Chrysler LLC Construction Standards s7

Chrysler LLC Construction Standards 12/17/04

SECTION 15220 - INDUSTRIAL WASTEWATER PIPING SYSTEMS

PART 1 - GENERAL

0.1 SUMMARY

A. This Section includes piping and specialties for the industrial wastewater, coolant transfer, and treated industrial waste piping system. System includes pipe, valves, and hangers. 1. Provide allowance for thermal expansion and contraction with anchors, guides, and expansion loops as indicated and as required by fiberglass piping manufacturer. 2. Provide valve pneumatic actuators as specified where indicated.

0.2 SYSTEM DESCRIPTION

A. This piping specification applies to the following piping systems: 1. Industrial Waste (IW) 2. Pumped Industrial Waste (PIW) 3. E-Coat Waste (EW) 4. Pumped E-Coat Waste (PEW) 5. Treated Waste (TW) 6. Treated Sludge (TS) 7. Chemical Recirculation (CR) 8. Skimmed Waste (SK) 9. Recycled Water System (RCW) 10. Cutting Machine Coolant Transfer and Treated industrial Waste Water Piping, located inside the building and on the Trestle (CX).

B. Service Rating 1. Pressure Range: 0-150 psig. 2. Temperature Range: Plus 32 deg F to minus 210 deg F.

0.3 QUALITY ASSURANCE

A. Materials and workmanship must comply with the applicable standards and specifications for piping system installation set forth by the latest issue of the applicable ANSI and ASME codes.

B. Fiberglass piping shall have minimum continuous working pressure rating of 150 psig at 210 deg F in accordance with ASTM Standard Method of Test D 2992-Procedure A.

C. Fiberglass pipe shall be in compliance with specification ASTM D 2996 Standard Specification for Filament Wound Pipe.

D. Fiberglass pipe shall be in compliance with specification ASTM D 2310 Standard Classification for Machine Made Reinforced Thermosetting Resin Pipe.

E. Fiberglass pipe shall comply with the following: ASTM D 2105 standard test method for longitudinal tensile properties of fiberglass pipe and tube.

F. Where details of fabrication are not shown on the drawings or specified in this or other specifications, fabrication shall be in accordance with applicable fabrication requirement of ANSI B31.3 "Code for Pressure Piping, Petroleum Refinery Piping."

G. Valves of same type shall be by a single manufacturer and shall comply with the requirements of Division 1 section “Materials and Equipment” under “Source Limitations” paragraphs.

H. Valves and valve components shall be silicone-free.

INDUSTRIAL WASTEWATER PIPING SYSTEMS 15220 - 1 of 10 Chrysler LLC Construction Standards 12/17/04

I. Double-wall pipe used for secondary containment shall meet requirements of Chrysler Manufacturing Technical Instructions SMI-156. Single-wall piping shall not be installed underground unless specifically required on the drawings.

0.4 SUBMITTALS

A. Result of stress analysis for fiberglass pipe with recommended locations for hangers, anchors, and guides.

B. Double-wall piping system data, including temperature, pressure, materials of construction, installation procedures, connector details, joint details, maintenance procedures, high point vent and low point drain details.

C. Product data for each valve type. Include body materials, valve design pressure and temperature classification, end connections, seat and trim materials, dimensions and required clearances, and operating torques, including breakaway torque.

0.5 DELIVERY, STORAGE AND HANDLING

A. Piping shall be received on site by the Contractor and stored according to instructions of the pipe manufacturer. Exercise caution to avoid damage to pipe during unloading and storage.

