

overload protection for ballasts, if specified ballasts should be

suitable for low temperature operation. Ballasts for fixtures to

be recessed in fire rated or insulated ceiling construction may be

required to be “low loss” type to bold ambient temperature down.

d. Plumb installation and horizontal and vertical

alignment.
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16A-19

e. End-caps, canopies, louvers, side panel guards, globes

in place and tight-glass side panels, if specified. Acrylic

plastic lens when specified.

f. Aiming of floodlights and all other adjustable fixtures.

g. Lamps that are to be installed for the project shall be

new, and installed just prior to completion (Project

Specifications)

h. Storage battery powered emergency lighting sets should

be checked against applicable Federal Specification for

requirement of Underwriters listing and other features. They

should be permanently installed strictly in accordance with

project specifications and NEC Article 700.

i. Emergency lighting circuits should be installed in

accordance with project specifications and NEC Article 700.

Circuit wiring should be kept independent of all other wiring

(NEC 700-17).

j. End-to-end mounted flourescent fixtures must have

Underwriters approval for mounting end-to-end (NEC 410-31) when

used as raceways.

k. Required characteristics specified.

l. Grounded properly.

16A-20 EQUIPMENT CONNECTIONS

a. Refer to applicable paragraphs of this chapter.

b. Check plans and specifications for any special features.

c. If Government-furnished equipment is involved, insure

the timely availability of all connection drawings.

16A-21 TRANSFORMER STATIONS (NEC 450)

a. Dry Type Transformers

Check enclosure for indoor or outdoor service. Install so

that air circulation will not be restricted around the

transformers. Close-to-ceilings installations should be avoided.

b. Transformer Taps

Connect to produce specified voltage under normal load.

c. Liquid-filled Transformers

Check to see that they are filled to proper level. Level

mark is indicated on transformer.

d. Nameplate Data

Check against specification requirements and approved shop

drawings (NEC 450-11).
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16A-20

e. Accessories

Check liquid-filled transformers for compliance with

specifications or with specified standards. Such include:

Connections for sampling, draining and filtering of insulating

liquid; level gage; thermometer; pressure and vacuum gages;

external tap changer; provisions for jacking, rolling and lifting;

provisions for pole, platform or slab mounting; provision

grounding of case and windings; and alarm devices actuated by

abnormal liquid level, temperature or pressure; and automatic

control devices for operation of forced air or other oil cooling

equipment which will permit operation of transformers at higherthan-normal ratings.

f. Bushings

Check to see that bushings are free of moisture, dust,

chips and cracks.

g. Insulating Liquid

Check against requirements. Non-flammable fluid insulated

power transformers are generally required indoors.

h. Grounding

Check grounding connections of metal housing, neutrals of

primary and secondary winding to the grounding system (NEC 450-9

and 250-26).

i. Ventilation

See that ventilation is adequate (NEC 450-45)

16A-22 SWITCHGEAR (NEC 384)

Switchboard and Free-Standing Panel Installation - Check

for:

a. Level floor location for gear and any roll—out

equipment.

b. Anchor bolts and floor plates in proper location.

Consult approved shop drawings and contract drawings.

c. Conduit entrances and wiring trenches in proper

location.

d. Bus duct connection provisions suitable for duct

attachment.

e. Ground bus connections brought to proper location.

Consult approved shop drawings.

f. Plumb and level installation of gear.

g. Installation in accordance with manufacturer*s

instructions.

h. Blocking removed from instrument and relays.

i. Adjustments made where required, taps and plugs at

proper settings. Consult manufacturer*s installation instructions.
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16A-21

j. Fuses in place and of proper type - voltage, current,

interrupting capacity - current limiting.

k. Indicating lamps with proper color caps in place.

l. Furnishing of spare fuses and lamps and any operating

handles or cranks.

m. Manufacturer*s instruction books, wiring diagrams. etc.,

delivered to responsible individual accepting installation. Make a

list and have it signed and filed.

n. Terminals marked in accordance with approved shop

drawings and specifications.

o. All wiring connections made up tight.

p. If switchgear is to be installed in any hazardous

locations, check the specifications and drawings for any required

special constructions features.

q. Check for sufficient clearance between back of

switchboard and wall. Minimum of 30 inches required if equipment

or wiring is accessible only from back. Additional clearance may

be required (NEC 110-16 and 34).

r. Check to be sore switchboard frame is grounded.

s. Check to be sure conduit stub—ups have coupling

installed at floor level if required by Project Specifications.

t. Check to be sure that proper phase relationship and

identification of connections including instrumentation has been

accomplished.

u. Special requirements, such as seismic.

16A-23 ENGINE GENERATOR SETS

a. See Chapter 130 for installation of sets.

b. Inspect for overall compliance with the specifications

as to type and rating of components - kva, kw, horsepower, rpm,

voltage - and in particular as to the following:

(1) Engine will be suitable for operation on the fuel

specified.

(2) Voltage ratings of starter, battery, and battery

charger will be the same. Voltage regulator may need to be reset

if nickel cadmium batteries are furnished.

(3) Check spare parts provided with unit to see that the

supply is complete and that they fit the unit furnished.

(4) Installation should be in accord with NFPA 30, 31, and

37, as required by Project Specifications. Check for proper

calibration of gagestick.

(5) That ventilation is adequate.

(6) See that operation and maintenance manuals are posted

in engine room.
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16A-22

(7) Check operation of transfer switches.

(8) Check governor operation.

(9) Check cranking cycle for reset.

(10) Check to determine that emergency shut—down prevents

recycling.

(11) Required field tests have been satisfactorily

completed.

(12) Check automatic transfer switch, lab test reports,

operation and settings.

16A-24 ELEVATOR INSTALLATIONS (NEC 620)

a. See Chapter 14A for installation features.

b. Check voltage rating of hoisting machinery.

c. Provide safety interlocks as specified and check

operation.

d. Record all performance of specified tests.

16A-25 MISCELLANEOUS SYSTEMS (NEC 720, 725, 760, 770, 800, 810)

Include several types of audible and visual paging systems,

nurses call, central dictation, intercommunication systems of

loudspeaker and telephone type, fire alarm systems, clock systems

and supervisory systems, and often these which combine more than

one function in a single system. Products of different

manufacturers of like systems may differ greatly. Manufacturer*s

installation instructions will be rigidly adhered to. The

following will apply to all systems generally:

a. Master sets and main or central station equipment and

switchboards of miscellaneous systems will be so placed as to be

easily accessible for operation and maintenance in locations

having adequate ventilation.

b. Generally, component parts of miscellaneous systems will

be products of one manufacturer.

c. Wiring between system components may be of special

character. Inspect for requirement for use of optical fiber cable,

shielded cables, twisted pairs, and isolation of any system from

another.

d. Check installation of miscellaneous systems equipment to

see that the proper type and sizes of fuses have been used, that

leads are connected to proper terminals and that the equipment is

designed to operate on the available supply voltage.

