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SECTION 15530 - REFRIGERANT PIPING

PART 1 - GENERAL

0.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including Conditions of Contract and
Division 1 Specification Sections, apply to this Section.

0.2 SUMMARY

A. This Section includes refrigerant piping used for air-conditioning applications, including
pipes, tubing, fittings, and specialties; special-duty valves; and refrigerants.

B. Related Sections: The following Sections contain requirements that relate to this Section:

1. Division 7 Section "Roof Accessories" for roof curbs, piping supports, and roof
penetration boots.
2. Division 7 Section "Through-Penetration Firestop Systems" for materials and
methods for sealing pipe penetrations through basement walls and fire/smoke
barriers.
3. Division 15 Section "Mechanical Identification" for labeling and identifying
refrigerant piping.
4. Division 15 Section "Pipe Insulation" for pipe insulation.

0.3 SUBMITTALS

A. Product Data: For each valve type and refrigerant piping specialty specified.

B. Shop Drawings: Show layout of refrigerant piping, specialties, and fittings, including pipe
and tube sizes, flow capacities, valve arrangements and locations, slopes of horizontal runs,
wall and floor penetrations, and equipment connection details. Show interface and spatial
relationship between piping and equipment.

1. Refrigerant piping indicated is schematic only. Size and design the layout and
installation of the piping, including oil traps, double risers, specialties, and pipe and
tube sizes, to ensure proper operation and conformance with warranties of connected
equipment.

C. Maintenance Data: For refrigerant valves and piping specialties to include in the operation
and maintenance manual specified in Division 1.

0.4 QUALITY ASSURANCE

A. ASME Compliance: Qualify brazing and welding processes and operators according to
ASME Boiler and Pressure Vessel Code, Section IX, "Welding and Brazing Qualifications."

B. Regulatory Requirements: Comply with provisions of the following codes:

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1. ASME B31.5, "Refrigeration Piping."

2. ASHRAE 15, "Safety Code for Mechanical Refrigeration."

C. UL Standard: Provide products complying with UL 207, "Refrigerant-Containing

Components and Accessories, Nonelectrical"; or UL 429, "Electrically Operated Valves."

D. Listing and Labeling: Provide products specified in this Section that are UL listed and
labeled.

0.5 SEQUENCING AND SCHEDULING

A. Coordinate the installation of roof curbs, equipment supports, and roof penetrations. Roof
specialties are specified in Division 7 Sections.

0.6 EXTRA MATERIALS

A. Furnish extra materials described below that match products installed, are packaged with
protective covering for storage, and are identified with labels describing contents. Deliver
to the Employer.

1. Refrigeration Oil Test Kits: 2 each, containing everything required to conduct 1 test.
2. Refrigerant: 2 containers each, with 10 kg of refrigerant.
3. Filter-Dryer Cartridges: 3 of each type.

PART 2 - PRODUCTS

0.1 PIPES AND TUBES

A. Hard Copper Tube: ASTM B 280, Type ACR, drawn temper.

B. Hard Copper Tube: ASTM B 88M, Type B, drawn temper.

C. Soft Copper Tube: ASTM B 88M, Type B, annealed temper.

D. Soft Copper Tube: ASTM B 88M, Type A, annealed temper.

0.2 PIPE AND TUBE FITTINGS

A. Copper Fittings: ASME B16.22, wrought-copper streamlined pattern.

0.3 JOINING MATERIALS

A. Brazing Filler Metals: AWS A5.8, Classification BAg-1 (Silver).

0.4 VALVES

A. Diaphragm Packless Valves: 3450-kPa working pressure and 135 deg. C working
temperature, globe or angle pattern, forged-brass or bronze body and bonnet, phosphor

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bronze and stainless-steel diaphragms, rising stem and handwheel, stainless-steel spring,
nylon seat disc, with solder-end connections.

B. Packed-Angle Valves: 3450-kPa working pressure and 135 deg. C working temperature,
forged-brass or bronze body, forged-brass seal caps with copper gasket, back seating, rising
stem and seat, molded stem packing, with solder-end connections.

C. Check Valves DN25 and Smaller: 3450-kPa operating pressure, 149 deg. C operating
temperature; cast-brass body, with removable piston, PTFE seat, and stainless-steel spring;
straight-through globe design. Valve shall be straight-through pattern, with solder-end
connections.

D. Check Valves Larger than DN25 : 3100-kPa operating pressure, 149 deg. C operating
temperature; cast-bronze body, with cast-bronze or forged-brass bolted bonnet; floating
piston with mechanically retained PTFE seat disc. Valve shall be straight-through or angle
pattern, with solder-end connections.

E. Service Valves: 3450-kPa pressure rating, forged-brass body with copper stubs, brass caps,
removable valve core, integral ball check valve, with solder-end connections.