B. Protect the fiberglass pipe and fittings from ultraviolet degradation according to the manufacturer’s instructions.

C. Valves shall be protected during shipping in accordance with API 609 standard, Articles 4.3, 4.4, 4.6.1, and 4.6.3.

D. Valves stored on site shall have protective end covers in place until used.

PART 2 - PRODUCTS

0.1 MANUFACTURERS

A. Unless otherwise directed by the Owner, provide products by one of the following: 1. Fiberglass Pipe and Fittings a. Smith Fiberglass; Red Thread II b. Bondstrand Series 2000 Pipe and fittings c. Fibercast 2. Double Wall Pipe System (Fiberglass Pipe) a. Smith Fiberglass b. Bondstrand c. Fibercast d. Bondstrand CX (Alternate) 3. Butterfly Valves (TFE Lined) a. Keystone b. Grinnell c. Bray 4. Butterfly Valves (EPDM Seat) a. Keystone b. Grinnell c. Bray 5. Butterfly Valves (BUNA-N Seat) a. Keystone b. Grinnell c. Bray

6. Lined Plug Valves a. Durco T-Line b. Tufline 061 c. Chem Plug 021 7. Plug Valves (TFE Sleeved) a. Tufline 067 b. Floroseal c. Chem-Plug 022 8. Check Valves, Wafer Style a. Gulf-Valve Co. Figure No. MB15 series b. Mueller Steam Specialties c. Powell Valve Co. (alloy 20 swing check) 9. Poppet Check Valves a. Dow Model 555 horizontal b. Dow Model 556 vertical 10. Expansion Joints a. Metroflex T-2-J b. Performance Plastics c. Resistoflex d. Ethylene 11. Nozzle Liners a. Aetna Plastics b. Performance Plastics 12. Ball Valves (nonmetallic) a. Nil-Cor 310 series 13. Ball Valves - Lined a. Atomac b. Xomox c. ITT-Richter d. Neotecha 14. Ball Valves - Carbon Steel a. KTM b. Neles Jamesbury c. PBM d. Worcester 15. Pinch Valves a. Grigsby (F-300) b. Larox (PVE) 16. Grooved Butterfly Valves a. Grinnell Gruvlok 7700, 8000GR b. Victaulic Style 300 17. Grooved Ball Valves a. Grinnell Gruvlok 7500 b. Victaulic 721 18. Grooved Check Valves a. Grinnell Gruvlok Series 7800 b. Victaulic Series 716

0.2 DOUBLE WALL PIPE SYSTEM

A. Carrier Pipe 1. Double-wall system carrier pipe shall be material suitable for service application. Carrier pipe materials include carbon steel or fiberglass-reinforced epoxy resin pipe as herein specified and as noted on the drawings. 2. Double-wall system carrier pipe shall be supported inside containment pipe by FRP “centralizers” which leave a clear space at top and bottom of pipe for leak detection. “Centralizers” shall be permanently bonded to carrier pipe.

B. Containment Pipe 1. Containment pipe materials shall be fiberglass-reinforced epoxy piping system. 2. Containment pipe interstitial supporting devices (“centralizes”) must be of same fiberglass-reinforced material and resin as the piping system or manufactured from molded polypropylene spider pipe clips, according to ASTM and ANSI. 3. FRP Fittings - For Double-Walled FRP Containment Pipe Systems a. Fittings shall be compression or contact molded using same resin and cure compound materials as the associated pipe system. b. Fittings shall be glass-fiber-reinforced epoxy resin with a minimum of 60 percent chopped glass fiber. Interior liner of pipe shall be resin rich. Connections shall be adhesive socket joints. c. Clam shell fittings are not allowed. d. Double-wall system fittings shall be factory assembled to include inner carrier and outer containment fitting as a single unit.

C. Leak Detection - Double-Wall Pipe 1. Provide drip legs for leak detection in double-wall pipe system at each vertical change in direction and every 250 feet in horizontal runs. Drip legs are to include drain valve accessible from grade (within 6 feet of floor) from containment pipe, as noted on the drawings for underground pipe.

D. Alternate System 1. Double-wall coaxial system fabricated through a progressive process. A porous layer shall separate the inner and outer pipe. 2. Secondary containment fittings shall be coaxial in design and fabrication. Closure fitting of the secondary pipe shall be of same material as the piping itself.