16A-26 TESTS

a. All Testing

(1) When testing of any electrical equipment or system is

required, advise the electrical inspector or engineer and obtain

his assistance. The following paragraphs cover a wide range of

testing and it will be your responsibility to obtain assistance

when such testing is beyond your capabilities or knowledge.
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16A-23

(2) Unless otherwise specified, testing should be performed

by the contractor when the inspector is present. All arrangements

for test should be made by the contractor. For tests of major

equipment and high voltage cables, the contractor should also

notify the manufacturers so they may witness the tests.

(3) The Using Agency should be notified when any unusual

testing is to he performed so that they may be present to witness

the test. Using Agency cooperation should be obtained well in

advance for any tests which may affect their facilities or

operations.

b. Precautions

Precautions should be taken to insure that test voltages

are applied only to equipment or circuits under test, and that all

instrument and control circuits are disconnected during the test.

Verify that all electrical equipment can be LOCK-OUT/TAG-OUT.

c. Electrical Tests

Electrical tests should not be conducted under ambient

conditions unsuitable for testing, such as excessively high

humidity conditions.

d. Records of Tests

Records of tests should be complete, including ambient

temperatures and weather conditions, circuit designation and

extent or wiring systems tested, name and serial number of the

machine tested, and signatures of those witnessing the tests.

e. Description of Tests

(1) De-energized operational testing will determine that

moving parts do not bind, rotating parts work freely and are not

obstructed by foreign materials, that they are lubricated as

required, and that such limits or stops as may be necessary to

restrict the motion of moving parts are in place and functioning.

(2) Operational testing will show that the equipment

performs all functions for which it is designed in accordance with

the design and manufacturer*s specifications.

(3) Continuity testing will determine that circuits are

continuous through out the circuit.

(4) High potential testing will determine that the

insulation has sufficient dielectric strength to withstand the

surges to which it might be subjected and to insure freedom from

pinholes and any other possible damage.

(5) Megger tests will determine that the wiring system and

equipment is free from short circuits and grounds and will measure

the insulation resistances of the circuit and/or equipment under

test.
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16A-24

f. Megger Tests

Megger tests of insulation resistance should be made when

specified and approved if satisfactory.

g. Method of Testing

(1) High-potential field tests should be made in strict

compliance with the applicable standards listed in the

specifications and with the recommendations of the manufacturer of

the equipment.

(a) Tests should not be repeated unless the necessity for

repetition has been determined by an electrical engineer or

specified.

(b) Make only after all safety precautions relative to

grounding of the test equipment have been checked.

(2) Insulation resistance and high-potential tests of

wiring systems should be made when required between one conductor

and ground with all other conductors and sheath or conduit

connected to the same ground. Tests should be made on each

conductor in this manner. Windings of rotating equipment and

transformers should be connected together and tested to ground.

(3) Rotating equipment operational tests should include an

inspection for alignment with driven machine, proper lubrication,

freedom from excessive vibration in operation, proper direction of

rotation, voltage and current drain check against motor nameplate

ratings, check of R.P.M. and excessive heating.

(4) Rotating equipment operational tests should include an

inspection for alignment with driven machine, proper lubrication,

freedom from excessive vibration in operation, proper direction of

rotation, voltage and current drain check against motor nameplate

ratings, check of R.P.M. and excessive heating.

(5) Switch and manual motor starter operational tests

should include an examination for proper operation, alignment of

contacts and contact pressure.

(6) Motor-starter operational tests should include manually

operating the armature or plunger and contact-bar to determine

that movement is free, contacts are in alignment, contact pressure

is adequate and that auxiliary contacts function properly. The

starter should be energized from all control points and the

operation of all control-circuit interlocks should be checked.

(7) Reduced voltages starters should be checked for correct

sequence and timing of application of incremental and full

voltages.

(8) Variable and adjustable speed motor controls should be

checked to see that operating speeds corresponds to the position

of the speed control device.

(9) Circuit-breaker operational tests for large air

circuit-breakers operating and test positions under manual

operation and through control circuits from each control point.

Checking of breaker mechanisms for alignment; freedom of motion

and adequate pressure of contacts; tripping, devices; inspection
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16A-25

to insure that breaker cannot be moved from operating position

while closed. Indicating lights, targets, annunciators and alarms

should be observed for operation in connection with associated

circuit- breakers, control switches and other operating devices to

insure that the signal indication corresponds to the switch

position of the indicating device.

(10) Protective relays should be checked to see that time

and current settings have been made as specified.

(11) Operational tests of relays should include: Checking

of operation at specified current or voltage and time values.

Checking of peak current of instantaneous elements; checking of

differential elements for operation only under condition of proper

direction of power flow.

(12) Rod electrodes should be tested for resistance to

ground. If resistance is greater than the specified resistance, or

maximum of 25 ohms, additional rods or longer rods should be

installed. Consult specifications (Project Specifications: NEC

250-83).

(13) Miscellaneous systems, for intercommunication, paging,

clock-control fire alarms, etc., shall be given operational tests

at all operating points to demonstrate that they will perform all

specified functions. In particular, it shall be demonstrated that

sounding devices are audible under normal ambient sound-level

conditions in areas for which coverage is specified, that false

signals cannot be transmitted over fire alarm systems specified to

be of the non-interfering type, that reserve—power attachments for

clock system will operate for the specified length of time, and

that all special features and accessories specified for each

system have been incorporated therein.

(14) Engine-generator tests include, but may not be limited

to, the following:

(a) If diesel engine driven, reference is usually made to

MIL-STD7058. This publication details electrical test requirement.

Be sure all factory or shop tests have been completed as

specified.

(b) Demonstrate starting of all units from all manual

control points and from automatic control as specified.

(c) Demonstrate voltage and frequency regulation are held

within specified limits under all load conditions.

(d) Establish load requirements for testing of units.

Either connected load or created load such as obtained with salt

water rheostat or other satisfactory method. Determine who will

furnish load banks, if required.

