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1GUIDE SPECIFICATION SECTION 230555-1

2Revised 16 February 2016 Pipe Flushing, Testing and Cleaning


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1 SECTION 230555 PIPE FLUSHING, TESTING AND CLEANING
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3 PART 1 - GENERAL
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6RELATED DOCUMENTS
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8Drawings and general provisions of Contract, including General and Supplementary Conditions and Division-1
9Specification sections, apply to work of this section.
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12SUBMITTALS
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14General: Submittals shall demonstrate compliance with technical requirements by reference to each subsection of
15this specification. Where a submitted item does not comply fully with each and every requirement of the
16Specifications, the submittal shall clearly indicate such deviations. Identification requirements for non-complying
17features of items are very specific. See Section 230210 for exact requirements.
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19Product Data: Submit product data for flushing and cleaning chemicals proposed for use.
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21Flushing Plan: Submit a flushing plan prior to the start of work. The plan shall detail how the contractor will flush
22each piping system in accordance with these requirements including provisions for temporary bypasses and pumps.
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25 PART 2 PRODUCTS (Not Used)
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28 PART 3 - EXECUTION
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31GENERAL
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33All new water and/or steam piping systems shall be flushed and tested as hereinafter specified.
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36//DELETE THE FOLLOWING PARAGRAPH FOR NEW WORK ONLY PROJECTS.
37FORRENOVATION PROJECTS, IF EXISTING PIPING REQUIRES CLEANING,
38INCLUDETHIS PARAGRAPH AND DEFINE PIPING TO BE CLEANED ON THE
39DRAWINGS.//
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41Where indicated on the drawings, existing water and/or steam piping systems shall be flushed and tested as
42hereinafter specified.
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44All temporary equipment and materials required to perform the tests and flushes shall be the responsibility of the
45Contractor.
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47Conduct flushing and pressure and leak tests prior to connection to any existing piping or new equipment.
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49If any change is made to the piping systems after testing and/or flushing has occurred, the affected portion shall be
50retested and flushed. If any portion of the piping system fails a test, it shall be retested. If any portion of the piping
51system is exposed to dirt or debris after flushing, it shall be reflushed.
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54PIPE FLUSHING
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56For underground piping, prior to flushing, inspect the piping and run clean water thorough piping to remove all dirt
57and debris. Run clean water until the water draining from the pipe is clear and clean. If draining water does not run
58clear and clean after at least 15 minutes, pull a pipe swab or pig sized for each associated pipe diameter for the
59entire length of the system (no more than 500 feet at one time.) The pig shall be pulled in the direction of downward
60slope.
1GUIDE SPECIFICATION SECTION 230555-2
2Revised 16 February 2016 Pipe Flushing, Testing and Cleaning
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2For above ground piping, prior to flushing, inspect the piping and run clean water thorough piping to remove all dirt
3and debris. Run clean water until the water draining from the pipe is clear and clean. Fill piping system with solution
4of clean water and 12% hypochlorite bleach (1 quart of bleach per 10,000 gallons of water for a residual
5concentration of 2-3 ppm chlorine), Nalco 2567 cleaner, or equivalent. The use trisodium phosphate cleaner is
6prohibited.
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8Circulate solution for at least 24 hours and then drain system to sanitary sewer.
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10Drain systems and fill with clean water for pressure and leak tests.
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13PRESSURE AND LEAK TESTING
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15After pipe flushing, perform pressure and leak testing.
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17Prior to the start of the test, verify the maximum test pressure and duration with the pipe manufacturer. Under no
18circumstances shall pipe be tested at pressures or durations that may cause damage to pipe or valves.
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20Prior to pressurization, remove all air from the system. Provide vent taps at each high point in the system as needed
21to do so. During the pressure test, verify that no air pockets, defective materials, or leaking joints exist in the line.
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23Pressure test piping as follows:
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25 Test each section of hydronic piping at the highest point in the line. Subject piping system to hydrostatic
26 test pressure that is not less than 1.5 times the design operating pressure. Test pressure shall not
27 exceed 125 psig or the maximum pressure rating for any vessel, pump, valve, or other component in system
28 under test, whichever is lower.
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30 Test each section of steam piping at the highest point in the line. Subject piping system to hydrostatic
31 test pressure that is not less than 1.5 times the design operating pressure. Test pressure shall not
32 exceed 300 psig or the maximum pressure rating for any vessel, valve, or other component in system under
33 test, whichever is lower. Verify that stress due to pressure does not exceed either 90 percent of specified
34 minimum yield strength or 1.7 times "SE" value in Appendix A of ASME B31.1.
