DaimlerChrysler Construction Standards

12/17/04

SECTION 15211 - GENERAL-SERVICE COMPRESSED-AIR PIPING

PART 1 - GENERAL

1.1  SUMMARY

  1. This Section includes piping and related specialties for general-service compressed-air systems operating at 125 psig and less.
  2. Related Sections include the following:
  3. Division15 Section "Meters and Gages" for thermometers and pressure gages.
  4. Division15 Section "General-Service Compressed-Air Equipment" for compressed-air equipment and accessories.

1.2  DEFINITIONS

  1. Low-Pressure Compressed-Air Piping: System of compressed-air piping and specialties operating at pressures of 125 psig and less.

1.3  SUBMITTALS

  1. Product Data: For the following:
  2. Pipes, tubes, and fittings.
  3. Flexible pipe connectors.
  4. Safety valves.
  5. Pressure regulators.
  6. Filters.
  7. Automatic drain valves.
  8. Quick couplings.
  9. Hose assemblies.
  10. Welding Certificates: As required by ASME Boiler and Pressure Vessel Code, SectionIX.

1.4  QUALITY ASSURANCE

  1. Welding: Qualify processes and operators according to ASME Boiler and Pressure Vessel Code: SectionIX, "Welding and Brazing Qualifications."
  2. Comply with ASMEB31.9, "Building Services Piping," for low-pressure compressed-air piping.

PART 2 - PRODUCTS

2.1  PIPING MATERIALS

  1. Refer to Part3 "Piping Applications" Article for applications of pipe, tube, fitting, and joining materials.

2.2  PIPES, TUBES, AND FITTINGS

  1. Schedule40, Steel Pipe: ASTMA53/A53M, TypeE or S, GradeA or B, black
  2. Steel Nipples: ASTMA733, made of ASTMA53/A53M or ASTMA106, Schedule40, seamless steel pipe. Include ends matching joining method.
  3. Malleable-Iron Fittings: ASMEB16.3, Class150 or 300, threaded. Provide Class300 and galvanized finish if indicated.
  4. Malleable-Iron Unions: ASMEB16.39, Class150 or 300, threaded. Provide Class300 if indicated.
  5. Wrought-Steel Fittings: ASMEB16.9, Schedule40, butt welding.
  6. Forged-Steel Fittings: ASMEB16.11, socket type.
  7. Steel Flanges: ASMEB16.5, Class150 or 300, carbon steel. Provide Class300 if indicated.
  8. Flexible Pipe Connectors: Corrugated tubing with wire-braid covering.
  9. Manufacturers: Unless otherwise directed by the Owner, provide products by one of the following:
  10. ANAMET Inc.
  11. Flex-Hose Co., Inc.
  12. Flexicraft Industries.
  13. Hyspan Precision Products, Inc.
  14. Mercer Rubber Co.
  15. Metraflex, Inc.
  16. Proco Products, Inc.
  17. Unaflex, Inc.
  18. Stainless-Steel-Hose/Steel Pipe Flexible Pipe Connectors: Corrugated-stainless-steel tubing with stainless-steel wire-braid covering and ends welded to inner tubing.
  19. Working-Pressure Rating: 200 minimum.
  20. End Connections NPS2 and Smaller: Threaded steel pipe nipple.
  21. End Connections NPS2-1/2 and Larger: Flanged steel nipple.

2.3  JOINING MATERIALS

  1. Refer to Division15 Section "Basic Mechanical Materials and Methods" for joining materials not in this Section.

2.4  VALVES

  1. General-Duty Valves: Refer to Division15 Section "Valves" for metal ball, butterfly, check, gate, and globe general-duty valves.