0.3 MATERIALS

A. Fiberglass Pipe And Fittings 1. Pipe shall be manufactured by the filament winding process using an amine cured epoxy thermosetting resin to impregnate strands of continuous glass filaments, which are wound around a mandrel at a 35-1/4 degree helix angle under controlled tension. Pipe shall be heat cured. Pipe shall be supplied with a matching tapered coupling and a matching tapered spigot. All pipe shall be 100 percent hydrotested at the factory before shipment at a minimum pressure of 300 psig. a. . 2. Fittings shall be manufactured using the same type materials as the pipe. Fittings may be manufactured either by compression molding or spray-up/contact molding methods. Fittings shall be adhesive bonded matched tapered bell and spigot or flanged. Gaskets shall be 1/8 inch thick, 60 to 70 durometer full-face type suitable for the service, and as recommended in the manufacturer's standard installation procedures. 3. Fittings 8 inches through 16 inches shall be compression molded filament wound or mitered fiberglass reinforced epoxy. 4. Fiberglass pipe 18-inch through 30-inch diameter shall be filament wound. 5. Fittings 18-inch through 30-inch shall be manufactured by hand fabrication technique. Filament wound sections used for fitting makeup shall be same materials as the pipe system. 6. Flanges shall be flat face and drilled in accordance with ANSI B16.5 150 lb. Bolt hole drilling. 7. Provide pipe with UV degradation protection.

0.4 CARBON STEEL PIPE AND FITTINGS

A. Carbon Steel 1-1/2 Inches and Smaller: Schedule 80, ASTM A106, seamless, Grade A, plain ends.

B. Two Inches and Larger: Schedule 40, ASTM A53, Type E (electric resistance welded), Grade A, plain ends.

C. Malleable Iron Threaded Fittings 1-1/2 Inches and Smaller: ASME B16.3, Class 150 banded.

D. Malleable Iron Unions 2 Inches and Smaller: ASME B16.1, Class 125; ground joint, threaded ends.

E. Wrought Steel Fittings 2 Inches and Larger: Butt weld, ASTM A234, standard weight.

F. Wrought Steel Flanges 2 Inches and Larger: ASME B16.5, raised face weld-neck, or flat face where in contact with fiberglass pipe.

0.5 DUCTILE IRON PIPE AND FITTINGS

A. Ductile Iron Pipe 3 Inches and Larger: Class 50, 1/32 inch coal tar enamel coating in accordance with AWWA C151.

B. Ductile Iron Fittings 3 Inches and Larger: Mechanical joint with 1/32 inch coal tar enamel coating; mechanical joints to have Hycar gaskets, ANSI A21.10 and AWWA C110.

0.6 FRP JOINTS

A. The pipe and fittings shall be able to be joined with an epoxy adhesive on matching tapered bell-and-spigot or socket ends. The adhesive shall consist of a compatible epoxy resin to be installed in accordance with piping manufacturer’s installation instructions. Pipe fittings and adhesive shall be of same manufacturers. Large diameter pipe 18 inches and larger may be joined by butt and wrap method.

B. Bolts shall be ASTM A307, Grade B, hex head machine bolts with heavy hex nuts. Use steel washer at bolts and nuts.

0.7 GROOVED END STEEL FITTINGS

A. Use for treated sludge piping only.

B. Rigid joints shall be Victaulic Style 07 Zero-Flex couplings or Grinnell Gruvlok Style 7401.

0.8 GASKETS

A. Gasket material for flanged connections shall use elastomer compatible with the service, 1/8 inch thick with hardener of 50 to 20 Durometer on Shore A scale.

B. Gaskets for piping systems with EPDM lined or seated valves shall have EPDM gaskets.

C. Gaskets for piping systems with Viton-fitted valves shall have Viton gaskets.

0.9 ALLOY BODY KNIFE GATE VALVE

A. Manufacturers: 1. Dezurik 2. A C Valve 3. Orbinox 4. KG Valve

B. One-piece cast 304 stainless steel body, drilled and tapped wafer lug style meeting ANSI B16.5 flange 150 pattern, OS&Y, PTFE impregnated braided synthetic fiber packing, 304 stainless steel gate, 316 stainless steel packing gland, aluminum bronze yoke sleeve, metal seats per MSS-SP-81, epoxy coated cast iron or steel hand wheel actuator.

