DaimlerChrysler Construction Standards

6/17/05

SECTION 15220 - INDUSTRIAL WASTEWATER PIPING SYSTEMS

PART 1 - GENERAL

1.1  SUMMARY

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

1.2  SYSTEM DESCRIPTION

  1. This piping specification applies to the following piping systems:
  2. Industrial Waste (IW)
  3. Pumped Industrial Waste (PIW)
  4. E-Coat Waste (EW)
  5. Pumped E-Coat Waste (PEW)
  6. Treated Waste (TW)
  7. Treated Sludge (TS)
  8. Chemical Recirculation (CR)
  9. Skimmed Waste (SK)
  10. Recycled Water System (RCW)
  11. Cutting Machine Coolant Transfer and Treated industrial Waste Water Piping, located inside the building and on the Trestle (CX).
  12. Service Rating
  13. Pressure Range: 0-150 psig.
  14. Temperature Range: Plus 32 deg F to minus 210 deg F.

1.3  QUALITY ASSURANCE

  1. 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.
  2. Fiberglass piping shall have minimum continuous working pressure rating of 150 psig at 210degF in accordance with ASTM Standard Method of Test D2992-Procedure A.
  3. Fiberglass pipe shall be in compliance with specification ASTM D2996 Standard Specification for Filament Wound Pipe.
  4. Fiberglass pipe shall be in compliance with specification ASTM D2310 Standard Classification for Machine Made Reinforced Thermosetting Resin Pipe.
  5. Fiberglass pipe shall comply with the following: ASTM D2105 standard test method for longitudinal tensile properties of fiberglass pipe and tube.

F.  All grooved joint couplings, fittings, valves, and specialties of a contract shall be the products of a single manufacturer. Grooving tools shall be of the same manufacturer as the grooved components.

  1. 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."
  2. 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.
  3. Valves and valve components shall be silicone-free.
  4. Double-wall pipe used for secondary containment shall meet requirements of DaimlerChrysler Manufacturing Technical Instructions SMI156. Single-wall piping shall not be installed underground unless specifically required on the drawings.

1.4  SUBMITTALS

  1. Result of stress analysis for fiberglass pipe with recommended locations for hangers, anchors, and guides.
  2. 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.
  3. 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.

D.  Grooved joint couplings and fittings shall be shown on drawings and product submittals and shall be specifically identified with the applicable style or series designation.

1.5  DELIVERY, STORAGE AND HANDLING

  1. 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.
  2. Protect the fiberglass pipe and fittings from ultraviolet degradation according to the manufacturer’s instructions.
  3. Valves shall be protected during shipping in accordance with API 609 standard, Articles4.3, 4.4, 4.6.1, and 4.6.3.
  4. Valves stored on site shall have protective end covers in place until used.

PART 2 - PRODUCTS

2.1  MANUFACTURERS

  1. Unless otherwise directed by the Owner, provide products by one of the following:
  2. Fiberglass Pipe and Fittings
  3. Smith Fiberglass; Red Thread II
  4. Bondstrand Series 2000 Pipe and fittings
  5. Fibercast
  6. Double Wall Pipe System (Fiberglass Pipe)
  7. Smith Fiberglass
  8. Bondstrand
  9. Fibercast
  10. Bondstrand CX (Alternate)
  11. Butterfly Valves (TFE Lined)
  12. Keystone
  13. Grinnell
  14. Bray
  15. Butterfly Valves (EPDM Seat)
  16. Keystone
  17. Grinnell
  18. Bray
  19. Butterfly Valves (BUNA-N Seat)
  20. Keystone
  21. Grinnell
  22. Bray
  23. Lined Plug Valves
  24. Durco T-Line
  25. Tufline 061
  26. Chem Plug 021
  27. Plug Valves (TFE Sleeved)
  28. Tufline 067
  29. Floroseal
  30. Chem-Plug 022