F. Solenoid Valves: Conform to ARI 760; 121 deg. C temperature rating, 2760-kPa working
pressure; forged brass, with PTFE valve seat, 2-way straight-through pattern, and solder-end
connections; manual operator; with NEMA 250, Type 1 solenoid enclosure with 13-mm
conduit adapter, and 24-V normally closed holding coil.

G. Pressure-Regulating Valves: Conform to ARI 770; pilot operated, forged brass or cast

bronze with pilot operator, stainless-steel bottom spring, pressure-gage tappings, 24-V dc
standard coil, and wrought-copper fittings for solder-end connections.

H. Pressure-Regulating Valves: Conform to ARI 770; direct acting, brass with pilot operator,
stainless-steel diaphragm, standard coil, and solder-end connections.

I. Pressure Relief Valves: Straight or angle brass body and disc, neoprene seat, factory sealed
and ASME labeled, for standard pressure setting.

J. Thermal Expansion Valves: Conform to ARI 750; thermostatic-adjustable, modulating

type; size as required and factory set for superheat requirements; solder-end connections;
with sensing bulb, distributor having side connection for hot-gas bypass line, and external
equalizer line.

K. Hot-Gas Bypass Valve: Adjustable, sized for capacity equal to last step of compressor
unloading; solder-end connections.

0.5 REFRIGERANT PIPING SPECIALTIES

A. Straight- or Angle-Type Strainers: 2960-kPa working pressure; forged-brass or steel body

with stainless-steel wire or brass-reinforced Monel screen, and screwed cleanout plug, with
solder-end connections.

B. Straight, Non-Cleanable-Type Strainers: 3450-kPa working pressure; steel shell with

stainless-steel screen, with solder-end connections.

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C. Moisture/Liquid Indicators: 3450-kPa operating pressure, 93 deg. C operating temperature;

forged-brass body, with replaceable, polished, optical viewing window with color-coded
moisture indicator, and solder-end connections.

D. Replaceable-Core Filter-Dryers: 3450-kPa operating pressure; steel shell, flange ring, and
spring, ductile-iron cover plate with steel cap screws, and wrought-copper fittings for
solder-end connections; with replaceable-core kit, including gaskets, as follows:

1. Filter Cartridge: Pleated media with integral end rings, stainless-steel support,
ARI 730 rated for capacity.
2. Filter-Dryer Cartridge: Pleated media with solid-core sieve with activated alumina,
ARI 730 rated for capacity.
3. Wax Removal Cartridge: Molded, bonded core of activated charcoal and desiccant
with integral gaskets.

E. Permanent Filter-Dryer: 2140-kPa maximum operating pressure, 107 deg. C maximum

operating temperature; steel shell, and wrought-copper fittings for solder-end connections;
molded-felt core surrounded by desiccant.

F. Flanged Unions: 2760-kPa working pressure, 165 deg. C maximum operating temperature;
2 brass tailpiece adapters for solder-end connections to copper tubing; forged-steel flanges
for 22 to 41 mm nominal copper-tube size and ductile iron for 54 to 79 mm nominal
copper-tube size with 4 plated steel bolts, with silicon bronze nuts and fiber gasket; factory-
applied rust-resistant coating on flanges and bolts.

G. Flexible Connectors: 3450 kPa operating pressure; seamless tin-bronze or stainless-steel

core, high-tensile bronze-braid covering, solder-end connections, and synthetic covering;
dehydrated, pressure tested, minimum 180 mm long.

H. Mufflers: 3450 kPa operating pressure, brazed-steel construction with fusible plug, sized
for refrigeration capacity.

0.6 RECEIVERS

A. 150 mm Diameter and Smaller: ARI 495, UL listed, steel, brazed; 2760-kPa pressure
rating, with tappings for inlet, outlet, and pressure relief valve.

B. More than 150 mm Diameter: ARI 495, welded steel, tested and stamped according to
ASME Boiler and Pressure Vessel Code, Section 8D; 2760 kPa with tappings for liquid inlet
and outlet valves, pressure relief valve, and liquid-level indicator.

0.7 REFRIGERANT

A. ASHRAE 34, R-123: Dichlorotrifluoroethane.

B. ASHRAE 34, R-134a: Tetrafluoroethane.

C. ASHRAE 34, R-22: Chlorodifluoromethane (for small size split units only).

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PART 3 - EXECUTION

0.1 EXAMINATION

A. Examine roughing-in for compliance with requirements for installation tolerances and other
conditions affecting performance of refrigerant piping. Do not proceed with installation
until unsatisfactory conditions have been corrected.