C. Optional replaceable resilient seat of Viton

0.10 BUTTERFLY VALVES

A. 2 Inches Through 14 Inches: 1. BFV-1: Tapped lug, ductile iron body, 150 psig pressure rating, TFE lined, TFE encapsulated disc, where noted. 2. BFV-2: Tapped lug ductile iron body, ductile iron disc, 150 psig pressure rating, EPDM seat where noted. 3. BFV-3: Tapped lug, ductile iron body, 150 psig pressure rating EPDM lined, EPDM encapsulated disc where noted. 4. BFV-4: Tapped lug ductile iron body, ductile iron disc, 150 psig pressure rating BUNA-N seat where noted. 5. Manual butterfly valves 4 inches and larger to be supplied with gear operator. 6. Butterfly valves in waste treatment building in chemical recirculation (CR) and butterfly valves in piping systems at batch tank nozzles shall be Type BFV-1 (TFE-lined). 7. Butterfly valves in industrial waste (IW), treated waste (TW), shall be Type BFV-4 unless noted otherwise. 8. Butterfly valves in EW, TS, SK, and RCW systems shall be BFV-4.

B. 14 Inches Through 16 Inches: 1. BFV-5: Tapped lug ductile iron body, ductile iron disc, 150 psig pressure rating BUNA-N seat where noted.

0.11 PLUG VALVES

A. 1 Inch Through 6 Inches: 1. PV-1: Plug valves shall be 150 lb flanged ductile iron body, FEP or PFA lined body and plug where noted on the drawings. 2. PV-2: Plug valves shall be 150 lb flanged ductile iron body, ductile iron plug, TFE sleeve where noted on the drawing. 3. Manual valves 4 inches and larger to be supplied with gear operator. 4. Use PV-1 valves for IW, EW, and CR systems; use PV-2 for TS, TW, SK, and RCW systems.

0.12 CHECK VALVES

A. CVA-1: Wafer style swing check shall be rated 150 lb, carbon steel body and plate, Viton seat, 316 SS pin and spring.

B. CVA-2: Vertical poppet check shall have ductile iron body, solid PTFE plug, wetted surfaces PTFE lined.

C. CVA-3: Horizontal poppet check valves shall have cast iron body, solid PTFE plug for 2 inches and under; polypropylene lined steel plug for 4 inches through 8 inches. Wetted surfaces shall be PTFE lined, except as indicated.

0.13 GROOVED BUTTERFLY VALVES

A. 2 Inches Through 12 Inches: Listed MSS SP-67, bubble-tight at 300 psig operating working pressure. Body shall be ductile iron with epoxy body coating (180 deg F maximum) or nylon

coating (220 deg F maximum). Disc shall be ductile iron with EPDM encapsulation. Trim shall be 416 stainless steel upper and lower shaft with bronze upper and lower shaft bearings. Valves shall be rated for dead-end service.

B. 14 Inches Through 24 Inches: Operating pressure to 200 psig non-shock. Body shall be cast iron to ASTM A126, Class B. Disc shall be nickel-plated ductile, aluminum bronze, or stainless steel. Liner material shall be EPDM. Teflon-reinforced upper and lower bearings. Trim shall be 316 or 416 stainless steel. Valves shall be rated for dead-end service.

0.14 GROOVED BALL VALVES

A. 1-1/2 Inches to 6 Inches: Standard port design rated for 600 psi WOG. 100 percent hydro pressure tested. Bidirectional flow, body and end caps shall be carbon steel zinc electroplated to ASTM B633, ball and stem guard shall be chrome-plated carbon steel. Seats and steam seals shall be 15 percent glass-filled TFE. Type 304 stainless steel seal spring. Stem shall be chrome-plated carbon and alloy steel. Handle shall be two-position.

0.15 GROOVED (NONSLAM) CHECK VALVES

A. Grinnell 7800 or approved substitute.

B. Check valve shall be nonslamming, spring closure design to seat the clapper before flow reversal occurs. The body shall be one-piece ductile iron conforming to ASTM A536 and shall have two plugged bosses, 1/2 inch NPT for pressure gage. The clapper shall be Type 302 or Type 304 stainless steel to ASTM A167 or ductile iron to ASTM A536. The spring shall be Type 302 stainless steel to ASTM A313.