2.5  SPECIALTIES

  1. Safety Valves: ASME Boiler and Pressure Vessel Code: SectionVIII, "Pressure Vessels," construction; National Board certified, labeled, and factory sealed; constructed of bronze body with poppet safety valve for compressed-air service.
  2. Pressure Settings: Higher than discharge pressure and same or lower than receiver pressure rating.
  3. Air-Pressure Regulators: Bronze body, direct acting, pilot operated, spring-loaded manual pressure-setting adjustment, and rated for 200-psiginlet pressure, unless otherwise indicated.
  4. Mechanical Filters: Two-stage, mechanical-separation-type, air-line filters in sizes, as required. Equip with deflector plates, resin-impregnated-ribbon-type filters with edge filtration, and drain cock.
  5. Automatic Drain Valves: Corrosion-resistant metal body and internal parts, rated for 150-psig minimum working pressure, capable of automatic discharge of collected condensate.
  6. Quick Couplings: Assembly with locking-mechanism feature for quick connection and disconnection of compressed-air hose.
  7. Manufacturers: Unless otherwise directed by the Owner, provide products by one of the following:
  8. Aeroquip Corporation.
  9. Bowes Manufacturing, Inc.
  10. Foster Manufacturing Co., Inc.
  11. Milton Industries, Inc.
  12. Parker Hannifin Corporation; Fluid Connectors Group; Quick Coupling Div.
  13. Rectus Corp.
  14. Schrader-Bridgeport; Amflo Div.
  15. Schrader-Bridgeport/Standard Thomson.
  16. Snap-Tite, Inc.
  17. TOMCO Products Inc.
  18. Tuthill Corporation; Hansen Coupling Div.
  19. Automatic-Shutoff Quick Couplings: Straight-through brass body with O-ring or gasket seal and stainless-steel or nickel-plated-steel operating parts.
  20. Socket End: With one-way valve and threaded inlet for connection to piping or threaded hose fitting.
  21. Plug End: Straight-through type with serrated outlet for attaching hose.
  22. Hose Assemblies: Compatible hose, clamps, couplings, and splicers suitable for compressed-air service, of nominal diameter indicated, and rated for 300-psig minimum working pressure, unless otherwise indicated.
  23. Hose: double-wire-braid, CR-covered hose for compressed-air service.
  24. Hose Clamps: Stainless-steel clamps or bands.
  25. Hose Couplings: Two-piece, straight-through, threaded brass or stainless-steel O-ring or gasket-seal swivel coupling with serrated ends for connecting two sections of hose.

PART 3 - EXECUTION

3.1  PREPARATION

  1. Interruption of Existing Compressed-Air Service: Do not interrupt compressed-air service to facilities occupied by Owner or others unless permitted under the following conditions and then only after arranging to provide temporary compressed-air service according to requirements indicated:
  2. Notify Owner not less than seven days in advance of proposed interruption of compressed-air service.

3.2  PIPING APPLICATIONS

  1. Install nipples, flanges, unions, transition and special fittings, and valves with pressure ratings same as or higher than system pressure rating used in applications below, unless otherwise indicated.
  2. Joining of Dissimilar Metal Piping: Use dielectric fittings. Refer to Division15 Section "Basic Mechanical Materials and Methods" for dielectric fitting types.
  3. NPS2 and Smaller: Dielectric unions.
  4. NPS2-1/2 to NPS4: Dielectric flanges.
  5. NPS6 and Larger: Dielectric flange kits.
  6. Low-Pressure Compressed-Air Piping: Use the following piping materials for each size range:
  7. NPS4 and Smaller: Schedule40, black-steel pipe; threaded malleable-iron fittings; and threaded joints.
  8. NPS6 to NPS12: Schedule40, black-steel pipe; wrought-steel fittings; and welded joints.

3.3  VALVE APPLICATIONS

  1. General-Duty Valves: Refer to Division15 Section "Valves" for metal general-duty valves. Use metal valves, unless otherwise indicated.
  2. Metal General-Duty Valves: Use valve types specified in "Valve Applications" Article in Division15 Section "Valves" according to the following:
  3. Low-Pressure Compressed Air: Valve types specified for low-pressure compressed air.
  4. Equipment Isolation NPS2 and Smaller: Safety-exhaust copper-alloy ball valve with exhaust vent and pressure rating at least as great as piping system operating pressure.

3.4  PIPING INSTALLATION

  1. Refer to Division15 Section "Basic Mechanical Materials and Methods" for basic piping installation.
  2. Install air and drain piping with 1 percent slope downward in direction of airflow.
  3. Install eccentric reducers where piping is reduced in direction of flow, with bottoms of both pipes and reducer fitting flush.
  4. Install branch connections to compressed-air mains from top of main. Provide drain leg and drain trap at end of each main and branch and at low points.
  5. Install flexible pipe connector on each connection to air compressors.
  6. Install thermometer and pressure gage on discharge piping from each air compressor and on each receiver; install according to Division15 Section "Meters and Gages."