(e) Engine-generator tests should incorporate full load

tests. Specifications will at times required 110% load testing for

a limited time.

(f) Satisfactory operation of transfer switch installation

in accordance with specifications requirements should be

demonstrated.
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16A-26

(g) Operational check of all safety controls should be

made. This will include operation of safety stop switches,

operation of high water temp, low oil pressure, over—speed, and

any other safety circuit required by the specifications.

(h) Demonstrate full load continuous operation without

overheating of the engine.

(i) Be sure all field tests specified are performed and

recorded.

(15) Transformers should be checked for shipping damage,

leakage, proper voltage and tap settings, grounding, and for signs

of water in the oil.

(16) Service equipment should be tested for ground fault

protection as specified and NEC 230-95.

(17) Operational test should be made on all switches,

dimmers, lighting, battery units and miscellaneous equipment.
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i

CHAPTER 16B

EXTERIOR ELECTRICAL

INDEX

Para. Title Page

16B-01 GENERAL 16B-1

16B-02 AERIAL DISTRIBUTION 16B-1

a. Wood Poles 16B-1

b. Crossarms 16B-2

c. Hardware 16B-2

d. Insulators 16B-2

e. Conductors (Aerial) 16B-2

f. Guying 16B-3

g. Transformers 16B-4

h. Primary and Secondary

Fuse Cutouts 16B-5

i. Lightning Arrestors 16B-5

j. Pole Top Switches 16B-5

k. Grounding 16B-6

l. Street Lighting 16B-6

m. Underground Risers 16B-7

16B-03 UNDERGROUND DISTRIBUTION 16B-7

a. Duct System 16B-7

b. Manholes, Handholes, and

Underground Vaults 16B-8

c. Primary Cables 16B-9

d. Direct Burial Cable 16B-9

e. Potheads 16B-10

f. Transformers in Fenced

Enclosures 16B-10

g. Pad Mounted Transformers

Without Fenced Enclosures 16B-11

h. Testing 16B-11

16B-04 CATHODIC PROTECTION 16B-11

a. General 16B-11

b. Shop drawings 16B-12

c. Anodes 16B-12

d. Conductors 16B-12

e. Conductor Connections 16B-12

f. Insulating Joints 16B-12

g. Bonding 16B-12

h. Test Points 16B-12

i. Foreign Pipes

and Structures 16B-13

j. Backfill for Underground

Metallic Structures 16B-13

k. Auxiliary Equipment 168-13

l. Electrical Measurements 168-13

m. Starting and Adjusting 16B-13

n. Record of Testing 16B-13

16B-05 ENERGY MONITORING AND 16B-13

CONTROL SYSTEMS

16B—06 RF SHIELDED FACILITY 16B-14
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16B-1

CHAPTER 16B

EXTERIOR ELECTRICAL

16B-01 GENERAL

This chapter covers exterior electrical distribution

systems, aerial and underground, and transformer stations.

Make an inspection of materials prior to installation for

conformance with specifications, plans, and approved shop

drawings. ENG Form 4288, Submittal Register, which lists approved

materials, is essential to this inspection. Components for

distribution systems will be inspected before they are installed

and energized. Initial inspection and follow-up inspections will

follow work as required by ER 1180-1-6.

16B-02 AERIAL DISTRIBUTION

a. Wood Poles

Note: If concrete or steel poles are provided be sure that

the poles meet the strength and other criteria provided in the

specifications.

(1) Check strength (class), length, conditions, and

treatment of poles against design requirements. (A current edition

of ANSI Standard 05.1, “Specifications and Dimensions for Wood

Poles,” should be available to the inspector). Be sure that

certification of compliance with applicable AWPA preservation

specification has been submitted.

(2) Be sure that contractor*s provisions for storage and

handling of poles are in accordance with specification

requirements.

(3) Usually, specifications require poles to be full

treated rather than butt treated. The preservation specification

should be checked for verification.

(4) Poles should be turned, chamfered, trimmed, roofed,

gained, and bored prior to pressure treatment. When field boring

or gaining is necessary, additional preservation should be applied

to bared surfaces.

(5) Examine type of handling tools.

(6) Be sure that gains have been made for all cross- arms.

(7) A site check of the pole line route and pole locations

should be made to be sure that pole lengths furnished will be

suitable to carry all intended circuits (including communications)

and still maintain required vertical and horizontal clearances

from the ground and other obstructions. (A current edition of

ANSI-C2, National Electrical Safety Code, should be available to

the inspector.)

(8) Be sure that the depths of pole holes are equal to

minimum specification requirements, and that the width of each

hole is adequate for backfilling and tamping in 6—inch lifts when

required by the specifications. Surplus earth should be piled

around the pole and tightly tamped to assist in drainage away from

the pole and to compensate for shrinkage of the backfill.
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16B-2

(9) If design requires numbering of poles, see that this is

done correctly.

(10) See that the grading of pole tops is even.

(11) When it is necessary to shorten a pole, see that the

cut is made at the top and that it is treated with hot

preservative.

b. Crossarms

(1) Check material meets specification requirements.

(2) Verify wooden crossarms use proper preservation

treatment.

(3) Examine fastening.

(a) Inspect installation, bolting, setting angle, number,

type and length of crossarm and secureness obtained.

(b) Check vertical spacing of multiple crossarms.

(c) Check pin hole spacing.

c. Hardware

(1) Be sure that all ferrous hardware (braces, bolts,

lamps, pins, nuts, washers, screws, etc.) is standard pole line

galvanized hardware.

(2) Be sure that all hardware is of the specified strength

size and length.

(3) Be sure crossarm pins are of the specified strength and

height.

(4) Bolts should not protrude more than approximately 2-

inches or less than 1/8-inch beyond the nut.

d. Insulators

(1) Check furnished insulators against specification

requirements.

(2) Inspect for damage.

(3) Check types and spacing of pins.

(4) Determine location of guy insulators.

e. Conductors (Aerial)

(1) Compare furnished supports with plans and

specifications:

(a) Stranded or solid.

(b) Copper, aluminum, or combinations of copper and steel

of aluminum and steel sized according to the specifications.

(c) Bare, weatherproof covered, or insulated conductors.

Insure that insulation meets the project specifications.
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16B-3

(d) If messengers are used to support cables check to see

that the are sized, attached and grounded properly.

(2) Check during installation:

(a) Tree trimming.

(b) Line Sag and Tension are within the specified

requirements of the contract or NESC.