0.16 ALLOY BODY KNIFE GATE VALVE

A. Manufacturers: 1. Dezurik 2. A C Valve 3. Orbinox 4. KG Valve

B. One-piece cast 304 stainless steel body, drilled and tapped wafer lug style meeting ANSI B16.5 flange 150 pattern, OS&Y, PTFE impregnated braided synthetic fiber packing, 304 stainless steel gate, 316 stainless steel packing gland, aluminum bronze yoke sleeve, metal seats per MSS-SP-81, epoxy coated cast iron or steel hand wheel actuator.

C. Optional replaceable resilient seat of Viton

0.17 PRESSURE GAGES

A. Pressure gages for Industrial Waste (IW) and E-Coat Waste (EW) Treated Waste (TW) and Treated Sludge (TS) piping systems shall have diaphragm seal and shall be nonsilicone filled.

B. Gauge: Similar to Trerice No. 450 LFB series, nonsilicone filled with 4-1/2 inch size, solid front, blowout back, fiberglass reinforced polypropylene case, brass movement with bronze brushing, phosphor bronze silver brazed Bourdon tube, 1/4 inch NPT brass socket; accuracy plus or minus 1 percent of range.

C. Diaphragm Seal: Similar to Trerice Part No. M510-01CS diaphragm seal. Exposed surface is steel. Diaphragm is 316 stainless steel, 1/4 inch NPT, 1/4 inch nipple required between gauge and diaphragm seal.

D. Pressure gauge range shall be twice normal operating pressure or as shown on drawings.

0.18 TFE EXPANSION JOINTS

A. Expansion joints shall be molded TFE, with reinforcing rings, flanged 150 lb ductile iron flanges with thrust restraints.

0.19 VALVE STEM EXTENSION

A. Valve stem extension where required shall extend above finish floor 3 feet. Stem extension shall be steel and shall adapt directly to valve stem either through a direct socket or a valve stem socket adapter.

0.20 FLEXIBLE RUBBER SPOOL JOINTS

A. Flexible butyl rubber flanged spool at batch treatment tank overflows to be similar to Metraflex Style 100 single bellows style.

0.21 NOZZLE LINERS

A. Nozzle liners where shown on drawings shall be Teflon (FEP or PTFE).

B. Nozzle liner lengths, outside diameter, and sizes as noted on the drawings shall be verified by the Contractor to prevent damage to pipe nozzle lining.

0.22 CHAIN OPERATORS

A. Chain operators are required for valves installed at an elevation above 7 feet above finish floor which need frequent opening (once per week or more) unless a stem extension is shown.

0.23 BALL VALVES

A. 1 Inch Through 8 Inches: 1. BAV-1: Flanged, 150 lb drilled graphite fiber reinforced vinyl ester body and ball, stainless steel stem insert molded in graphite fiber reinforced vinyl ester, TFE seat and seal; manual lever handle. Valve shall be used as block and drain valves at pressure gauges, unless noted otherwise. 2. BAV-2: Flanged 150 lb ductile iron body and ball, PFA or TFE lined body and ball, PTFE seats and seals, PFA lined stainless steel stem. 3. BAV-3: Flanged, 150 lb ANSI drilled, carbon steel body, stainless steel ball, Teflon seats and seal. 4. Use BAV-1 in pressure gauge isolation and drains, systems. Use BAV-3 for IW,PIW and CX systems.