3.5  VALVE INSTALLATION

  1. Refer to Division15 Section "Basic Mechanical Materials and Methods" for basic piping and valve installation.
  2. Install general-duty valves according to Division15 Section "Valves."
  3. Install shutoff valve at each connection to and from general-service compressed-air specialties, equipment, and accessories. Install strainer if indicated.
  4. Install check valves to maintain correct direction of fluid flow to and from compressed-air piping specialties and equipment.
  5. Install safety valves on receivers in quantity and size to relieve at least the capacity of connected air compressors.
  6. Install automatic drain valves on intercoolers, aftercoolers, receivers, and dryers. Discharge condensate over nearest floor drain.
  7. Install safety valves where recommended by specialty manufacturers.

3.6  JOINT CONSTRUCTION

  1. Refer to Division15 Section"Basic Mechanical Materials and Methods" for basic piping joint construction.
  2. Pressure-Seal Joints: Select correct type of O-ring seals. Make joints with fitting manufacturer's tools and according to fitting manufacturer's written instructions.
  3. Dissimilar Metal Piping Material Joints: Use dielectric fittings.

3.7  HANGER AND SUPPORT INSTALLATION

  1. Refer to Division15 Section "Hangers and Supports" for pipe hanger and support devices. Install the following:
  2. Vertical Piping: MSS Type8 or 42, clamps.
  3. Individual, Straight, Horizontal Piping Runs: MSS Type1, adjustable, steel, clevis hangers.
  4. Install supports according to Division15 Section "Hangers and Supports."
  5. Support horizontal piping within 12 inches of each fitting and coupling.
  6. Support vertical piping and tubing at base and at each floor.
  7. Rod diameter may be reduced 1 size for double-rod hangers, with 3/8-inch minimum rods.
  8. Install hangers for Schedule40, steel piping with the following maximum horizontal spacing and minimum rod diameters:
  9. NPS1/4 to NPS1/2: 96 inches with 3/8-inch rod.
  10. NPS3/4 to NPS1-1/4: 84 inches with 3/8-inch rod.
  11. NPS1-1/2: 12 feet with 3/8-inch rod.
  12. NPS2: 13 feet with 3/8-inch rod.
  13. NPS2-1/2: 14 feet with 1/2-inch rod.
  14. NPS3: 15 feet with 1/2-inch rod.
  15. NPS3-1/2: 16 feet with 1/2-inch rod.
  16. NPS4: 17 feet with 5/8-inch rod.
  17. NPS5: 19 feet with 5/8-inch rod.
  18. NPS6: 21 feet with 3/4-inch rod.
  19. NPS8: 24 feet with 3/4-inch rod.
  20. NPS10: 26 feet with 7/8-inch rod.
  21. NPS12: 30 feet with 7/8-inch rod.
  22. Install supports for vertical, Schedule40, steel piping every 15feet

3.8  CONNECTIONS

  1. Drawings indicate general arrangement of piping, fittings, and specialties.
  2. Install piping adjacent to specialties and equipment to allow service and maintenance.
  3. Connect piping to air compressors, accessories, and specialties with shutoff valve and union or flanged connection.

3.9  FIELD QUALITY CONTROL

  1. Perform the following field tests and inspections and prepare test reports:
  2. Test and adjust piping safety controls. Replace damaged and malfunctioning safety controls.
  3. Piping Leak Tests: Test new and modified parts of existing piping. Cap and fill general-service compressed-air piping with oil-free dry air or gaseous nitrogen to pressure of 50 psig above system operating pressure, but not less than 150 psig. Isolate test source and let stand for four hours to equalize temperature. Refill system, if required, to test pressure; hold for two hours with no drop in pressure.
  4. Repair leaks and retest until no leaks exist.
  5. Report results in writing.
  6. Connect appropriately sized temporary steel bag filter housing with bag filter or fine mesh screen at the end of the blowdown opening during blowout procedure described Article 3.4 of Division 15 Section “Cleaning and Flushing of Piping Systems.” Provide a temporary silencer for these blowdown openings.

END OF SECTION

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