(c) Handling Watch for methods which will produce twists,

kinks, abrasions, or cuts.

(d) Method of dead ending.

(e) Connectors and treatment of conductors at connectors or

splices.

(f) Armor rod and/or armor tapes on aluminum conductors at

supports.

(g) Tie wires and methods of securing conductors to

insulators.

(h) Installations requiring racks and utilization of same.

(i) Horizontal and vertical clearance between conductors

(ANSI C2).

(j) Installation and location of drip loops.

(k) Connectors on service drops - If dissimilar metals are

connected be sure that approved connector is used.

(l) Dead ending with approved clamps with strength not less

than that of the conductor.

(m) Area requiring special protection.

(n) Requirements for neutrals.

f. Giving

(1) Compare the type of guy with its intended use.

(2) Check type and size of anchors against ground

conditions.

(3) Check materials to be used especially in areas where

anchor rod corrosion may be a problem.

(a) Check for protective thimbles and thimble eye bolts.

(b) Examine three-bolt clamps at guy terminals.

(4) Check during installation:

(a) Anchor distance from poles (Anchor and guy strength is

based on 1 to 1 slope. If the distance between pole and anchor

rods has to be decreased, strengths must be increased)

(b) Location of guy insulator if required.
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16B-4

(c) Point of attachment on pole.

(d) Installation of rock anchors.

(e) Location of expansion anchors and log anchor rods.

(f) Need for additional guys.

(g) Installation of guy protectors.

(h) Gaining of poles for push braces.

(i) Identification of primary phases stamped on all

transition poles and at all substations entering and leaving.

(j) Length of anchor rods.

(k) Grounding and bonding of guys when specified.

(l) Guy markers are in place.

g. Transformers

(1) Check method of mounting:

(a) Determine capacity of transformer or banks of

transformers.

(b) See if method of mounting is similar to adjacent

connected system, and notify supervisor of deviation.

(2) Check materials:

(a) Conformance with applicable ANSI and IEEE Standards.

(b) Primary and secondary voltage rating, kva capacity, and

taps.

(c) Applicable ANSI and IEEE Standards for accessories of

different capacity transformers, such as thermometers, liquid

level indicators, liquid sampling devices, external tap changers.

(d) Transformer hangers for rigid mounting on the

crossarms.

(e) Transformer bushings for rigid mounting with no

evidence of cracks of chips.

(f) Transformer tanks for pin hole leaks.

(g) Impulse test certification if required by

specification.

(3) Check during installation:

(a) Correct tap setting.

(b) Even distribution of weight of transformer banks.

(c) Mounting, crossmans, braces, wiring on pole mounting of

H frame mountings.
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16B-5

(d) Primary and secondary connections.

(e) Grounding of transformer tanks.

(f) Rating of protective fuses.

(g) Accessibility of fused cutouts on pole.

(h) Type of electrical connections.

(i) Fused cutouts and lightning arrestors installed on the

primary side of each transformer supplied from an exterior

distribution system.

h. Primary and Secondary Fuse Cutouts

(l) See that approved type is used. Is it indicating or

dropout; enclosed or open?

(2) Check current and voltage rating and short circuit

interrupting capacity against design requirements.

(3) Be sure fuse links are of the capacity and delay

specified and that they do not exceed the capacity of connected

conductors. (Capacity tables for conductors may be found in NFPA

Handbook 70, National Electrical Code).

(4) Check connection points of line conductors and load

conductors.

(5) Examine type of bracket. Be sure bracket is secure,

clear of adjoining structure, and convenient for operation.

i. Lightning Arrestors

Check:

(1) Location.

(2) Voltage rating and type against specification

requirement.

(3) Mounting bracket.

(4) Grounding connectors.

(5) Ground resistance prior to energizing the line.

(6) Arrestors are not used as insulators to support

conductors.

j. Pole Top Switches

(1) Compare switches with approval, making sure that

correct current and voltage rated ones are used.

(2) Assure that contact surfaces will operate under ice

conditions.

(3) Watch arcing horns for contact during operation.
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16B-6

(4) See that operating rods are provided with an insulator

in the rod if specified.

(5) Make sure operating handle is equipped with lock and

keys. If interlocking keying is specified, be sure it is

furnished. Check out interlocking.

(6) Examine location of operating handle for convenience

and safety.

k. Grounding

(1) Check type of ground conductors against design.

(2) Inspect exothermic welded ground connections for size

rod, connector and powder charge against manufacturer*s

recommendations.

(3) verify that ground rods are properly spaced relative to

the pole.

(4) Examine mechanical grounding connectors.

(5) Check connectors to aluminum conductors. Connectors

must be approved for aluminum.

(6) See that grounding conductors are protected from

mechanical injury.

(7) Determine and record ground resistance; also determine

need for additional ground rods.

(8) Record driven depth of ground rods.

(9) Insure that all noncurrent carrying metal parts on pole

are grounded when specified.

(10) Check for separate grounding conductors and rods for

lightning arrestor and equipment when required by specifications.

l. Street Lighting

(1) Examine all street lighting components.

(a) Check lighting bracket.

(b) When inspecting fixtures watch for:

- Light diffusing pattern.

- Open or enclosed type.

- Gaskets to protect the globe.

- Film cutouts on series systems.

- Free access for maintenance.

- Insulating transformers.

(c) Inspect regulator for kw rating, input voltage, and

output current.
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16B-7

(d) Verify protector and control equipment voltage rating.

(2) Check during installation:

(a) Height of fixture.

(b) Lightning arrestors and fused cutouts installed on each

phase of the supply to the protector.

(c) All ferrous surfaces hot dip galvanized.

(d) Each fixture will be secured with required number of

through bolts of correct size.

(e) All metallic poles or standards.

m. Underground Risers

(1) Examine conduit clamps for size and number.

(2) Check duct seal at the conduit terminations.

(3) Look for listed insulated bushings at the conduit

termination.

(4) Check cable terminations.

(5) Inspect during installation:

(a) Lag screws used on the conduit clamps.

(b) Cable supports to eliminate weight on the cable

terminations.

(c) Metallic conduit below grade has approved protective

finish as required.

(d) Stress cones on shielded cable.

(e) Safe climbing space.

16B-03 UNDERGROUND DISTRIBUTION

a. Duct System

(1) Check:

(a) Materials

(b) Method of encasement

(c) Painting

(d) Duct supports and spacers for size to maintain duct

spacing.

(2) Check during installation:

(a) End bells and bushings at duct terminations.