0.24 PINCH VALVES

A. Model F-300, enclosed cast iron body, 125 lb flange, BUNA-N sleeve.

0.25 PNEUMATIC ACTUATORS A Mfr. & Model N AUTOMAX SUPER NOVA SERIES C Type of Actuator RACK and PINION T Close at Open at 0 PSI 60 PSI U Travel Limits 1/4 TURN T Fail Position FAIL CLOSE R Handwheel & Location NONE P Mfr. & Model N ASCO w/ BRASS BODY

O Function 3 WAY S Solenoid Valve Enclosure NEMA 4, 4X, 7, 9 T Solenoid Valve Voltage 120 VAC N Air Supply Pressure 80 PSI O Limit Switch (2 SPST) OPEN/CLOSE P Mfr. & Model N WESTLOCK #2007X-BY T Enclosure Class NEMA 4, 4X, 7, 9

0.26 PERFORATED MONITORING DRAINS (PMD)

A. Porous wall porous underdrain pipe as manufactured by Walker Poroswall Pipe Co., ASTM C654.

B. Wrapping for Subsurface Drains: Equal to Mirafi, Inc. “Mirafi 140N” or “BIDM” geotextile filter fabric.

C. Aggregate Filer: Pea gravel.

D. Provide monitoring drains and install as a complete system.

PART 3 - EXECUTION

0.1 INSTALLATION

A. Wear saddles shall be installed in piping system at points of contact. Saddles shall consist of one half section of same pipe material bonded to pipeline wall or steel saddle with 1/8-inch-thick rubber gasket material between pipe and saddle.

B. Anchors installed in piping system shall not permanently set until ambient temperature reaches 60 deg F, but does not exceed 90 deg F.

C. Wear saddles bonded to piping shall be of same material as piping system and installed in accordance with piping manufacturer’s recommendations.

D. Hanger spacing for fiberglass pipe shall not exceed piping manufacturer’s recommendations. Provide hangers or support either side of valves to support valve length.

E. Pipe hangers used with fiberglass pipe shall be of width equivalent to or exceeding the manufacturer’s minimum strap width for hangers.

F. Flanges in fiberglass piping system shall be used only against flat-face flanges.

G. Fiberglass piping system shall be installed in accordance with piping manufacturer’s requirements. Joints installed or constructed in the field shall be assembled by employees of Contractor who have been trained by the pipe manufacturer. Pipe manufacturer or authorized representative shall train Contractor’s employees in proper joining and assembly procedures, including hands-on training by Contractor’s employees.

H. Fiberglass piping system shall not be tested with air or gas because of safety hazards created.

I. Piping shall be joined using manufacturer’s approved methods for the piping system. Hangers, anchors, and guides shall be installed where shown on the drawings. Field changes of the pipe routing, support spacing, or support details shall be submitted to the Architect/Engineer for approval. Pipe manufacturer shall review pipe, complete stress analysis and determine recommended location of anchors and guides for fiberglass pipe system. Completed analysis and recommendation of supports, anchors, and guides shall be submitted for review.

J. Piping shall be joined by flanges or epoxy adhesive with bell and spigot joints. Butt wrap joining methods will not be allowed.

K. Butterfly valves above 4-inch size shall have gear operators. Others shall have notched lever handles. Chain-operated valves shall be gear operated.

L. Ball valves above 4-inch size shall have gear operators. Others shall have lever handles. Chain operated ball valves shall be gear operated.

M. Plug valves above 3-inch size shall have gear operators.

N. Pressure testing of piping systems shall be performed in accordance with Division 15.

O. Cleaning and flushing of piping systems shall be performed in accordance with Division 15 Section "Cleaning and Flushing of Piping Systems."

P. Piping system shall be identified in accordance with Owner's requirements.

Q. Double-wall piping system shall be installed in accordance with manufacturer’s instructions. Manufacturer shall provide instruction for Contractor personnel who will be involved in installation of system. Training shall include loading procedures and joint construction. Double containment system is to be prefabricated.

R. Bedding and first foot of backfill of FRP pipe underground shall be with pea gravel. Material with stones, rocks, or other sharp-ended objects shall not be used. Compact to manufacturer’s requirements.

S. Provide valved vent and drain connections as needed to independently drain each main, branch and header.

T. Install cleanout constructed of a full size wye with flanged and bolted blind, wye branch angled vertical up, at a spacing of 150 feet. Blind flange shall have centered, plugged 3/4 inch hose coupling connection.

END OF SECTION

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