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36Examine each section of piping for leaks in conjunction with the pressure test for a minimum of 2 hours.
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39PIPE CLEANING
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41Systems shall be cleaned after completion of flushing and testing. Cleaners that contain trisodium phosphate are
42prohibited.
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44Prior to initial cleaning, verify that systems have been flushed, filled, started, and vented. Add cleaner to closed
45systems at concentrations as recommended by the manufacturer. Remove water filter elements from the system
46before starting circulation.
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48Use neutralizer agents on recommendation of the system cleaner supplier and approval of the A/E.
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50Flush systems using pre-cleaning chemicals designed to remove construction deposits such as pipe dope, oils, loose
51mill scale, and other extraneous materials. Where existing piping is reused, evaluate existing scale condition. Add
52recommended dosages and recirculate for six to eight hours. Drain and flush until total alkalinity of rinse water is
53equal to makeup water. Drain completely and refill with treated clean water.
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55Remove, clean, and replace strainer screens.
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57Inspect, remove sludge, and flush low points and fill system with clean water after cleaning process is completed.
58Include disassembly of components as required.
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61//SELECT/EDIT THE FOLLOWING PARAGRAPHS BASED ON PROJECT REQUIREMENTS.//
1GUIDE SPECIFICATION SECTION 230555-3
2Revised 16 February 2016 Pipe Flushing, Testing and Cleaning
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2Hot Water Systems: Add cleaner to the system water until the M alkalinity value is 250 above that of the initial fill
3water. Verify the M alkalinity level before and after the addition of the cleaner by means of chemical tests that are
4observed by the Owner's construction representative; include results of all tests in the Operating and Maintenance
5manuals. Apply heat while circulating, slowly raising temperature to 160F and maintain for 12 hours minimum; vent
6all high points to assure 100% system circulation. Remove heat and circulate to 100F or less; drain system as
7quickly as possible and refill with clean water. Circulate for 6 hours at design temperature, vent air at all high points,
8then drain. Refill with clean water and repeat until the system cleaner is removed and the M alkalinity level returns to
9normal. Remove and clean all strainers. Re-vent the system and install clean filter elements in water filters. Treat
10with scale and corrosion inhibitors before using the system for building heating.
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12Chilled/Condenser/Heat Pump Water Systems: Add cleaner to the system water until the M alkalinity value is 250
13above that of the initial fill water. Verify the M alkalinity level before and after the addition of the cleaner by means of
14chemical tests that are observed by the Owner's construction representative; include results of all tests in the
15Operating and Maintenance manuals. Circulate for 48 hours, then drain system as quickly as possible. Refill with
16clean water, circulate for 24 hours, then drain. Refill with clean water and repeat until system cleaner is removed and
17the M alkalinity level returns to normal. Remove and clean all strainers. Re-vent the system and install clean filter
18elements in water filters. Treat with scale and corrosion inhibitors before using the system for building cooling.
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20Steam Systems:
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22 Place control valves in the full-open position
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24 Fill boilers only, using the water and cleaner solution.
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26 Use neutralizer agents on recommendation of the system cleaner supplier and with approval of the A/E.
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28 Flush systems using pre-cleaning chemicals designed to remove construction deposits such as pipe dope,
29 oils, loose mill scale, and other extraneous materials. Where existing piping is reused, evaluate existing
30 scale condition. Add recommended dosages and recirculate for six to eight hours. Drain and flush until total
31 alkalinity of rinse water is equal to makeup water. Drain completely and refill with treated clean water.
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33 Remove, clean, and replace strainer screens.
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35 Apply heat, slowly raising boiler temperature to 160F for 12 hours minimum. Cool, then drain as
36 quickly as possible. Refill with clean water, drain, refill and check for sludge. Repeat until system is
37 free of sludge. Apply heat to produce steam for piping system and maintain for 8 hours minimum.
38 Bypass traps and waste condensate to sanitary sewer.
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40 For clean steam system, flush as indicated above followed by passivation in accordance with ASTM A380.
41 Flush with reverse osmosis water followed by four hours with clean steam and wasting all condensate. The
42 clean steam generator is to be valved out of the system except when clean steam is generated.
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45CERTIFICATION
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47Upon completion of flushing and testing of each pipe section, provide a letter to the A/E certifying that the tests and
48flushes were performed in accordance with the specification; what the final results were; what the intermediate results
49were; and what actions were taken to correct any leaks or problems. The letter shall be signed and dated by the
50Contractors representative.
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55END OF SECTION 230555