(b) Ground bushings at all conduit terminations.
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16B-8

(c) Strength of concrete and presence of reinforcing steel

where required under roads, paved areas, etc.

(d) Compacted subgrade.

(e) Spacers and spacing between ducts and minimum concrete

cover all sides of ductbank.

(f) Spacing between electric and signal ducts.

(g) Alignment and grade of conduits, especially during

encasement with concrete.

(h) Staggering of conduit joints.

(i) Adapters for joining dissimilar types of duct (see that

they are not field fabricated)

(j) Changes in direction made with factory fabricated

devices.

(k) Ducts secured in the forms.

(l) Ducts pitched to drain.

(m) Duct plugs used during construction and on all spare

ducts.

(n) Cleaning of ducts.

(o) Seal duct entrances into manholes.

(p) Cover over ducts.

(q) Pull wires in place.

(r) Minimum curve radius of duct line in accordance with

specification.

(s) Installation of marker if required by specifications.

b. Manholes, Handholes. and Underground Vaults

(1) Verify size according to specifications.

(2) Check that duct entrances are located to avoid sharp

cable bends or sufficient space is allotted to permit a reverse

cable bend.

(3) Determine strength of concrete.

(4) Check quantity and size of reinforcing steel.

(5) Check strength of cover and frame, marking of cover,

and machine finished joint between frame and cover.

(6) Be sure that approved cable racks, pulling irons,

steps, ground rod, etc., are provided in the specified quantity.

(7) Check during installation:

(a) Sequence of concrete placement (Construction joints are

undesirable between the base and walls.)
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(b) Seal around duct entrances and plug unused ducts.

(c) Pull irons are located opposite duct entrances.

(d) Waterproofing.

(e) Sump or drain.

(f) Quantity and location of cable racks, hooks, and

insulators.

(g) Ground rod and ground cable.

(h) Grounding of cable racks and lead cable sheaths.

c. Primary Cables

(1) Inspect splicing kits and methods.

(2) Check qualification of cable splicer.

(3) Check cables for insulation, shielding, stranding,

jacket or sheath and voltage rating.

(4) Examine potheads and pothead compounds.

(5) Check during installation that proper cable limits,

pulling techniques and equipment are used to prevent cable damage.

(a) Type of pulling compounds: Verify that the compound is

compatible with the cable and does not affect the flame

retardation of the cable.

(b) Setup of reels (Do not kink).

(c) Cables sealed for pulling.

(d) Abrasion to sheaths on manhole frames.

(e) Even tension used in cable pulling.

(f) Cable routing in manhole.

(g) Splicing or terminating of cable.

(h) Conductor identification tags.

(i) Stress cones at splices and terminations.

(j) Ground shielding at splices and potheads.

(k) Abrasion or damage to cable by dragging on ground.

(l) Fireproofing cables in manhole when specified.

(m) Required tests.

d. Direct Burial Cable

(1) Verify cable burial depth.
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(2) Check protective covering or armor. Check

manufacturer*s designation for use. Compare material with approval

data.

(3) Check during installation:

(a) Type of bedding and covering (should be smooth and free

of stones and sharp objects)

(b) Use of untreated plank over cable when specified.

(c) Method of laying.

(d) Weaving of cable in trench.

(a) Radius of bends.

(f) Splices (minimization).

(g) Use of approved splicing kits.

(h) Installation of concrete cable markers with letter and

arrow or tape markers as specified..

(i) Concrete encased conduits with bushings under traffic

crossings.

(3) Spacing between cables.

(k) Compaction over cables.

a. Potheads

(1) Check size of the conductors or cables.

(2) Check stuffing box or wiping sleeve.

(3) Verify that compound is approved and installed as

required.

(4) Make sure that installer is a qualified splicer.

(5) Check stress cones.

(6) Test compound for correct pouring temperature.

f. Transformers in Fenced Enclosures

(1) See that ferrous materials are protected with

galvanized finish or are painted per specifications.

(2) Insure transformers, potheads, fused cutouts and

lightning arrestors conform with the electrical characteristics

specified and/or approved.

(3) Check installation of primary and secondary cabling for

stress cones, waterproof connections, and insulators.

(4) Check during installation:

(a) Swing of gates.
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16B-11

(b) Drainage of transformer pad.

(c) Elevation of transformer off pad.

(d) Grounding of all noncurrent carrying metal within the

enclosure.

(e) Grounding of the fence and gate.

(f) Proper grounding of primary (e.g. surge arresters) and

secondary (e.g. neutral) equipment.

(g) Space available in transformer enclosure

(h) Bonding of all metal conduits terminating in the

transformer enclosure to the ground system.

(i) Proper warning signs affixed to enclosure fence.

(j) Welds on fence structure are protected in accordance

with specifications.

g. Pad Mounted Tranformers without Fenced Enclosures

(1) See 16B-02g, and 16B-03f.

(2) See that tamper proof enclosure has not exposed bolts,

nuts, or fittings, the removal of which would give access to live

internal parts and that meters, valves and other accessories are

within locked enclosure or otherwise resistant to tampering, and

that ventilation openings are so protected that a wire cannot be

inserted to contact a live part.

(3) Verify that accessories, such as lightning arrestors,

switches, gauges, etc., are furnished as specified.

h. Testing General discussion with the contractor on LOCKOUT/TAG-OUTprocedure before any testing.

16B-04 CATHODIC PROTECTION

a. General

(1) Cathodic protection is provided to preserve underground

or underwater metallic structures including submerged interior

surface of water storage tanks from corrosion. Corrosion takes

place at points where electrical current leaves the metal and

travels through the ground or electrolyte to another metal or to a

different place on the same pipe or structure. Corrosion is

arrested when an electromotive force is impressed on an

underground or underwater metallic structure in such a way as to

make the entire structure cathodic with respect to the adjacent

soil or water.

(2) Cathodic protection can be provided as described above

or in the following manner: Sacrificial galvanic anodes are used

having a difference of potential with respect to the structure to

be protected. The anodes are made of a material, such as magnesium

or zinc, which is anodic with respect to the protected structure.

The galvanic — anode system is designed to deliver relatively

small current from a large number of anodes.
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16B-12

(3) In addition to the following, complete the CP

Acceptance Criteria during the Quality Assurance inspection.

b. Shop drawings

(1) The following items, if required in the work, must be

approved prior to installation:

Anodes Electrical boxes

Conductors Splicing materials

Rectifiers Anode Hanger for tanks

Conduit Transformer

(2) Check material brought to the job site against approved

shop drawings.

c. Anodes

(1) Be sure the anodes are not broken while being installed

(Some anodes, such as duriron, are very brittle)

(2) Do not vary the spacing of the anodes more than 5%

either way.