8.  Grooved Plug Valves (Eccentric Type)

a.  Victaulic Co. of America

  1. Check Valves, Wafer Style
  2. Gulf-Valve Co. Figure No. MB15 series
  3. Mueller Steam Specialties
  4. Powell Valve Co. (alloy 20 swing check)
  5. Poppet Check Valves
  6. Dow Model 555 horizontal
  7. Dow Model 556 vertical
  8. Expansion Joints
  9. Metroflex T-2-J
  10. Performance Plastics
  11. Resistoflex
  12. Ethylene
  13. Nozzle Liners
  14. Aetna Plastics
  15. Performance Plastics
  16. Ball Valves (nonmetallic)
  17. Nil-Cor 310 series
  18. Ball Valves - Lined
  19. Atomac
  20. Xomox
  21. ITT-Richter
  22. Neotecha
  23. Ball Valves - Carbon Steel
  24. KTM
  25. Neles Jamesbury
  26. PBM
  27. Worcester
  28. Pinch Valves
  29. Grigsby (F-300)
  30. Larox (PVE)
  31. Grooved Butterfly Valves
  32. Victaulic Style 300 MasterSeal™
  33. Grooved Ball Valves
  34. Victaulic 721
  35. Grooved Check Valves
  36. Victaulic Series 716

2.2  DOUBLE WALL PIPE SYSTEM

  1. Carrier Pipe
  2. 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.
  3. 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.
  4. Containment Pipe
  5. Containment pipe materials shall be fiberglass-reinforced epoxy piping system.
  6. 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.
  7. FRP Fittings - For Double-Walled FRP Containment Pipe Systems
  8. Fittings shall be compression or contact molded using same resin and cure compound materials as the associated pipe system.
  9. 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.
  10. Clam shell fittings are not allowed.
  11. Double-wall system fittings shall be factory assembled to include inner carrier and outer containment fitting as a single unit.
  12. Leak Detection - Double-Wall Pipe
  13. 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.
  14. Alternate System
  15. Double-wall coaxial system fabricated through a progressive process. A porous layer shall separate the inner and outer pipe.
  16. 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.

2.3  MATERIALS

  1. Fiberglass Pipe And Fittings
  2. 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.
  3. .
  4. 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.
  5. Fittings 8 inches through 16 inches shall be compression molded filament wound or mitered fiberglass reinforced epoxy.
  6. Fiberglass pipe 18-inch through 30-inch diameter shall be filament wound.
  7. 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.
  8. Flanges shall be flat face and drilled in accordance with ANSI B16.5 150 lb. Bolt hole drilling.
  9. Provide pipe with UV degradation protection.

2.4  CARBON STEEL PIPE AND FITTINGS

  1. Carbon Steel 1-1/2 Inches and Smaller: Schedule 80, ASTM A106, seamless, Grade A, plain ends.
  2. Two Inches and Larger: Schedule 40, ASTM A53, Type E (electric resistance welded), GradeA, plain ends.
  3. Malleable Iron Threaded Fittings 1-1/2 Inches and Smaller: ASME B16.3, Class 150 banded.
  4. Malleable Iron Unions 2 Inches and Smaller: ASME B16.1, Class 125; ground joint, threaded ends.
  5. Wrought Steel Fittings 2 Inches and Larger: Butt weld, ASTM A234, standard weight.
  6. Wrought Steel Flanges 2 Inches and Larger: ASME B16.5, raised face weld-neck, or flat face where in contact with fiberglass pipe.

2.5  DUCTILE IRON PIPE AND FITTINGS

  1. Ductile Iron Pipe 3 Inches and Larger: Class 50, 1/32 inch coal tar enamel coating in accordance with AWWA C151.
  2. 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.

2.6  FRP JOINTS

  1. 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.
  2. Bolts shall be ASTM A307, Grade B, hex head machine bolts with heavy hex nuts. Use steel washer at bolts and nuts.

2.7  GROOVED END STEEL FITTINGS

  1. Use for treated sludge piping only.
  2. Rigid joints shall be Victaulic Style 07 Zero-Flex or equal couplings for sizes through NPS 12. Style W07 or equal rigid couplings for NPS 14 through NPS 24.