0.2 APPLICATIONS

A. Aboveground, within Building: Type ACR drawn-copper tubing.

B. Aboveground, within Building: Type B drawn-copper tubing.

C. Belowground for DN50 and Smaller: Type B annealed-copper tubing.

D. Belowground for Larger than DN50 : Type A annealed-copper tubing.

0.3 INSTALLATION

A. Install refrigerant piping according to ASHRAE 15.

B. Basic piping installation requirements are specified in Division 15 Section "Basic

Mechanical Materials and Methods."

C. Install piping in short and direct arrangement, with minimum number of joints, elbows, and
fittings.

D. Arrange piping to allow normal inspection and service of compressor and other equipment.
Install valves and specialties in accessible locations to allow for service and inspection.

E. Install piping with adequate clearance between pipe and adjacent walls and hangers, or
between pipes for insulation installation. Use sleeves through floors, walls, or ceilings,
sized to permit installation of full-thickness insulation.

F. Belowground, install copper tubing in conduit. Vent conduit outdoors.

G. Insulate suction lines and liquid lines, but insulate them together if adjacent.

1. Do not install insulation until system testing has been completed and all leaks have
been eliminated.

H. Install branch lines to parallel compressors of equal length, and pipe identically and
symmetrically.

I. Install copper tubing in rigid or flexible conduit in locations where copper tubing will be
exposed to mechanical injury.

J. Slope refrigerant piping as follows:

1. Install horizontal hot-gas discharge piping with a uniform slope of 0.4 percent
downward away from compressor.

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2. Install horizontal suction lines with a uniform slope of 0.4 percent downward to
compressor.
3. Install traps and double risers where indicated and where required to entrain oil in
vertical runs.
4. Liquid lines may be installed level.

K. Use fittings for changes in direction and branch connections.

L. Install exposed piping at right angles or parallel to building walls. Diagonal runs are not
permitted, unless expressly indicated.

M. Reduce pipe sizes using eccentric reducer fittings installed with level side down.

N. Provide bypass around moisture-liquid indicators in lines larger than DN50 .

O. Install unions to allow removal of solenoid valves, pressure-regulating valves, expansion

valves, and at connections to compressors and evaporators.

P. Install flexible connectors at the inlet and discharge connection, at right angles to axial
movement of compressor, parallel to crankshaft.

Q. Install replaceable-core filter-dryers, with isolation valves and valved bypass.

R. Install refrigerant valves according to manufacturer's written instructions.

S. When brazing, remove solenoid-valve coils; remove sight glasses; and remove stems, seats,
and packing of valves, and accessible internal parts of refrigerant specialties. Do not apply
heat near bulb of expansion valve.

T. Electrical wiring for solenoid valves is specified in Division 16 Sections. Coordinate

electrical requirements and connections.

U. Mount thermostatic expansion valves in any position, close to evaporator.

1. Where refrigerant distributors are used, mount directly on expansion-valve outlet.

2. Install valve so that diaphragm case is warmer than bulb.
3. Secure bulb to clean, straight, horizontal section of suction line using 2 bulb straps.
Do not mount bulb in a trap or at the bottom of the line.
4. Where external equalizer lines are required, make connection where it will reflect
suction-line pressure at bulb location.

V. Install pressure relief valves as required by ASHRAE 15. Pipe pressure relief valves on
receivers to outdoors.

W. Charge and purge systems, after testing, and dispose of refrigerant following ASHRAE  15
procedures.

X. Charge system as follows:

1. Install filter-dryer core after leak test, but before evacuation.

2. Evacuate refrigerant system with vacuum pump, until temperature of 1.7 deg. C is
indicated on vacuum dehydration indicator.
3. Maintain vacuum for a minimum of 5 hours.
4. Break vacuum with refrigerant gas and charge to 14 kPa.

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0.4 HANGERS AND SUPPORTS

A. General: Hangers, supports, and anchors are specified in Division 15 Section "Hangers and
Supports." Provide according to ASME B31.5 and MSS SP-69.

B. Adjustable steel clevis hangers for individual horizontal runs less than 6 m in length.

C. Roller hangers and spring hangers for individual horizontal runs 6 m or longer.

D. Pipe rollers for multiple horizontal runs, 6 m or longer supported by a trapeze.

E. Spring hangers to support vertical runs.

F. Install hangers for copper tubing with the following maximum spacing and minimum rod
sizes. Tube sizes are nominal or standard tube sizes as expressed in ASTM B 88M.

1. 15 mm: Maximum span, 1500 mm; minimum rod size, 6 mm.

2. 18 mm: Maximum span, 1500 mm; minimum rod size, 6 mm.
3. 28 mm: Maximum span, 1500 mm; minimum rod size, 6 mm.
4. 35 mm: Maximum span, 1800 mm; minimum rod size, 8 mm.
5. 42 mm: Maximum span, 2400 mm; minimum rod size, 10 mm.
6. 54 mm: Maximum span, 2400 mm; minimum rod size, 10 mm.
7. 67 mm: Maximum span, 2700 mm; minimum rod size, 10 mm.
8. 79 mm: Maximum span, 3 m; minimum rod size, 10 mm.
9. 105 mm: Maximum span, 3.6 m; minimum rod size, 12 mm.