(3) The location of the anode bed should not be changed

without consulting your supervisor.

(4) Be sure the anodes are installed in accordance with

design and specifications.

d. Conductors

The insulation on the conductors must not be damaged during

construction on impressed current systems. If it is damaged, the

conductor may be soon be destroyed by electrolytic action.

e. Conductor Connections

Assure that joints are mechanically secure and that they

are water tight.

f. Insulating Joints

Determine if insulating joints in pipe structures are

required. Install in accordance with construction drawings. The

insulating joints are used to accomplish the following: Isolate

dissimilar metals; sectionalize pipe lines with dissimilar

coatings; sectionalize one cathodic protection systems from

another.

g. Bonding

(1) See that pipe joints are bonded (if called for in the

contract) before the pipe line is backfilled.

(2) Be sure that bonds to other piping systems or

structures are installed. If they are the resistor type, see that

they are adjusted.

h. Test Points

Test points must be located exactly as shown on contract

drawings.
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16B-13

i. Foreign Pipes and Structures

(1) Foreign pipes and structures may require cathodic

protection.

(2) If you should discover, in the vicinity of the cathodic

protection system, underground metal pipes or tanks that were

unknown to the designer, bring them to your supervisor*s

attention.

j. Backfill for Underground Metallic Structure

(1) Backfill of pipes and tanks must not contain rock or

materials which would damage the coating on the structure or pipe.

(2) Check to see that only specified type of backfill is

used. Cinder backfill should never he used.

k. Auxiliary Eguipment

Check the installation of the rectifiers, transformers,

conduit, and other electrical equipment using applicable parts of

Chapter 16.

l. Electrical Measurements

(1) Impressed current system — Inform your supervision when

the installation is complete.

(2) Sacrificial type anode system (using metallic anodes

without external power supply) - Inform your supervisor when

system is complete, prior to bonding the anodes to the structure.

m. Starting and Adjusting

Do not start the system to make adjustments. Request your

supervisor or the CQC representative to obtain the services of one

qualified in cathodic protection systems to perform these

functions.

n. Record of Testing

Obtain a copy of the readings taken by the cathodic

protection expert, including the potential measurements of the

pipe before and after protection is applied, rectifier current and

voltage readings for each set of potential measurements after the

system is connected. These readings should be kept in the job

records and turned over to the using agency when the work has been

completed.

16B-05 ENERGY MONITORING AND CONTROL SYSTEMS (EMCS)

When inspecting Energy Monitoring and Control Systems use

Huntsville Division*s publication, CEHND-SP-91-005-DE-ME, April

1991 or as updated, Quality Verification Guidelines for EMCS. In

order to provide the best product for the customers, the

District*s Construction Division EMCS Technical Coordinator must

be actively involved during the construction phase. Any questions

which the Area/Resident Engineer cannot answer, should go to the

technical Coordinator. The District can then call a Special

Evaluation Group meeting to resolve any unusual or
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16B-14

precedent setting questions. All Value Engineering proposals

presented during any phase of the project must be reviewed by the

Mandatory Center of Expertise (MCX) for EMCS at Huntsville

Division.

16B-08 RF SHIELDED FACILITY

Direct all questions which arise during the construction

phase of a C41 (RF Shielded) facility to the Protective Design

Mandatory Center of Expertise (PD-MCX)
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i

CHAPTER 16C

ELECTRICAL HEATING

INDEX

Para. Title Page

16C-01 GENERAL 16C-1

a. Definition 16C-1

b. Approvals 16C-l

c. Storage and Handling 16C-1

d. Coordination of Work 16C-1

e. Layout of Work 16C-1

16C-02 ELECTRIC WATER HEATERS 16C-1

16C-03 ELECTRIC HEATERS 16C-2

16C-04 COORDINATION WITH MECHANICAL WORK

FOR ELECTRIC WATER HEATERS 16C-2

a. Pressure — Temperature

Relief Valve 16C-2

b. Piping and Insulation 16C-2
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CHAPTER 16C

ELECTRICAL HEATING

16C-01 GENERAL

a. Definition

This chapter covers materials, equipment, and good

workmanship practices for the installation of electrical heating

system.

b. Approvals

Insure that all material, equipment, and shop drawings are

approved prior to the Preparatory Inspection meeting and prior

to installation of the electrical heating equipment. Obtain any

helpful manufacturers installation information.

c. Storage and Handling

(1) Insure that all materials and equipment are handled

carefully to prevent damage.

(2) Reject damaged material and equipment. Have it removed

from the site.

(3) Check storage facility for adequate weather

protection, possible damage, and safety hazard.

(4) When outside storage is necessary, store materials and

equipment above ground.

d. Coordination of Work

Continually check for interferences between electrical,

mechanical, architectural, and structural features.

e. Layout of Work

(1) The contractor must provide equipment and mechanical

room layout drawings, which include location of hot water

heater, for review and approval.

(2) Check location of water heater for accessability for

mechanical and electrical, maintenance, and future replacement

if necessary.

(3) The contractor must coordinate installation of

electric heaters with work of other trades, to avoid obstruction

to heating pattern and overheatings of adjacent surfaces.

Coordinate changes in heater layout with supervisor.

16C-02 ELECTRIC WATER HEATERS (Project Specifications,

Plumbing)

a. Check for the required number of heating elements

(Federal Specification).

b. Check to determine that each heating element is

controlled by a separate thermostat (Federal Specification).
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16C-2

c. Check for manual-reset type high-limit cutout. Highlimit cutout to open all electrical connects to all heating

elements (Federal Specification).

d. Voltage rating of heaters to be in accordance with

specification requirements. 240 volt units, if operated on 208V,

will only deliver approximately 75% of design heating capacity.

16C-03 ELECTRIC HEATERS

a. Check voltage rating of equipment furnished.

b. Check wattage rating of heater (Project Specification

or Design)

c. Check to see whether a high-limit switch is required

(Project Specification)

d. Check physical requirements of heater. Embedded

elements are usually specified.

e. Heaters for hazardous areas are to bear a tag

indicating Underwriters Laboratories approval.

f. A functional test is required on electric heaters.

g. Check thermostats for range of operation, differential,

locking facilities, thermometer, and lock-shield requirements

(Project Specifications).