C.  Steel-Piping, Grooved-End Fittings: ASTMA234, galvanized, forged steel; ASTM A53, factory fabricated from steel pipe; or ASTMA536, galvanized, ductile-iron casting; with dimensions matching steel pipe. Sizes 14 inches and larger Victaulic style AGS or equal grooved end.

2.8  GASKETS

  1. 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.
  2. Gaskets for piping systems with EPDM lined or seated valves shall have EPDM gaskets.
  3. Gaskets for piping systems with Viton-fitted valves shall have Viton gaskets.

2.9  ALLOY BODY KNIFE GATE VALVE

  1. Manufacturers:

1.  Victaulic Co. of America

  1. Dezurik
  2. A C Valve
  3. Orbinox
  4. KG Valve
  5. One-piece cast 304 stainless steel body or two-piece carbon steel body, drilled and tapped wafer lug style meeting ANSI B16.5 flange 150 pattern or grooved end type, OS&Y, standard rope packing or PTFE impregnated braided synthetic fiber packing, 316 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.
  6. Optional replaceable resilient seat of Viton

2.10  BUTTERFLY VALVES

  1. 2 Inches Through 14 Inches:
  2. BFV-1: Tapped lug, ductile iron body, 150 psig pressure rating, TFE lined, TFE encapsulated disc, where noted.
  3. BFV-2: Tapped lug ductile iron body, ductile iron disc, 150 psig pressure rating, EPDM seat where noted.
  4. BFV-3: Tapped lug, ductile iron body, 150 psig pressure rating EPDM lined, EPDM encapsulated disc where noted.
  5. BFV-4: Tapped lug ductile iron body, ductile iron disc, 150 psig pressure rating BUNA-N seat where noted.
  6. Manual butterfly valves 4 inches and larger to be supplied with gear operator.
  7. Butterfly valves in waste treatment building in chemical recirculation (CR) and butterfly valves is piping systems at batch tank nozzles shall be Type BFV-1 (TFE-lined).
  8. Butterfly valves in industrial waste (IW), treated waste (TW), shall be Type BFV-4 unless noted otherwise.
  9. Butterfly valves in EW, TS, SK, and RCW systems shall be BFV4.
  10. 14 Inches Through 16 Inches:
  11. BFV-5: Tapped lug ductile iron body, ductile iron disc, 150 psig pressure rating BUNA-N seat where noted.

2.11  PLUG VALVES

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

5.  Use Victaulic grooved end plug valves Series 365 or equal with grooved end piping systems.

2.12  CHECK VALVES

  1. CVA-1: Wafer style swing check shall be rated 150 lb, carbon steel body and plate, Viton seat, 316 SS pin and spring.
  2. CVA-2: Vertical poppet check shall have ductile iron body, solid PTFE plug, wetted surfaces PTFE lined.
  3. 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.

2.13  GROOVED BUTTERFLY VALVES

  1. 2 Inches Through 12 Inches: Comply with the intent of MSS SP67, 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 electroless nickel coated ductile iron with EPDM pressure responsive seat. 416 stainless steel stem offset from the disc centerline to provide continuous 360-degree seating. Valves shall be rated for dead-end service. Victaulic Vic-300 MasterSeal™ or equal.
  2. 14 Inches Through 24 Inches: Operating pressure to 200 psig non-shock. AGS grooved end body shall be ductile iron to ASTM A536, Grade 65-45-12. Disc shall be PPS coated ductile iron . Reinforced PTFE upper and lower bearings. Trim shall be 416 stainless steel. Valves shall be rated for dead-end service. Victaulic Style W706 or equal.

2.14  GROOVED BALL VALVES

  1. 1-1/2 Inches to 6 Inches: Standard port design rated for 800 psi CWP. 100 percent hydro pressure tested. Bidirectional flow, body and end cap shall be ductile iron, ball and stem shall be chrome-plated carbon steel. Seats shall be TFE, and seals shall be fluoroelastomer. Stem shall be chrome-plated carbon steel. Handle shall be two-position. Victaulic Style 726 or equal.

2.15  GROOVED (NONSLAM) CHECK VALVES