G. Support vertical runs at each floor.

0.5 PIPE JOINT CONSTRUCTION

A. Basic pipe and tube joint construction is specified in Division 15 Section "Basic Mechanical
Materials and Methods."

B. Fill pipe and fittings with an inert gas (nitrogen or carbon dioxide) during brazing to prevent
formation of scale.

0.6 VALVE INSTALLATIONS

A. Install refrigerant valves according to manufacturer's written instructions.

B. Install valves on suction and discharge of compressor, for gage taps at compressor inlet and
outlet, for gage taps at hot-gas bypass regulators, on inlet and outlet, and on each side of
strainers.

C. Install check valves on compressor discharge and on condenser liquid lines on multiple
condenser systems.

D. Install refrigerant-charging (packed-angle) valve in liquid line between receiver shutoff

valve and expansion valve.

E. Install globe valves on each side of strainers and dryers, in liquid and suction lines at
evaporators, and elsewhere as indicated.

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F. Install a full-sized, 3-valve bypass around each dryer.

G. Install solenoid valves ahead of each expansion valve and hot-gas bypass valve. Install
solenoid valves in horizontal lines with coil at top.

1. Electrical wiring for solenoid valves is specified in Division 16 Sections. Coordinate

electrical requirements and connections.

H. Mount thermostatic expansion valves in any position, close to evaporator.

1. Where refrigerant distributors are used, mount directly on expansion-valve outlet.

2. Install valve so that diaphragm case is warmer than bulb.
3. Secure bulb to clean, straight, horizontal section of suction line using 2 bulb straps.
Do not mount bulb in a trap or at the bottom of the line.
4. Where external equalizer lines are required, make connection where it will reflect
suction-line pressure at bulb location.

I. Install pressure-regulating and relief valves as required by ASHRAE 15.

0.7 SPECIALTIES APPLICATION AND INSTALLATION

A. Install liquid indicators in liquid line leaving condenser, in liquid line leaving receiver, and
on leaving side of liquid solenoid valves.

B. Install strainers immediately upstream of each automatic valve, including expansion valves,
solenoid valves, hot-gas bypass valves, and compressor suction valves.

C. Install strainers on main liquid line where multiple expansion valves with integral strainers
are used.

D. Install moisture-liquid indicators in liquid lines between filter-dryers and thermostatic

expansion valves and in liquid line to receiver.

E. Install pressure relief valves on ASME receivers, and pipe to outdoors.

F. Install replaceable-core filter-dryers in vertical liquid line adjacent to receivers and before
each solenoid valve.

G. Install permanent filter-dryers in low-temperature systems, in systems using hermetic

compressors, and before each solenoid valve.

H. Install solenoid valves in liquid line of systems operating with single pump-out or pump-
down compressor control, in liquid line of single or multiple evaporator systems, and in oil
bleeder lines from flooded evaporators to stop flow of oil and refrigerant into suction line
when system shuts down.

I. Install receivers on systems 18 kW and larger, and on systems with long piping runs, sized
to accommodate pump-down charge.

J. Install flexible connectors at or near compressors where piping configuration does not
absorb vibration.

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0.8 CONNECTIONS

A. Electrical: Conform to applicable requirements of Division 16 Sections for electrical

connections.

0.9 FIELD QUALITY CONTROL

A. Inspect and test refrigerant piping according to ASME B31.5, Chapter VI.

1. Pressure test with nitrogen to 1380 kPa . Perform final tests at 186-kPa vacuum and
1380 kPa using halide torch or electronic leak detector. Test to no leakage.

B. Test and adjust controls and safeties. Replace damaged or malfunctioning controls and
equipment.

C. Repair leaks using new materials; retest.

0.10 ADJUSTING

A. Adjust thermostatic expansion valve to obtain proper evaporator superheat requirements.

0.11 CLEANING

A. Before installation of copper tubing other than Type ACR, clean tubing and fittings with
trichloroethylene.

0.12 COMMISSIONING

A. Charge system using the following procedures:

1. Install core in filter dryer after leak test, but before evacuation.
2. Evacuate refrigerant system with vacuum pump until temperature of 1.67 deg. C is
indicated on vacuum dehydration indicator.
3. During evacuation, apply heat to pockets, elbows, and low spots in piping.
4. Maintain vacuum on system for minimum of 5 hours after closing valve between
vacuum pump and system.
5. Break vacuum with refrigerant gas, allowing pressure to build up to 14 kPa.
6. Complete charging of system, using new filter-dryer core in charging line. Provide
full-operating charge.

END OF SECTION 15530

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