16C-04 COORDINATION WITH MECHANICAL WORK FOR ELECTRIC WATER

HEATERS

a. Pressure — Temperature Relief Valve

Check to see that relief valve is stamped for the

specified pressure and temperature. Check to see that relief

valve is correctly positioned and piped to safely discharge.

Check to see if relief valve will reset after being manually

activated. Relief valves may be separate or combination pressure

and relief on equipment used for heating water or storing hot

water.

b. Piping and Insulation

See Section 15A for piping and Section 15C for Insulation.
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i

CHAPTER 16D

ALARM AND DETECTION SYSTEM

INDEX

Para. Title Page

16D-01 GENERAL 16D-1

a. Definition 16D-1

b. Approvals 16D-1

c. Storage and Handling 16D-1

d. Layout of Work 16D-1

e. Coordination of Work 16D-1

16D-02 FIRE DETECTING DEVICES 16D-2

a. Smoke Detectors,

Ionization Type 16D-2

b. Smoke Detectors, Photo

electric Type. 16D-2

c. Heat Detectors 16D-2

16D-03 FIRE ALARM STATIONS 16D-2

16D-04 SIGNALING DEVICES 16D-2

16D-05 CONTROL UNITS 16D-2

a. Smoke Detector Panel 16D-3

b. Annunciator Panel 16D-3

16D-06 POWER SUPPLY 16D-3

16D-07 TESTING 16D-3
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CHAPTER 16D

ALARM AND DETECTION SYSTEMS

16D-01 GENERAL

a. Definition

This chapter covers materials, equipment, and good

workmanship practices for the installation of fire alarm and

detector system. The inspector must closely coordinate this

chapter with Chapter 15A, 16A and 16B. It is important that the

inspector have a thorough knowledge of the NEC and applicable NFPA

codes, contract specifications, and the fire protection plan for

the whole building. Any missing or non consistent application of

the various fire protection parts should be called to the

attention of your supervisor. See specification and 1984 NEC,

Article 760, Fire Protective Signaling System. Paragraph 760-1

lists NFPA codes applicable to the several protective systems.

b. Approvals

Insure that all materials, equipment, and shop drawings are

approved prior to preparatory inspection and installation. Obtain

helpful manufacturer's installation information.

c. Storage and Handling

(1) Insure that all materials and equipment are new and

handled carefully to prevent damage. Reject damaged materials or

equipment and have it removed from the site.

(2) Check storage facility for adequate weather protection,

possible damage, and safety hazard.

d. Layout of Work

(1) Check equipment requirements and locations on contract

drawings and specifications.

(2) Check approved shop drawings for complete wiring and

schematic diagram for equipment furnished, equipment layout, and

other details required to demonstrate that the system has been

coordinated and will function as a unit.

(3) Check contract specification for requirements for

contractor to furnish spare parts and spare parts data, operating

instruction manual, maintenance instructions manual, and

performance test reports. Note requirement in specifications which

items are to be turned over and which items are to be posted

permanently in the building.

a. Coordination of Work

(1) Continually check for interferences between electrical,

mechanical, architectural, and structural features. Insure that

paint is not accidently applied to sensors, nameplates on

equipment, or on posted operating instructions.

(2) Electrical work is to be installed under the guidance

of Section, 16A Interior Electrical. Other coordination 
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16D-2

requirements are with Section 15H; Fire Protection Systems; and

15A, Piping Systems. Mechanical installation will normally be in

accordance with NFPA 13 unless otherwise specified in the contract

specification.

16D-02 FIRE DETECTING DEVICES

Fire detecting device will be located as shown or otherwise

indicated. Unless otherwise shown the devices will be surface

mounted. Smoke detectors will not be located in direct supply air

flow nor closer than 3 feet from an air supply diffuser.

a. Smoke Detectors, Ionization Types

Check for dual chamber design. Check for sensitive

adjustment. Check for correct operating voltage and type of

current (AC or DC). Check for indicator lamp. Check duct-mounted

detector to see if the air sampling tube length is equal to width

of duct. Smoke detectors located in the underfloor spaces will

only be mounted in upper portion of the space with the detector

facing downwards, or mounted sideways.

b. Smoke Detectors, Photo-eletric Type

Check for factor calibration and not field adjustment.

Check for light source lamp or LEO of specified voltage.

c. Heat Detectors

1. Check heat detector requirements for fixed temperature

or combination fixed temperature and rate-of-rise ratings. Check

for replaceable fixable elements. Check for specified locations of

detectors.

2. Heat detectors located in spaces where the ambient

temperature can be over 100 degrees F will be rated higher than

ordinary temperature; e.g. Detectors located in attic spaces

should have an intermediate temperature rating.

16D-03 FIRE ALARM STATIONS

Check for type of station specified. Check for coded or

non-coded requirement. Check for test key requirement. Check locks

for being keyed alike with fire alarm control panel. Check

mounting requirements.

16D-04 SIGNALING DEVICES

Check for locations as indicated on contract documents.

Bells are normally mounted on removable adapter plates over

electrical outlet boxes. Exterior bells: check for weather proof

type bells with metal housing and protection grills. Visual fire

alarm indicators are mounted same as bells. Trouble Indicators are

normally mounted in flush mounted panels.

16D-05 CONTROL UNITS

Check control unit for complying with approved shop

drawings. Check for proper operating voltage. Check to see that

upon failure of power supply, that system shall operate from backup power supply. Check panel for metal construction, with factory

applied red enamel finish, accessable from the front, and surface

mounted unless otherwise indicated. Check for proper labeling of

control panels such as descriptive labeling of zones.
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16D-3

a. Smoke Detector Panel

Check for proper voltage power supply. Check for back up

power system. Panel fabrication; paint color, and mounting same as

control units.

b. Annunciator Panel

Check annunciation panel for complying with approved unit.

Check for tamper proof.

16D-06 POWER SUPPLY

Check specifications for power feed, overload protection,

conductor hook-up equipment. Check specifications for back up

power requirements, i.e. primary, batteries, and charges.

16D-07 TESTING

Check specifications for 30 day contractor*s notification

to contracting office before conducting performance end acceptance

tests. Test to be conducted in presence of CO or his authorized

representative. Check specification for description of tests to be

conducted. Check to see that all quality control records, teat

reports, and records of corrective actions are furnished to the

Government.
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i

CHAPTER 16E

ALUMINUM CONDUCTORS

INDEX

Para. Title Page

16E-01 GENERAL 16E-1

16E-02 MATERIAL 16E-1

a. Conductors 16E-1

b. Bolts, Nuts, and Washers 16E-1

16E-03 INSTALLATION 16E-1

a. Conductor Size 16E-1

b. Removing Insulation 16E-2

c. Surface Preparation 16E-2

d. Connections 16E-2

a. Connection to Vibrating

or Cycling (Intermittent

Duty) Equipment 16E-3

16E-04 ENVIRONMENTAL CONDITIONS 16E-3

16E-05 INSPECTION AND ANALYSIS 16E-3
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16E-1

CHAPTER 16E

ALUMINUM CONDUCTORS

16E-01 GENERAL

The information included is important because of recurring

and serious problems in public and private construction where

aluminum conductors are used in the wiring system. We permit a

limited use of aluminum conductors. Special skills and tools are

required when making connections and terminations with aluminum

conductors.

16E-02 MATERIAL

a. Conductors

(1) The electrical systems shown on drawings indicate

copper wire size given in gauge number, American Wire Gauge

(AWG).

(2) Aluminum is permitted only for copper wire sizes No. 6

AWG and larger.

(3) Aluminum wire size substitutions for copper wire must

have ampacity of not less than the copper wire size shown. The

tables in Article 310 of the National Electric Code (NEC) show

the allowable ampacities of insulated copper and insulated

aluminum conductors. The correct size aluminum wire can be

determined by using the ampacity value for copper wire in a

given size in the aluminum conductor table. The equivalent

temperature rating of the conductor must match-up with the

conductor being installed.

b. Bolts, Nuts and Washers

(1) Check these materials for proper alloy and finish. An

anodized finish may be required.

(2) Plain, standard series flat washers are required;

Narrow series washers cannot be used.

(3) Antioxidant Joint Compound

Use approved oxide-inhibiting joint compound when makingup aluminum conductor/pressure fitting connections and at bus

bar connections.

(4) Connectors

(a) Pressure connectors must be tinned aluminum bodies.

(b) Must be rated for use with aluminum conductors.

(c) Must be required size, material, and tightened to

specified torque.

16E-23 INSTALLATION

a. Conductor Size

(1) Aluminum wire used must be number 4, AWG or larger.
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(2) Check for the equivalent aluminum gauge size as the

size shown on the drawings is for copper.

b. Removing Insulation

(1) Check removal or stripping method; wire should not be

damaged. Recommended methods are:

Whittling - Using a knife as in sharpening a pencil.

Peeling - Using a knife from the end of the conductor to

peel back, and cut off the insulation, cutting away from the

wire.

Stripping - Using the proper size stripping tool. A tool

that will nick or ring the wire shall not be used. (Ringing is

to cut the wire over its circumference)

(2) Wire conductors which are nicked or ringed should have

damaged portion removed and the conductor properly prepared.

(3) A nick or ring reduces conductor ampacity and

introduces a weak point.

c. Surface Preparation

(1) Check for clean surface.

(2) Wire may require wire brushing to assure aluminum

oxide is removed.

(3) Cleaning may require a coating of antioxident joint

compound and a second wire brushing.

(4) Check for the required costing of antioxident joint

compound on wire immediately before the connection is made.

(5) On aluminum bus bars check for silver plating at

connection point surfaces.

(6) Also check for a light coating of antioxidant joint

compound at bus bar connections.

d. Connections

(1) Are bolted connections tightened with an approved

calibrated torque wrench?

(2) Check that compression connectors are applied with the

proper tool and force.

(3) Are screw connections properly torqued?

(4) Are terminal lugs and connectors made from approved

materials? Must be of aluminum and tin and so labeled. Also cap

be nickel plated copper.

(5) Are compression terminals and connectors tightened

with the special tool?

(6) Screws of bolt type terminals and connectors must be

tightened with an approved, calibrated torque wrench.
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16E-3

(7) Check torque wrenches for calibration by an approved

testing firm. These wrenches are designed to slip when the

present torque is exceeded.

e. Connection to Vibrating or Cycling (Intermittent Duty)

Equipment

Aluminum conductors are not recommended for this

equipment. Use standard or solid copper conductors as specified.

(1) Check for use of aluminum conductors to vibrating

equipment. Extreme movement and vibration induces stresses in

aluminum wire. Aluminum wire has poor workability.

(2) Check for use of aluminum conductors in cycling

equipment. The aluminum conductor receives high current and

stress each time equipment is energized. This causes connections

to loosen from creep.

16E-04 ENVIRONMENTAL CONDITIONS

Conditions which can effect Aluminum Conductors

(a) Salt water, air pollution and high relative humidity

conditions or corrosive soil will accelerate corrosion of

unprotected aluminum wire.

(b) Extreme changes in the ambient temperature will

adversely affect workability and the extent of creep and

oxidation.

(c) When any of these conditions are present check for use

of aluminum conductors. When used, check for a protection tape

wrap for the exposed bare aluminum wire. Apply oxide— inhibiting

joint compound to the surface of exposed connectors and

terminals.

16E-05 INSPECTION AND ANALYSIS

a. Wrong wire size? Aluminum wire gauge must be No. 4 AWC

or larger. See Article 310, NEC, for aluminum equivalent size

for copper size shown.

b. Is the conductor ringed or nicked? Disapprove and

require a new section of undamaged conductor be prepared using

proper methods.

c. Terminal material must be bi-metalic when copper and

aluminum are used on the same terminal or bus. Check for stamped

letters “AL-CU” for an approved bi-metalic terminal. Check for

both proper size and type of terminals and connectors.

d. Is aluminum bus, silver plated at the connection point

surfaces? If not, disapprove, as it must be factory plated.

e. Is aluminum wire cleaned and coated with oxideinhibiting joint compound immediately before making connections?

f. Is an approved, calibrated torque wrench used to

tighten bolted and screwed connections? Check calibration date

for being recent.
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16E-4

g. Check for proper crimping tool use in compression

connections.

h. Is connection loose or otherwise poorly made? After

electrical system is activated check for:

(1) Voltage drop across the connection (there is no

voltage drop across a good connection)

(2) Discoloration of the aluminum wire and/or insulation

at the connection : gray-white color coating on the wire

indicates aluminum oxide corrosion. A brown-black color on the

insulation, or if the insulation is brittle, indicates a

failure.

i. A “Hot Spot Check” with an infra-red scan will indicate

thermal build-up at points of failure.